Training

The most frequent form of our courses is lecturing accompanied with animated  MS PowerPoint® presentation. Courses are sectioned to 50 minutes training hours. Each participant receives his own guide.

Let you have a look at several demonstrations of training presentations.

To see the detailed content and duration of a course either click on the List... below or download the Training Catalogue. The courses may be modified according to customer specific needs.

If you are interested in the training at your company site, please, contact us and we will send you a quotation. The training price is given by a training duration and not by the number of participants. The travel and participant guides costs will be included in quoted price, however the guides are available also free in electronic versions for printing by customer.

We do not organize the open courses with inividual partiipation.

List and Description of Courses

(or you can download Training Catalogue)

The Tools and Methods for Analysis, Measurement and Continuous Improvement

The course provides in 3 hours an overview and basic information about tools and methods for quality control; it is dedicated particularly to management from the field of quality, technology and manufacturing as an introductory training.

Content:

  1. Advanced quality approach – Taguchi Loss Function
  2. Methods and tools for the quality planning  - QFD, FMEA, benchmarking, simple tools: brainstorming, cause and effect diagram (Ishikawa), process mapping, team decision techniques,  plotting, Pareto diagram, histogram
  3. Cost of quality
  4. Process capability, quality measurement – process variability, capability indices, process of capability investigation (repeatability and reproducibility of measurement system, data distribution, statistical stability)
  5. Control Charts – principle of statistical process control (SPC), control chart like a nonconformance prevention tool
  6. Design of Experiments - DOE – principle, comparing with traditional experiments, contribution
  7. Linear regression, ANOVA  - basic purpose
  8. 8D – Problem solving method – description of 8 steps

QFD – Quality Function Deployment

The course explaines in 4 hours the value of QFD method and the process of its development demonstrated on an example from machinery industry. The course is determined particularly for designers and engineers from the area of process development, quality control and manufacturing control. 

Content: 

  1. The purpose and history of QFD, basic principles and methodology of performing
  2. Product quality planning, 1st quality matrix, description of 10 steps of product design planning phase
  3. Parts quality planning, 2nd quality matrix, description of 6 steps of product parts design planning phase
  4. Process planning, 3rd quality matrix, description of 6 steps of product manufacturing processes planning phase
  5. Manufacturing planning, description of basic steps of product manufacturing planning phase 

DFMEA – Failure Mode and Effect Analysis in Design

The course explaines in 3 hours the value of DFMEA method and the process of its development  in compliance with the methodology according Chrysler, Ford, GM - FMEA Reference Manual, 4. Edition and is demonstrated on an example from machinery industry. The course is determined particularly for product designers and engineers from the area of quality control. 

Content:

  1. FMEA types and purpose
  2. Basic principle, block scheme/system structure, requirement identification, team forming
  3. Process of  DFMEA preparing, criteria of risk evaluation, each step of analysis explanation
  4. Results record

PFMEA - Failure Mode and Effect Analysis in Process

The course explaines in 3 hours the value of PFMEA method and the process of its development  in compliance with the methodology according Chrysler, Ford, GM - FMEA Reference Manual, 4. Edition and is demonstrated on an example from machinery industry. The course is determined particularly for designers and engineers from the area of quality control. The course is determined particularly for  process and technology designers, quality and manufacturing control engineers. 

Content:

  1. FMEA types and purpose
  2. Basic principle, block scheme/system structure, requirement identification, team forming
  3. Process of  PFMEA preparing, criteria of risk evaluation, each step of analysis explanation
  4. Results record

Process Control Plan

The course explaines in 2 hours the procedure of Control Plan development in compliance with APQP Reference Manual, 2nd Edition – Chrysler, Ford a GM. It is determined for company metrologists, product, technology and process designers and quality and manufacturing control engineers 

Content:

  1. The Process Control Plan purpose
  2. The process of development
  3. The description of content 

8D – Problem Solving Methodology

The course explaines in 5 hours process of utilization of 8D (Global 8D) methodology and  each of problem solving steps. It is determined for a wide extent of working functions dealing with problem solving.  

Content:

  1. Purpose, overall process and scope of 8D utilization
  2. Step D0 – Preparing for problem solving process, symptom description
  3. Step D1 – Team forming
  4. Step D2 – Problem description: transforming of symptom to problem, technique of problem description
  5. Step D3 – Interim Containment Actions identification, typical containments
  6. Step D4 – Definition and verification of root cause and escape point, theory of root causes, techniques utilized, C&E Diagram (Ishikawa), 5Why method, verification methods
  7. Step D5 – Identification and verification of permanent corrective actions, criteria for  selection, risk analysis, verification
  8. Step D6 -  Implementation and validation of permanent corrective actions, potential barriers identification and prevention
  9. Step D7 – Prevention, system changes
  10. Step D8 – Team and members contributions
  11. 8D report form

Root Cause Analysis

The course explaines in 2 hours the principle, technique and suitable tools for analysis and identification of root causes of problems; it is determined  for a wide extent of working functions dealing with problem solving. 

Content:

  1. Root cause definition
  2. General process of root cause identification, team work, brainstorming
  3. All possible causes identification: Cause and Effect Diagram (Ishikawa Diagram), Failure Tree Analysis (FTA)
  4. The most probable/root causes identification: multivoting, criteria analysis, 5Why method
  5. Root cause verification: graphic methods, hypothesis tests (informative only), DOE (informative only)

Process Capability

The course explaines in 3 hours  the value of process capability (performance) estimation and the technique and formulas how to express it in compliance with Chrysler, Ford, GM - SPC Reference Manual, 2. Edition.  It is determined for product, technology and process designers and quality and manufacturing control engineers. 

Content:

  1. Current quality approach - Taguchi Loss Function, target value and variance
  2. Process variability – normal distribution, process variability determination
  3. Capability / performance indices Cp, Cpk / Pp, Ppk - the sense of indices, calculation method, one-sided/two-sided spcifications 
  4. The assumptions about data for calculation, sources of variance, measurement system analysis contribution to process variability, normality testing, statistical stability testing 
  5. Cpk vs. ppm, interval estimation of Cp/Cpk, a problem of multiple product/process characteristics

Statistical Process Control

The course explaines in 4 hours  the principle and the ways to statistically control a process (SPC) and procedures to implement them in compliance with methodology of Chrysler, Ford, GM – SPC Reference Manual, 2.Edition.  It is determined for product, technology and process designers and quality and manufacturing control engineers. 

Content:

  1. Current quality approach, process variability, target values and variance of characteristics, process variability, normal distribution
  2. Statistical process control  - principle, common and special causes of variability, basic types of signals about special variability causes 
  3. Control charts of continuous variables – types of control charts: sample means and ranges, medians and ranges, means and standard deviations, individual values and moving ranges
  4. Control charts of attributive variables  - types of control charts: number of defective parts, proportion of defective parts, number of defects, proportion of defects
  5. Control chart CUSUM and EWMA - principle 

Quality and Customer Satisfaction

The course explaines by popular form in 2 hours  the causes and effects of customer satisfaction/dissatisfaction and the significant role of quality in that. It is determined for wide extent of people from middle management up to operators and workers.

Content:

  1. How do you react in the role of ordinary customer
  2. How does react disssatisfy customer and what are the effects
  3. Who is our customer, external and internal customers
  4. What is an effect of poor quality
  5. Identification of customer needs and requirements  – workshop

Measurement System Analysis

The course explaines in 6 hours  the basics of  measurement errors theory, types of errors and their estimation for  industrial  purposes in compliance with Chrysler, Ford, GM – MSA Reference Manual, 4.Edition and VDA 5, July 2012.  It is determined for company metrologists, product, technology and process designers and quality and manufacturing control engineers.  Remark: participants are supposed to be generally familiar with basics of statistics.

Content:

  1. Measurement error types
  2. Measurement error analysis of continuous variables – bias, repeatability and reproducibility (R&R), stability linearity, consistency and homogeneity
  3. Methods of determination of bias, linearity, stability, R&R (averages and ranges method or ANOVA)
  4. easurement process capability according VDA 5, Cg/Cgk, determination of combined measurement uncertainty
  5. Gauge performance curve 
  6. Measurement error analysis of attributive variables  - kappa statistics

Design of Experiments (DOE)

The course explaines in 4 hours  the value of DOE methodology, describes the procedures of basic  two-level full and half-fractional factorial experiments  and the methodology of results analysis and interpretation.  It is determined product, technology and process designers and quality and manufacturing control engineers. 

Content:

  1. DOE principle and purpose – Taguchi loss function, continuous improvement, cost reduction, product development time reduction
  2. Experimental method, problem and goal
  3. Dependent and independent characteristics (factors), constants, noise factor levels
  4. Designs for two, three and four factorial full experiments, fractional four factorial experiment
  5. Experiment analysis (screening) – response, interactions, average prediction, multi-dimensional analysis, dependence equation
  6. Experiment verification – experimental error, effects significance, results confirmation (t-test)

TPM - Total Productive Maintenance

The course explaines in 3 hours  the principle and individual pillars of TPM methodology what  serves as a tool for effectiveness increasing of manufacturing processes and machines.  It is determined to engineers, technicians and foremen controlling quality, manufacturing processes, maintenance and repairs. 

Content:

  1. TPM purpose and principle, the basics and pillars
  2. 5S+
  3. Equipment performance improvement by elimination the 6 types of losses related to equipment, OEE – overall equipment effectiveness 
  4. Autonomous maintenance – the operators role at maintenance and equipment understanding
  5. Maintenance planning – periodical, preventive and predictive maintenance
  6. Maintenance-focused education and training
  7. Preventive maintenance application plan during the equipment development

Advanced Product Quality Planning (APQP) and Process Control Plan

The course explaines in 4 hours the systematic approach how to plan the quality of product supplied to automotive industry and the procedure of Control Plan development both in compliance with APQP Reference Manual, 2nd Edition – Chrysler, Ford a GM. It is determined for company metrologists, product, technology and process designers and quality and manufacturing control engineers 

Content:

  1. Definition and planning: inputs and outputs description
  2. Product design and development: inputs and outputs description
  3. Process design and development: inputs and outputs description
  4. Product and process validation: inputs and outputs description
  5. Feedback, assessment and corrective actions
  6. Control Plan methodology

Production Part Approval Process (PPAP)

The course explaines in 4 hours the requirements and procedure of production parts supplied to automotive industry in compliance with PPAP Reference Manual, 4th Edition – Chrysler, Ford, GM and VDA Band 2 - Quality Assurance of Supplies, Production Process and Product Approval, 4.Edition 2004 (English version). It is determined particularly for quality control managers, process designers, manufacturing control managers and company metrologists.

Content:

  1. Section 1: General, comparison to VDA 2
  2. Section 2: PPAP process requirements, comparison to VDA 2
  3. Section 3: Customer notification and submission requirements, comparison to VDA 2
  4. Section 4: Submission to customer – levels of evidence, comparison to VDA 2 
  5. Section 5: Part submission status, comparison to VDA 2
  6. Section 6: Record retention, comparison o VDA 2

 

Also, 3 hours courses are also available:

- PPAP - according PPAP Reference Manual, 4th Edition – Chrysler, Ford, GM

- PPA - according VDA Band 2 - Quality Assurance of Supplies, Production Process and Product Approval, 4.Edition 2004 (English version).

Waste Reduction and Process Speed

The course explaines in 2 hours the basic concepts of waste reduction (Lean) and its basic metrics. It is determined particularly for technology and process designers, quality and manufacturing control managers. 

Content:

  1. Waste reduction concept (Lean), seven kinds of waste (Muda)
  2. Process Lead Time (PLT), definition and determination
  3. Work in process (WIP) and Process Exit Rate
  4. The effect of process lead time reduction
  5. Process efficiency, value added activities

Generic and Replenishment Pull System

The course explaines in 4 hours the basic Lean concept of Process Lead Time control by Work In Process (WIP) control; it is determined particularly for technology and process designers, quality and manufacturing control managers.

Content:

  1. Principle of generic pull systems
  2. Determination of optimized WIP Cap
  3. Replenishment pull system in production process
  4. Strategic buffers, safety stock, Kanban system
  5. Key parameters of replenishment pull system, calculation

Value Stream Mapping

The course explaines in 3 hours concept of value stream, purpose and procedure how to mapping it in actual status (As  Is) and improved status (Should Be).  It is determined particularly for technology and process designers, quality and manufacturing control managers.

Content:

  1. Value and its stream, value stream map, recommended process of development
  2. Strategic goal and product family identification, development of processes and activities map
  3. Record of important variables, material and information stream recording 
  4. Identification of important process data and processing times  
  5. Identification of waste
  6. Application of Lean solutions
  7. Priorities determination and implementation plan development

Basics of Statistics

The course explaines in 2x6 hours the basic statistical concepts, methods and tools . It is determined for university/secondary school graduated people who are  expected to use industrial statistics applications like data analysis, SPC implementation, measurement systems analysis, DOE evaluation, analysis in improvement projects etc. 

Content:

  1. Data types and scale of notation
  2. Probability, population and sample 
  3. Parameters, statistics, frequency, frequency distribution, distribution function and their properties
  4. Location and dispersion metrics, quantiles, percentiles, mean value, median, modus, sigma
  5. Binomial distribution, Normal distribution, Histogram, Box plot, Central limit theorem
  6. Point and interval estimations
  7. Statistical hypothesis test principle, z-test, t-test, paired t-test, F-test
  8. Analysis of variance (ANOVA)

Lean Six Sigma Green Belt

The course,  in 10 x 6 hours, supplemented by  2 x 6 hours dealing with Lean Six Sigma projects of participants, prepares  Green Belts for company Lean Six Sigma program. It is determined particularly for designated Green Belts, but also for those university/secondary school graduated people, who are expected to deal with process and product improvement. 

Course is acredited by Ministry of Education of Slovak Republic, acreditation No. 3081/2009/610/1 

Content:

  1. Introduction of  Lean Six Sigma - Lean Six Sigma (LSS) concept, organizational structure of  Lean Six Sigma, the way of program realization, methods and tools in LSS – DMAIC, project charter and plan
  2. Project team forming  - introduction, Quad Chart, RACI diagram, Belbin theory of team roles
  3. Voice of customer analysis – voice of customer, Model Kano, KPOV, KPIV, SIPOC diagram, basic metrics in Six Sigma – DPU, DPMO, yield  (FPY, RTY),  Sigma level, basic metrics in Lean - PLT, PCE
  4. Basics of statistics – data types, probability, population, sample, parameters, statistics, probability distribution, properties of distribution function, quantiles 
  5. Introduction to descriptive statistics – location, dispersion and shape metrics, binomial and normal distribution, histogram, Stem and Leaf plot, Box and Whisker plot, sampling, central limit theorem, degrees of freedom, point and interval estimations, confidence interval, workshop in Excel/JMP
  6. Process speed – process lead time (PLT), work in process (WIP), Exit rate (ER), Value added time (VA Time), process cycle efficiency (PCE)
  7. Value stream mapping – 1st part  - Value Stream Map As Is, hidden fab
  8. Data collection – data collection plan, data stratification, cause and effect diagram, multivoting, cause and effect matrix, Pareto diagram
  9. Statistical hypothesis tests – principle of Z-test,  I.type and II.type error, test power, two tail/one tail test, p-value, overview of  mean tests - t-test,  t-test in Microsoft Excel/JMP, F-test for variance, F-test in Microsoft Excel/JMP, analysis of variance – ANOVA,  ANOVA in Microsoft Excel/JMP, statistical and technical significance
  10. Correlation and regression analysis – correlation coefficient, correlation in MS Excel/JMP, one-factor linear regression, estimation of  0 a 1, R-square coefficient, prediction, Lack of Fit error, residual analysis
  11. Measurement system analysis - bias, linearity, stability, variability of measurement, repeatability and reproducibility, homogeneity, consistency, attributive systems – kapa statistics, workshop – R&R, evaluation in MS Excel/JMP
  12. Process capability – capability study, sampling plan, statistical stability, short-term/long-term capability, capability indices Cp/Cpk, relation to %R&R
  13. Control charts – selection of control chart, rational subgrouping, sources of variance, control chart types, process of development, rules of out of control status, out of control action plan, control charts: Xbar – R, Me – R,  Xbar – s, X – MR, control charts for attributive characteristics, Pre-control chart, over-adjustment, workshop – control chart parameter calculation 
  14. Root causes identification – basic tools, other methods
  15. Selected methods for improvement - Mistake Proofing, 5S, rapid exchange (SMED), TPM, FMEA
  16. Generic pull systems – principle, WIP Cap determination, workshop to compare push and pull system
  17. Replenishment pull system – manufacturing replenishment pull system, balance-on-hand buffer, safety stock, Kanban, key parameters of replenishment pull system and its calculation
  18. Design of experiments – assumptions, process of design, goals, input and output characteristics identification, factor setting, coding, model equation for two level full factorial experiment, replications and repetitions, workshop – design and evaluation of DOE 
  19. Value stream mapping – 2nd part - Future Value Stream Map
  20. Control plan – goal and principle of development

Microsoft Excel – Formulas and Charts

The course teaches in 2x4 hours  tables and forms creation using calculations and data analysis using charts and diagrams. It is determined for those who are expected to create forms and tables in Excel complemented by calculations and charts. Prerequisite: basic computer/Excel skills 

Content:

  1. Arithmetical operations, formulas, absolute and relative references, references from other sheets and files, formula copy/paste, trace precedents and dependents
  2. Text functions (LEFT, RIGHT...), date and time functions (DATE, TIME...)
  3. Conditional formatting, data validation
  4. Prepare data for a chart, chart creation, chart types, secondary axis, user defined chart types

Microsoft Excel – Database Tools

The course teaches in 4 hours  to utilize standard database tools; it is determined for those who are expected to deal with large tables/databases. Prerequisite: basic computer/Excel skills  in the extent of MS Excel – Formulas and charts course minimum.

Content:

  1. Sorting, user defined series, auto filter, advanced filter, function SUBTOTAL
  2. Filters and charts
  3. Pivot table
  4. Lookup functions (VLOOKUP, HLOOKUP)

Microsoft Excel – Special Functions and Options

The course teaches in 4 hours  to utilize special functions and options; it is determined for those who are expected to create in Excel complex mathematical-graphical solutions and specialized calculators and who need to utilize Excel more intensive than the extent of previous two courses

Content:

  1. Function with output in the form of a field, database functions (DAVERAGE...)
  2. Control forms in a sheet, indirect references (INDIRECT, OFFSET, ...
  3. Solver, cyclical references

JMP – Working with JMP and Basic Statistical Tools

The course teaches in 3X5 hours  to sort data for JMP, work with JMP data table, utilize selected JMP tools. It is determined for those who are expected to perform statistical data analysis. Prerequisite: basic computer skills, knowledge of statistics in th extent of course Basics of Statistics (20).

Content:

  1. Distribution analysis, process capability
  2. Correlation analysis,  spinning plot, Pareto chart, causes and effect chart, control chart, contour plot, surface plot
  3. Test for mean values (t-test), test for variances, (ANOVA, multivari chart)
  4. Gage capability study

JMP - Industrial Experiments Design and Analysis (Doe)

The course teaches in 3X5 hours  to prepare experiment plan in JMP, use the tools for analysis of experiment and interpretation of results. It is determined for those who are expected to preform/be responsible for process/product characterization and improvement. Prerequisite: basic computer skills, knowledge of statistics in th extent of course Basics of Statistics (20) and pass or have knowledge in the extent of previous course JMP (25a).

Content:

  1. Model, full factorial design,  fractional and other plans
  2. Experiment prepare, regression analysis
  3. Experiment realization and analysis