Program overview:

What is Daily Work Management

DWM & its linkage to Policy Deployment

Breakthrough & DWM

Methodology for effective DWM deployment

Duration: 1 Day

Methodology:

QSYS proven Mature Learning Process for adults through presentation and workshop

Benefits to your organization:

Effective deployment of Organizational Policies

Culture of organized Daily Work Management

Robust processes leading to continual improvement &

Saving through elimination of wastes in terms of time and energy spent on non-

value added activities

Training Title: Daily Work Management

Program Overview:

Green Belt training serves two purposes. First, it trains team members to function as part

an effective Six Sigma team; and second it begins to prepare them to lead projects and

eventually become future Black Belts.

Duration: 3 days Course Objectives:

Become a Six Sigma Green Belt

Conduct or participate in Six Sigma projects

Apply Six Sigma tools in a real project using a statistical software package

Session Topics:

How to think about Six Sigma

Six Sigma Improvement Methodology (Define-Measure-Analyze-Improve-Control)

Introduction to Probability and Statistics

Calculating Six Sigma Metrics

Project Selection & Project Charters

Planning for Data Collection

Measure Project Y in Y = f(X)

Pareto Charts and Stratification

Process Mapping

Determining Project X's in Y=f(x)

Hypothesis Testing (inferential statistics)

Improvement Tools & Techniques

Designing Controls to Hold the Gains

Training Title: Six Sigma Green Belt Training

Learning Objective:

This course aims to provide you with the opportunity to learn about the subject of auditing

of quality management systems, specifically those based on the ISO 9000 family

Duration: 2 days

At the end of the course, participants will learn about:

Purpose of a Quality Management System.

Principles of Quality Management.

Purpose, content and interrelationship of TS16949:2009 and ISO 19011.

Interpretation of ISO 9001 requirements in the context of an audit.

Roles and responsibilities of auditors and lead auditors.

Planning and conducting an audit in accordance with ISO19011.

Reporting of audit, including writing valid, factual and value-adding non-conformity

reports.

Undertaking audit follow-up activities, including evaluating the effectiveness of

corrective action.

Role of Auditor and Management Representative

Course Contents:

Day One

Course introduction

Management system – why and what?

Why, and what is an, Audit?

ISO 9000: Purpose and requirements

Plan an audit

Training Title: Internal Quality Auditor Training Course

based on ISO/TS 16949:2009 Series

Day Two

Auditor skills

Conduct an Audit

Complete audit simulations.

Evaluation, Report and Follow up

Course conclusion, reflection and personal action plan

Target Participants:

Participants must have some understanding of the content, application and

implementation of the appropriate series of standards prior to the commencement of the

course.

Teaching Methodology: This course has been designed with input and feedback from a number of trainers,

customers and training consultants. The course design reflects a high level of interaction

between the trainer and the participants. It is built upon the participants input all

throughout the course. This input by being mapped on the classroom walls will help the

participants follow and remember the course structure and content.

Certificate: On successful completion of the course, a certificate will be issued to the participant.

Venue, Training Facility: Customer Premise and facility

Duration: 1 day

Training Methodology:

Lecture, PPT presentation, Interactive session,

Exercise and QUIZ:

Training contents

Introduction with participants

Introduction to quality circles

Genesis of quality circles

Definition, philosophy, concept objective

Organizational structure

Launching quality circles

Training requirements

Process of operation and tools

Benefits of quality circles

Question /answer

Training feedback

Training Title: Program on Launching Quality Circle

and tools of Quality Circles

Program Overview

The 8D Problem Solving Process Tools Workshop provides participants with the skills and

knowledge that they will need to solve problems using the Global 8D industry standard

model. This workshop provides an emphasis on the practical use of common problem-

solving tools. The presentation includes technical concepts, classroom discussion, and

hands-on exercises. Teams of participants will apply the problem solving tools during the

course.

Duration: 2 days

Course Venue: Client premises, all training aid is to be provided by the client.

Course Objectives:

At the completion of this workshop, the participants will be able to:

Describe the benefits of using the 8D model for solving problems

Identify the steps of the 8D problem solving model

Compare the 8D problem solving model to other industry models, including PDCA

and DMAIC

Identify which problem solving tools are best used in conjunction with any

particular step in the 8D process.

Use a Check Sheet to record data

Construct a Pareto Chart

Use an IS/IS NOT analysis for problem definition

Use the 5 Whys

Use Brainstorming

Create a Cause and Effect (Fishbone) Diagram

Use the Nominal Group Technique

Describe the use of a Force Field Analysis

Describe the use of an Action Matrix

Create a Histogram

Create a Scatter Diagram

Construct a Run Chart

Explain the six basic principles of Statistical Process Control

Describe basic types of control charts

Course Title: 8D Problem Solving Process Tools

Program Overview

This course gives an in-depth understanding of the TS 16949:2002 requirements and

Process approach. It has been specifically designed to meet the needs of the Auto

Industry. Those responsible for planning and implementing process for TS 16949:2002

and those who must perform audits to TS 16949:2002 for quality assurance.

Duration: 1 Day

Who should attend Anyone who want to dedicate a full day to take a class on ISO/TS 16949:2009, wants to

quickly and efficiently understand what ISO/TS 16949:2002 and ISO 9001:2008 are

about, and ISO 9001:2008 are about, and wants to upgrade his/her knowledge and

expertise from TS16949 2000 to ISO/TS 16949:2009.

Course includes

The structure of the training is as follows:

The Standard

The Process Approach

Scope

Quality Management System

Management Responsibility

Resource Management

Product Realization

Measurement, Analysis and Improvement

Certificate requirements

The course uses a continuous evaluation method with on-going quizzes to facilitate the

information retention. If your final average is equal or greater to 70% you will be issued

a training certificate. If your final average evaluation is less than 70%, you will have to

take a final exam and score above 70% to be issued the training certificate.

Training Title: Course Outline for ISO/TS 16949:2009

Training

Program Overview:

SPC Training is a comprehensive, PPT based interactive training system that teaches

operators, engineers, and supervisors how to use statistical process control. This training

is ideal for training new employees how to use control charts in their jobs and is also a

good refresher for experienced employees.

Duration: 1 Day

Course Objectives:

Better understand variation in manufacturing processes including patterns and

measures of variation.

Monitor and control variation with variable and attribute control charts.

Describe basic process capability concepts and the importance of capability when

using control charts.

Course Venue: Client Premises. All training aid is to be provided by the client.

Course Outline:

Unit 1 – SPC Overview

Training Title: SPC Training

CONTENTS OF APQP:

A) APQP DETAILS

PLAN AND DEFINE PROGRAM.

PRODUCT DESIGN AND DEVELOPMENT PROGRAM.

PROCESS DESIGN AND DEVELOPMENT PROGRAM.

PRODUCT AND PROCESS VALIDATION PROGRAM.

FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION.

CONTROL PLAN METHODOLOGY.

B) FAILURE MODE EFFECT ANALYSIS

Types of FMEA:

System FMEA – Power transmission system ( case study)

Design FMEA – Axle shaft ( case study)

Process FMEA – Heat treatment ( case study)

C) CONTROL PLAN

Pre Launch

Prototype

Production

D) Case Study Duration: 1 Day

Training Title: Advanced Product Quality Planning

(APQP)

Program Overview:

5S is a simple but highly effective set of techniques that remove waste from your work

Environment through better workplace organization, visual communication and general

Cleanliness.

Duration: 1 Day The 5 pillars of 5S are defined as:

5S's - Sort

5S's - Set in order

5S's - Shine

5S's - Standardize

5S's - Sustain.

This 5S training program will clearly position its methods within the proper context of

Lean and value stream improvement. In order to have product or services flow in small

batches, workplace organization, cleanliness and standardization are absolutely

essential. During the 5S training program, pilot areas are chosen for improvement during

class from the future state value stream map. The program can be taught in either the

office or shop floor environment. Upon completion of this training program, participants

will be able to understand and immediately apply the following 5S Concepts in their own

workplace:

Sort - 1st of the 5Ss

Clearly distinguish the items needed in a work area from those no longer needed. Red

tagging is the activity that eliminates these unneeded items.

Set In Order - 2nd of the 5Ss

Keeping the needed items in the correct place to allow for easy and immediate retrieval.

Training Title: Training on 5S Training Overview

Shine - 3rd of the 5Ss

Keeping work areas, all work surfaces and equipment clean and free from dirt, debris, oil,

etc.

Standardize - 4th of the 5Ss Standard activities, procedures, schedules and the persons responsible for helping keep

the workplace in a clean and organized.

Sustain - 5th of the 5Ss

Drive the organization to be disciplined in maintaining these new standards and

procedures and in continuously improving the state of the workplace.

Typical One Day Session:

5S Training Program Half Day Preparation - Instructor and Sponsors Only Trainer tours

facility

First Half

Introduction

Overview of Lean

Types of waste in the workplace

5S and flow

Getting started

Sort

Exercise - apply sort to pilot area

Second Half

Set in order

Exercise - create a visual layout for all material and tools in pilot area

Shine

Exercise - design shine schedules and assignments for pilot area

Standardize

Exercise - create visual aids and standard work for the pilot area

Sustain

Exercise - defining outstanding actions to complete pilot area Complete

implementation

Program overview:

Introduction and getting started

Define Kaizen

Identify a specific Value Stream problem

Clearly develop a problem statement

Analyse the Problem

Observe the affected area and / or process

Gather critical data, information and observations

Team exercise to identify and select possible solutions

Review problem, possible solutions

Team select best Solution

Team develop Implementation Plan

Complete Implementation Plan

Implement

Document changes

Workshop conclusion

Duration: 1 Day Venue: Customer premises Training Methodology PPT presentation, Templates building, Case Study – Industry perspectives, Exercise, Quiz

Interaction Question and Answers

Program Benefits On attending of this training delegates will be able to connect the KAIZEN in their

respective organizational processes, will be fully aware of the philosophy and motivate

others to participate in the improvement process. The available formats and program

material is a good reference any time. The consultants will take up follow up activities

with delegates via email limited to three numbers from a individual delegates.

Training Title: Training Kaizen

Program overview:

Introductions and Overview

Lean Culture and Culturally Stimulated Wastes

Group Exercise: Defining the Cultural Current State

Behaviours and Values: Building Blocks of Cultural Change

Individual Exercise: My Behavioural Style Preferences

How Our Behavioural Style Preferences Influence Our Approach

Group Problem Solving in a Lean Environment: Human adaptability and the ‘flexing’

of our styles

Lean Implementation: Working with Behaviours and Values

Group Exercise: Inter-departmental Cooperation when Implementing Lean

Day One Summary

Update of Personal Learning and Application Plans

Venue Customer premises

Duration: 1 Day Training Methodology PPT presentation, Templates building, Case Study – Industry perspectives, Exercise, Quiz,

Interaction Question and Answers

Training Title: Training Lean Management

Program Overview:

This one-day training is the first step toward internal deployment and includes an

overview of Six Sigma, deployment strategies, scientific tools and methods, and

improvement, measurements, and management controls.

Duration: 1 Day Who Should Attend

Senior management and leadership team of a single organization.

Workshop Goals

Achieve an effective understanding of the Six Sigma™ Strategy and the Six Sigma™

process within the organization's Six Sigma infrastructure.

Training Contents

Defining Our Values: Introduction to Why Six Sigma is Being Implemented.

Business Metrics: Introduce New Concepts on Six Sigma Performance

Measurement, with Discussion on Corporate Strategy.

History Of Quality: The Evolution of Quality and Continual Improvement.

Where does Six Sigma fit in?

Breakthrough Strategy: Terminology, Strategy and Roadmap of the Six Sigma

Methodology. Understanding the Six Sigma Define-Measure-Analyze-Improve-

Control (DMAIC) process.

Process Characterization: Process Performance in Terms of Yield, Capability and

Sigma.

Statistics: The basics of statistical thinking and what to expect to see and how to

use the information in a Six Sigma project report.

Tools: Overview of Main Tools Used as Part of the Six Sigma Toolkit – what to

expect in a Six Sigma report?

Training Title: Six Sigma TM Breakthrough Techniques

for World Class Result

Duration: 2 days Objective:

Plan and control stock successfully and cost effectively using proven techniques of

inventory management.

Forecast demand and control lead time.

Classify, count and reduce inventory.

Reduce inventory investment and surplus.

Use the right key performance indicators for the measurement and evaluation of

the inventory department

Course Outline:

Introduction to Inventory Management

Objectives and Responsibilities of Inventory Management

Customer Service in Inventory Management

Inventory Management

Description and Classification of Inventory

Types of Inventory

The ABC Inventory Classification

Materials Specifications/ Cataloguing

Forecasting Demand and Lead Time

Techniques of Forecasting

Seasonal Demand

Moving Average

Exponential Smoothing

Control of Lead Time

Inventory Systems

Inventory Costs

The Max-Min System

When and How Much to Order

Controlling Safety Stocks

How to Deal with Quantity Discounts

Training Title: Inventory Planning and Stock Control – Materials

Management

Counting and Controlling Inventory

Counting Methods and Accuracy

Periodic and Cycle Counting

Reducing Inventory Investment

Identification and Disposal of Surplus

Just-In-Time (J. I. T.) Method

Measuring Inventory Management Performance

Key Performance Indicators (KPIs) and Targets

Duration: 1 day Program Overview of Supply chain:

What Is Supply chain, Supply chain entities, SCM Evolution, Supply Chain drivers,

SCOR Model:

Outline of SCOR Model

Logistics as a key supply chain driver:

Importance of Logistics in SCM , Logistics goals & Strategies , Strategic issues in ware

housing , Transportation as an element of Logistics , 3 PL & 4 PL , Unique features of

International logistics

Supply chain planning in Industry:

S & OP, MPS, MRP, Capacity Planning

CRM & SRM:

Need for CRM, CRM strategy, Role of SRM, Supplier selection , Performance measurement

& Retention

Recent trends in Supply chain:

Supply Chain mapping & Supply chain audit

IT & SCM:

Role of IT as an integrator, Different SCM IT tools

Training Title: Essentials of Supply Chain Management - Sr. Level

Duration: 3 days

Course Outline

A. Identifying key competencies and weaknesses across your supply chain

Evaluating risk and value in your supply chain

Understanding key value drivers and value enablers

Key components of a value preposition

Developing a supply chain value proposition

Identifying critical success factors

Considering implications to key stakeholders

Developing a lean supply chain strategy according to organizational

objectives

Understanding corporate cultural differences in the supply chain

Principles of Lean Thinking

Applying Kaizen principles to supply chain management

Cycle time reduction tools

Lead time analysis

Communication

Risk mitigation strategies

Logistics: warehousing, domestic and global transportation, documentation

requirements and costs, third-party logistics, reverse logistics

Tips for trimming waste throughout the chain

Tips for eliminating barriers and non-value-adding steps

Tips for accelerating flow in each link of the chain

Integrate outsourcing to your lean chain

Identify efficiency opportunities of freight, inventories, flows, and systems

Training Title: Cost Effective Supply Chain Management

Developing Sourcing and Contracting Strategies

Forming lean supplier partnerships, Building an integrated supplier network

Building a supplier data warehouse

Involving suppliers earlier in new product development

Using supply chain assets collectively

Using your resources to help a supplier

B. Streamlining the Make versus Buy Decision (manufacturing industries)

Streamlining the internal versus outsource decision (service-related

industries)

Procuring services with statements of work, Standardization, Simplification

Realistic strategies for JIT sourcing, Lean inventory tracking methods

Eliminating barriers to continuous material flow

Making effective use of contract manufacturers and turnkey service

providers

Integrating EDI or Web-based procurement into your overall strategy

Forming a proprietary "extranet"

Measuring supply chain performance for continuous improvement

Defining objectives and critical success factors for the measurement system

Gathering marketplace information

Finding potential benchmarking partners

Cost modeling

Target costing, setting specs, calculating target costs, cost-based pricing,

design or purchase

Non-price cost issues

Duration: 2 days

Part -I: Program Overview

Current Market Dynamics

Introduction to Logistics Management

What’s & Why’s of Logistics

How does Logistics provides Business & value

Return on Investment focus

Fundamentals of :Logistics & Supply Chain Mgt

How does effective Logistics leads to better Supply Chain Management

Part II- Strategic Sourcing–Aligning Procurement needs with Business

Goals

Introduction

Strategic Sourcing Model

How to Achieve Strategic Sourcing

Part III - Collaboration & Partner ship

Buyer – Supplier Relations / Buyer - Supplier Attributes

Best Practices in Supplier Relationship Management

Part IV – Quality Assurance & Lean Management

Quality Initiatives & Lean Management Tool Kit

Frame work for Vendor Quality Improvement Program

Part V – Inventory Management

5.1 Understanding Pitfalls in Inventory Management

5.2 Opportunities for Cost Reduction

Part VI– Logistics & Information Technology Check list for Excellence / Review & Integration (CASE STUDY: BASED ON THE REQUIREMENT)

Training Title: Logistics Management Work Shop

Duration: 1 Day

Objective of the Workshop:

Triggering the Idea

Defining & explaining the factors responsible thru Activity / exercise / Inputs

facilitating Growth Process

Understanding the components of Organizational Behavior

Management v/s Leadership

Attitudinal Understanding

Emotional intelligence

Emotional traits that support Growth ( EQ V/S IQ )

Bring about a change in the mindset

Factors of Success

Decision making in the area of Materials management

Methodology adopted Activity / Exercises

Interactive sessions

Experience Sharing - Lecture / Presentation based

Training Title: Preparing for Future Competencies

Duration: 1 Day

The Role of Purchasing: Current Business Environment and Importance of Purchasing Function, Purchasing

Process, Purchasing Market Research, Global Sourcing.

E-Procurèrent:

Reverse Actions, MRP & ERP

Negotiations: Process & Phases, Characteristics of Successful Negotiators.

Inventory Management:

Lead Time Management, Just-in-Time Inventory,

ABC/HML/SDE/SOS/GOLF/VED/FSN/XYZ Analysis, MUSIC, Management of Spare Parts

Financial Aspects of Materials Management

Modern Storage and Warehousing Practices:

Automated Storage and Retrieval Systems, Automated Identification Systems, RFID,

Legal and Commercial Aspects of Purchasing and Materials Management.

Overseas Buying: INCO Terms 2000 of the International Chamber of Commerce

Logistics & Supply Chain Management:

Role of 3PL/4PL Service Providers.

How Suppliers Can Add Value:

Key Supplier Account Management (KSAM), Supplier Relationship Management,

Measuring Purchasing & Materials Management's Performance, Impact & Productivity

Modern Concepts:

Benchmarking, Green Purchasing, Best Practices in Supply Management, Business

Process Outsourcing.

Training Title: Purchasing & Materials Management – Level 2

(Including Logistics & Supply Chain Management)

Duration: 1 Day

Program Overview:

Stores Management covering function of stores , Type of stores ,Responsibility of stores ,

Receipts , Issues , Preservation , Physical verification , Safety & security , Inventory

covering , What is Inventory , Types of Inventory , Inventory Classification Like ABC ,

VED , FSN , HML etc , E O Q , Replenishment model ,Materials . Handling Principles ,

Equipments maintenance etc, Store manual

Training Title: Stores Management

Duration: 1 Day Program Overview:

Types of Procurement / Purchasing in Industry, Budgeting

Purchasing Cycle , Review of Demand , Source Identification

Approved vendor list , RFQ ,RFP ,RFI , Tendering process , Type of tenders ,

Comparative statement , P O , Follow up , Receipt of Materials

Payments , Price analysis , Cost Analysis , Vendor development

Vendor appraisal , vendor performance evaluation , Purchase Research etc , INCO

Terms for Imports , Purchase policy . Purchase .Manual , Reverse Auction

Training Title: Procurement Management