Total Quality Management For Manufacturing Excellence

Description

Total Quality Management is an organisation-wide approach to improving quality, productivity and customer satisfaction. This course provides practical knowledge of TQM principles and proven quality tools used in manufacturing. Participants will learn how to control process variation, solve recurring problems, reduce defects, improve supplier performance and build a sustainable culture of continuous improvement.

Course Details

The course explains how quality can be built into every stage of manufacturing instead of depending only on final inspection.

Through practical examples and assignments, participants will learn to:

• Understand customer requirements.
• Apply PDCA and SDCA.
• Use the 7 QC tools.
• Monitor processes using basic SPC.
• Solve problems using 8D methodology.
• Implement Daily Work Management.
• Understand Policy Deployment.
• Promote Maker’s Quality and quality at source.
• Conduct quality audits.
• Improve supplier quality.
• Sustain Kaizen and continuous improvement.

Course Modules

Module 1: Fundamentals of TQM

• Meaning and evolution of quality.
• Quality Control, Quality Assurance and TQM.
• Principles and benefits of TQM.
• Leadership and employee involvement.

Module 2: Customer-Focused Quality

• Internal and external customers.
• Voice of the Customer.
• Customer satisfaction and complaints.
• Quality, cost and delivery expectations.

Module 3: Quality Measurement

• Quality-performance indicators.
• Rejection, rework and defects.
• First Pass Yield and Right First Time.
• Cost of Quality and Cost of Poor Quality.

Module 4: PDCA, SDCA and Kaizen

• PDCA for improvement.
• SDCA for maintaining standards.
• Standardisation and work instructions.
• Continuous improvement practices.

Module 5: Seven Quality-Control Tools

• Check sheet.
• Pareto chart.
• Cause-and-effect diagram.
• Histogram.
• Scatter diagram.
• Control chart.
• Stratification and flowchart.

Module 6: Basic Statistical Process Control

• Process variation.
• Common and special causes.
• Control limits and specification limits.
• Basic control charts.
• Process stability and capability.

Module 7: 8D Problem Solving

• Problem definition.
• Containment action.
• Root-cause analysis.
• Corrective action.
• Prevention of recurrence.
• 8D report preparation.

Module 8: Daily Work Management

• Daily quality, cost and delivery monitoring.
• Visual-management boards.
• Daily review meetings.
• Escalation and corrective actions.
• Sustaining routine performance.

Module 9: Policy Deployment

• Organisational and departmental objectives.
• Breakthrough targets.
• Action planning.
• Performance review.
• Alignment of improvement activities.

Module 10: Maker’s Quality

• Quality at source.
• Operator ownership of quality.
• Self-inspection.
• Mistake-proofing.
• Defect prevention.

Module 11: Quality Audits

• System, process and product audits.
• Audit planning and checklists.
• Nonconformity reporting.
• Corrective-action follow-up.
• Document and record control.

Module 12: Supplier Quality Management

• Supplier selection and evaluation.
• Supplier rating.
• Incoming-quality performance.
• Supplier audits.
• Supplier development and partnership.

Module 13: TQM Implementation

• Assessing the current quality system.
• Identifying improvement priorities.
• Establishing quality objectives.
• Developing a TQM implementation plan.
• Sustaining a quality culture.

Certificate :

On successful Completion of the Course, the Certificate will be Issued by Kriatec Services Pvt Ltd.