120 Apprentice Online and/or Classroom,


 The course blends all core tools in several workshop exercises around the same product and processes. The correct utilization of these core tools will lead to continuous improvement, defect prevention and the reduction of variation and waste. :



Subject 1: Standardized Job Elements & Workplace Organization Learn the best practices to establish a repeatable, predictable baseline for continuous improvement involving the highest levels of safety, quality and productivity through 5S. Additional tools included:


  • Visual Management(5S)


Subject 2: Failure Mode Effects Analysis (FMEA) w/ Control Plans Case: Participants will highlight and prevent future failures from occurring. FMEA focuses on reducing risk of failure occurrences by making design and process changes, which has proven to save organizations significant amounts of money by prevention of failures/product recalls. Additional tools included:


  • Process Control Plan(PCP)


Subject 3: Problem Solving (8D)

Case: Participants will conduct a root cause analysis using problem-solving tools presented and demonstrated in this session. Both internal and external field failure, customer complaints is introduced. Teams use these tools to identify, analyze and determine root cause and ultimately solve the issues. Understanding is gained through practical, hands-on exercises using common measurement gauges. Problems are introduced to demonstrate the typical formats for reporting the findings, applying solutions, corrections and improvements. Additional tools included:


Subject 4: Statistical Process Control (SPC / 6 SIGMA)

Case: Participants run a group of sequentially produced parts and then measure them to determine average, range and sigma. Control limits are calculated using these same parts and additional samples are measured and plotted to determine where the process is going and why. Interpretations of results are part of this course as well as capability study exercises.


  • Common Cause Variation

  • Special Cause Variation


: Measurement Systems Analysis (MSA)

Case: Participants complete a GRR in the course. We've all heard the expression "garbage in, garbage out". The same can be applied when process control decisions or product acceptance are based on invalid data. MSA examines the sources of variation in the measurement process as well as information about measurement characteristics based on accuracy, precision, and stability. Additional tools included:



Subject 5: IATF 16949 / ISO 9001:2015 is a structured method of

Defining and establishing the steps necessary to ensure that a product satisfies the customer in an effective and efficient way. Additional tools included:






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