7 QC Tools

With continuous improvement (kaizen) and Total Quality Control (TQC) becoming increasingly important to world class companies, there's an urgent need to build quality into every management decision.

The tools, also known as 7 New QC Tools, represent the most important advance in quality deployment and project management in recent years. Unlike the seven traditional QC tools, which measure quality problems that already exist and are used by quality circles, these seven new QC tools make it possible for managers to plan wide-ranging and detailed TQC objectives throughout the entire organization.

These tools will help you to: Expand the scope of quality efforts company-wide, Set up and manage the systems necessary to resolve major quality problems, Anticipate potential quality problems and actually eliminate defects before they happen.

Duration : Two days

At the end of this training, participants should be able to:
  • Understand the fundamental principles of problem-solving
  • Use each of the Basic 7 QC tools and New 7 QC Tools to resolve complex issues and projects
  • Defined the purpose, value and applications of each of the tools
  • Facilitate the use of the 7 new tools in groups and based on its stage in the process
  • Using combination of both Basic & New 7 QC Tools
  • Comment critically on corrective actions raised as a result of applying the tools
  • Interpret and measure the effectiveness of implemented solutions
Group Discussions, Case studies, Exercises, samples, Group projects.
Expected participants
Manager, project leaders, team leaders, and facilitators, and the other employees involved in planning and completing specific projects and/or the resolution of complex issues or task.

8 D Problem Solving

8D (Eight Disciplines of Problem Solving) is a meticulous process used to solve complex problems. This is a popular method for problem solving because it is reasonably easy to teach and effective. 8D uses composite problem solving methodology, by borrowing tools and techniques from various approaches. The original 8D process was pioneered by Ford Motor Company and called TOPS (Team Oriented Problem Solving). The process is documented on a form with attachments; however, following the form does not complete the 8D process and will not yield desired results.

Duration : Two days

The session objectives involve a complete understanding of the process:
  • 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.
  • Design a Check Sheet for recording data
  • Construct a Pareto Chart
  • Use an IS/IS NOT analysis for problem definition
  • Use the 5 Whys (Multiple Whys)
  • Use Structured Brainstorming techniques
  • Create a Cause and Effect (Fishbone) Diagram
  • Use the Nominal Group Technique (NGT)
  • Use a Force Field Analysis
  • Use an Action Matrix
  • Create a Histogram
  • Create a Scatter Diagram
  • Construct a Run Chart
  • Describe the fundamentals of Value Stream Mapping
  • Explain the six basic principles of Statistical Process Control
  • Describe basic types of control charts
  • Describe the use of Process Capability (Cp and Cpk)
Interactive and group exercises on application of the tools.

Analytical Tools and Techniques

This Template is a suggested outline for two days training program on Analytical tools and Techniques that teaches about the basics of problem solving techniques and application of analytical skills in day to day work .w E have designed an interactive program to make it easy for participants to understand the concept and also to make it interesting. The Outline below identifies the overall training objectives for this training, the domains (knowledge, awareness and skills) included in the training and also the structure.

Duration : Two days

  • Understand the importance of analytical tools and techniques
  • Explaining Deming Cycle andBasic StepsOf ProblemsolvingTechniques
  • Observation and data collection
  • Important do’s and don’ts of data collection
  • Application of these tools in day to day operation
  • Concept of variation, histogram, force filed analysis
  • Standardizations and conclusions
  • Improve their respective processes by applying these tools
  • Demonstrate the effectiveness of tools to their peers
Interactive and group exercises on application of the tools.
Expected participants
Individuals with supervisory and managerial responsibility required to utilize analytical skills to solve problems at workplace.


A failure modes and effects analysis (FMEA) is a procedure in product development, systems engineering and operations management for analysis of potential failure modes within a system for classification by the severity and likelihood of the failures. A successful FMEA activity helps a team to identify potential failure modes based on past experience with similar products or processes, enabling the team to design those failures out of the system with the minimum of effort and resource expenditure, thereby reducing development time and costs. Because it forces a review of functions and functional requirements, it also serves as a form of design review. It is widely used in manufacturing industries in various phases of the product life cycle and is now increasingly finding use in the service industry. Failure modesare any errors or defects in a process, design, or item, especially those that affect the intended function of the product and or process, and can be potential or actual.Effects analysis refers to studying the consequences of those failures.

Duration : Two days

  • Describe the purpose of an FMEA and explain the benefits of using FMEAs in both design and process engineering situations.
  • Explain the ten steps to conducting an FMEA.
  • Contribute effectively to an FMEA team.
  • Customize FMEA rating scales.
  • Participate on an FMEA team
  • Making immediate contributions to quality and productivity improvement efforts.
Interactive and group exercises on application of the tools.

Design of Experiment

The training course presents concepts and software tools that you could use to help your organization Design experiments that are effective for studying the factors that may affect a product or process. Analyze experimental results in order to identify the significant factors and evaluate ways to improve and optimize the design. Go beyond traditional DOE techniques in order to apply the proper analysis treatment for the response information that is often of interest to reliability engineers - product lifetime data.

Duration : Two days

After undergoing the session , participant will be able to learn the following:-
  • Need for systematic approaches to data analysis and design of experiments. Overview of the subject
  • Introduction to probability and statistics for engineers
  • Statistical inferences: Fundamentals, confidence intervals, hypothesis tests, comparison of means and variances
  • Data analytic tools: Correlation, Analysis of Variance (ANOVA); Interpretation of results from experiments; Reporting experimental data
  • Models and Methods: Linear Regression - bivariate and multivariate; Least Squares
  • Methods - basic and variants; Confidence interval constructions; Non-linear regression; Model assessment
  • Design of experiments: Statistical principles in experimental design - blocking, complete randomization; Factorial design;
  • Factor Effect Analysis: Analysis of individual factor and interaction effects; Response surface methodologies
  • Advanced topics: Variable selection; Fractional factorial design; Robustness
Multiple Case Studies and Applications, Interactive group work.


Forecasting is the process of making statements about events whose actual outcomes (typically) have not yet been observed. A commonplace example might be estimation for some variable of interest at some specified future date. It is a very important aspect for organizational development and growth for employees to be able to make effective and accurate forecasting based on data available

Duration : Two days

After undergoing the workshop, participants will be able to learn following :
  • Learn the objectives and techniques of forecasting
  • Understand the difference between cash flow and profit
  • Prepare forecasts using different sources of information
  • Understand the factors to consider when performing forecasts
  • Learn the Dos and Don’ts of forecasting
  • Understand and prepare a cash flow forecast
  • Understand the basics of capital expenditure forecasting
  • Update forecasts for actual results and evaluate actual results against forecasts
  • Learn how to monitor, report and make decisions based on forecasts
  • Use forecasting as a performance measurement tool
  • Prepare a forecast (comprehensive case study)
  • Failure forecast
Who should attend ?
Entrepreneurs, line managers, project leaders, persons involved in budgeting and forecasting or persons who use budgets and forecasts

Cost of Quality

What are quality related costs and how do you manage the costs within an organization? Find out in this two - day interactive workshop, which explains the role of quality cost management in an organization and offers insights into the quality cost model and how to implement it. The workshop includes useful advice on how to develop a system to track costs, create an action plan and understand tools to support managing the quality costs in an organization.

Duration : Two days

After undergoing the workshop, participants will learn the following :
  • Understand what the term Cost of Quality means
  • Define quality for each work process
  • Determine how to prevent work process failures.
  • Establish performance standards and calculate acceptable quality standards
  • Understand the meaning of “Conformance to Requirements”
  • Determine Non-Conformance Requirements
  • Determine preventative measures for all work processes
  • Create standards of performance
  • Measure the cost of conformance, non-conformance, internal failure and external failure
  • Calculate the cost of quality
  • Develop a Quality Statement
Experiential activities, group activities.
Who should Attend ?
Employees who need to improve their understanding and use of all quality measurements that can be used in the analysis of key business processes.

Lean Manufacturing

Lean manufacturing, lean enterprise, or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination. Working from the perspective of the customer who consumes a product or service, "value" is defined as any action or process that a customer would be willing to pay for.

Essentially, lean is centred on preserving value with less work. Lean manufacturing is a management philosophy derived mostly from the Toyota Production System (TPS)

Duration : Two days

Participants will be able to understanding the following after the workshop :
  • Define lean manufacturing.
  • Define waste in terms of lean manufacturing.
  • Identify common types of waste.
  • Explain the advantages of lean manufacturing.
  • Describe goals for a lean company that produces large volumes of a few products.
  • Describe goals for a lean company that produces small batches of many products.
  • Explain the importance of reducing product changeover times.
  • Explain the importance of reducing inventory.
  • Explain the importance of encouraging continuous product flow.
  • Describe a pull system.
  • Describe a cell.
  • Identify sources of process variation.
  • Distinguish between inspection and error detection.
  • Explain the necessity of employee involvement.
  • List the activities of a Five S Approach.
  • Explain the importance of continuous improvement.
  • Six sigma
Experiential activities, group activities, case studies
Who should Attend ?
All employees working at a company instituting Lean Manufacturing

Market Research

Market research is any organized effort to gather information about markets or customers. It is a very important component ofbusiness strategy.Market research is a key factor to get advantage over competitors. Market research provides important information to identify and analyze the market need, market size and competition.Market research, includes social and opinion research, [and] is the systematic gathering and interpretation of information about individuals or organizations using statistical and analytical methods and techniques of the applied social sciences to gain insight or support decision making.

Duration : Two days

Content :
  • Market research and its applications in decision making
  • Relevance of research to the automobile industry
  • Issues in market facing the automobile industry and the use of research
  • Incorporating the Voice of customer in the design of automobiles
  • Research design -types and application areas
  • Secondary and primary research and applications
  • Exploratory and descriptive designs
  • Sampling – relevance
  • Sampling methods
  • Choice criteria for sampling methods
  • Data collection methods
  • Applicability of methods
  • Errors in data collection
  • Accuracy of data collection
  • Designing questionnaire
  • Methods, precautions
  • Types of questions and sequencing
  • Practical session on making the questionnaire
  • Statistical methods of analysis of data
  • Logics of analysis
  • Voice of customer – what to look for
  • Presentation methods

Project Management

Project Management: From Idea to Implementation is a two-day program that is part of a series that allows managers to improve the performance of their work unit through developing their project management skills. Participants gain practical project management tools and techniques and acquire a model to follow when managing a project. The Program empowers a project manager to provide the needed focus and learn how to work with his or her key employees so that they can excel as the trainers for employees new to the task

Duration : Two days

After undergoing the workshop, participant will be able to understand the following :
  • Discuss the phases of the Project Management Life Cycle and a project manager's role in each phase.
  • List and discuss basic project success criteria and common reasons for project failure.
  • Discuss techniques for setting up a strong project team.
  • List and discuss elements of a Risk Management Plan.
  • Discuss techniques for planning and sequencing project activities.
  • Identify the Critical Path for completing a project on schedule.
  • List and discuss the cost elements that should be included in a project budget.
  • Discuss techniques for controlling for deviation from budgets and schedules.
  • Discuss key elements of project management communications and reporting tools.
  • Discuss key activities of project close-out.
Hands on experiential techniques, simulations, case studies, group work
Expected participants
Managers and team members of a project.

Time Motion Study

Time-and-motion study is the analysis of the time spent in going through the different motions of a job or series of jobs in the evaluation of industrial performance. Such studies were first instituted in offices and factories in the U.S. in the early 20th century. They were widely adopted as a means of improving work methods by subdividing the different operations of a job into measurable elements, and they were in turn used as aids in standardization of work and in checking the efficiency of workers and equipment. Objectives of the Training Program.

Duration : One days

  • To understand how it can be used to reduce the number of motions in performing a task in order to increase productivity.
  • To study the effective cost of an employee, per unit of time for the task they are primarily responsible for.
  • Understand the allocation of time to various ‘productive’ and ‘non-productive’ tasks.
  • Review of alternatives to make the best use of time.
Hands on experiential techniques, simulations, case studies, group work

Warehousing&Inventory Management

A simple definition of a warehouse is:‘A warehouse is a planned space for the storage and handling of goods and material. In general, warehouses are focal points for product and information flow between sources of supply and beneficiaries. However, in humanitarian supply chains, warehouses vary greatly in terms of their role and their characteristics.

Duration : Two days

Content :
  • Supply chain
    • Understand the body and the mind as roots of human creativity
  • Inventory (inward and outward)
    • Supply chain and inventory relationships
    • Types of inventory
    • Inventory policy and its role in warehousing
    • Role of forecast in Inventory management
    • Safety stock optimization
    • Sales inventory
    • Branch and attached warehouse operations
    • Sales forecast and inventory matching
    • Spare parts inventory management
  • Warehouse management
    • Warehouse operations
    • Trends and challenges
    • Storage norms
    • Storage of ‘critical’ goods
    • Storage and removal of goods
    • FIFO concept
    • Coding of materials
  • Transportation and handling
    • Loading and unloading
    • Transportation methods
    • Material handling methods
    • Protection and safely in handling
  • Latest trends in supply chain management
    • JIT approach
    • Technology in supply chain management
    • E commerce and supply chain management – impact on warehousing
Methodology :
Hands on experiential techniques, simulations, case studies, group work
Audience :
Employees involved at warehousing , Inventory or anyone who wants to learn about ware housing and inventory

World Class Manufacturing

A company embarking on World Class Manufacturing is the organization and empowerments of LEADERS and ASSOCIATES to maximize customer value throughout the entire business value stream by way of process flow and on demand response to the CUSTOMER. It strives to ensure customer value and sustained profitability through the relentless pursuit of perfection in terms of quality, cost and delivery in product design, manufacturing, logistics, supply chain, and all administrative business function.

This two-day workshop is jam-packed with practical tips, techniques and strategies for building a high-performance operation through adoption of Best Practices. These Best Practices have demonstrated substantial improvements in Cost, Quality, Delivery, Safety and Morale at hundreds of facilities worldwide. Whether you are looking to create a leaner, more productive operation, improve capacity utilization or explore alternative shift scheduling systems, this workshop will address practical, proven solutions.

Duration : Two days

Participants will understand and learn the following :
  • World Class Manufacturing Today
  • A high-level comparison: Six Sigma, Lean Manufacturing and Theory of Constraints (TOC)
  • What Are the Key Factors and Challenges to Implementing Lean?
  • World Class Benchmarking and Measurement
  • Good & Bad Metrics: How do metrics drive World Class Performance?
  • World Class Manufacturing Metrics: Are You Measuring the Right Things?
  • Value Stream Mapping: Visualizing the Waste
  • How to identify breakthrough performance opportunities for six sigma, Lean manufacturing, and TOC
  • A Closer Look at World Class Manufacturing Tools
  • "kaizen" problem solving:
    • The 7 Wastes
    • Analyze Video Examples for waste and discuss
    • A Quick Exercise to See the Difference 5 - S Can Make
    • How does information Flow in Your Facility


Statistical process control (SPC) is a method of quality control which uses statistical methods. SPC is applied in order to monitor and control a process. Monitoring and controlling the process ensures that it operates at its full potential. At its full potential, the process can make as much conforming product as possible with a minimum (if not an elimination) of waste (rework or trash). SPC can be applied to any process where the "conforming product" (product meeting specifications) output can be measured. Some key tools are used in SPC. These include control charts; a focus on continuous improvement and the design of experiments. An example of a process where SPC is applied is manufacturing lines.

Duration : Two days

  • 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
  • Understand basic geometric controls, datum’s and basic dimensions.
  • understand fixture and jig design
Hands on experiential techniques, simulations, case studies, group work

Data Analysis

Analysis of data is a process of inspecting, cleaning, transforming, and modeling data with the goal of highlighting useful information, suggesting conclusions, and supporting decision making. Data analysis has multiple facets and approaches, encompassing diverse techniques under a variety of names, in different business, science, and social science domains.

Data mining is a particular data analysis technique that focuses on modeling and knowledge discovery for predictive rather than purely descriptive purposes. Business intelligence covers data analysis that relies heavily on aggregation, focusing on business information. In statistical applications, some people divide data analysis into descriptive statistics, exploratory data analysis (EDA), and confirmatory data analysis (CDA). EDA focuses on discovering new features in the data and CDA on confirming or falsifying existing hypotheses. Predictive analytics focuses on application of statistical or structural models for predictive forecasting or classification, while text analytics applies statistical, linguistic, and structural techniques to extract and classify information from textual sources, a species of unstructured data. All are varieties of data analysis.

Duration : Two days

  • An awareness of the situation of qualitative data analysis within the inductive paradigm
  • An awareness of the situation of quantitative data analysis within the deductive paradigm
  • Skills in critically appraising the data analysis component of research studies
  • An appreciation of the different approaches to qualitative data analysis
  • An appreciation of the different approaches to quantitative data analysis
  • Skills in undertaking basic qualitative and quantitative data analysis
Hands on experiential techniques, simulations, case studies, group work

Six Sigma

Six Sigma is a business management strategy, originally developed by Motorola in 1986. Six Sigma became well known after Jack Welch made it a central focus of his business strategy at General Electric in 1995, and today it is widely used in many sectors of industry.

Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes. It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization ("Black Belts", "Green Belts", etc.) who are experts in these methods. Each Six Sigma project carried out within an organization follows a defined sequence of steps and has quantified financial targets (cost reduction and/or profit increase).

Duration : Two days

  • Significantly improved business results using a new Six Sigma methodology specifically designed for services companies
  • Develop proficiency among Black Belts, Green Belts and Yellow Belts with practical tools for maximizing effectiveness in a services environment.
  • Develop a capability for using simulation tools, process mapping, decision point analysis and process management to minimize the risks associated with the improvements typical in a services company situation.
  • Attain proficiency in Minitab and IGrafx software tools.
  • Acquire the leadership and technical skills required to implement Six Sigma, including developing useful metrics, selecting and managing projects, leading teams, and effectively managing change
Hands on experiential techniques, simulations, case studies, group work


Kaizen Japanese for "improvement", or "change for the better" refers to philosophy or practices that focus upon continuous improvement of processes in manufacturing, engineering, game development, and business management. It has been applied in healthcare, psychotherapy, life-coaching, government, banking, and other industries. When used in the business sense and applied to the workplace, kaizen refers to activities that continually improve all functions, and involves all employees from the CEO to the assembly line workers. It also applies to processes, such as purchasing and logistics that cross organizational boundaries into the supply chain. By improving standardized activities and processes, kaizen aims to eliminate waste (see lean manufacturing). Kaizen was first implemented in several Japanese businesses after the Second World War, influenced in part by American business and quality management teachers who visited the country. It has since spread throughout the world and is now being implemented in many other venues besides just business and productivity.

Duration : Two days

  • Understanding the need to change
  • How to use kaizen for problem solving
  • Understanding 5s
  • Process requires ongoing inspection and enforcement to ensure “Standardized Work” is being followed
  • Process does not improve automatically
  • Following standards will only maintain, not improve, the process.- Improvement focuses on the entire process.
  • Understanding JIT(just in time)
Using case studies,hands on experiential techniques, simulations, case studies, group work

QFD – Quality Function Deployment

Quality Function Deployment (QFD) was developed to bring a personal interface to modern manufacturing and business. In today's industrial society, where the growing distance between producers and users is a concern, QFD links the needs of the customer (end user) with design, development, engineering, manufacturing, and service functions.QFD is:
  • Understand the importance of concepts and process of communication
  • Develop an understand of Articulation, confidence, conviction and enthusiasm as components of superior communication
  • Have an understanding of how better listening skills lead to superior communication
  • Understand the verbal and non verbal behaviors which are commonly expressed during communication and how to use each one of these behaviors in different situations for maximum impact
  • Practice ways to reduce the vernacular Influence in verbal communication
  • Develop skills for result oriented business writing
Duration : One - Two days
Content :
  • Quality
    • Definitions of Quality
    • Quality and customer satisfaction
    • Customer delight as a concept
    • Listening to the voice of the customer
    • Understanding customer needs and perceptions of Quality
  • Quality assurance systems
    • Quality assurance systems and effectiveness
    • Limitations of Quality assurance systems
    • Thinking beyond the technical assurance of quality
  • Quality function deployment
    • The Quality function deployment tool
    • The Origins of QFD, need and benefits
    • Uniqueness of QFD to Quality function
    • Information needs for QFD
    • Translating the Voice of customer to quality parameters –the process
    • Finding the correlations between the VOC and technical requirements
    • Structuring the QFD diagram
    • Common problems in structuring the QFD diagram
Interactive group techniques using application exercises

Productivity improvement techniques and tools

Productivity can be said to have improved when more output is achieved for the same input or when the same output is achieved for the less input. To improve productivity, either the process itself, the equipment and machinery used, the workforce or the indirect processes affecting production must be addressed.

Productivity improvement techniques can be applied effectively in enterprises ofany size, from one-person companies to corporations with thousands of staff. The majority of the techniques were first seen in mass-production operations but the benefits they can yield in SMEs is not to be underestimated. Indeed, the absence in SMEs of many of the rigidities commonly found in large companies make it easier for them to reap the benefits of productivity improvement techniques.

Duration : 02 Days

Content :
  • Overview of productivity and tools
    • Understanding productivity
    • Differences between efficiency and productivity
    • Identification of productivity improvement areas
    • Implementation of productivity enhancement techniques
    • Employee involvement
  • Shop floor management
    • Throughput and its relationship to productivity
    • Identifying idle materials and labor
    • Identifying bottlenecks
    • Debottlenecking
    • Reengineering processes
    • Work place layout improvements
    • Improvement in material handling methods
  • 5 S - techniques and effect on productivity
  • Human angle - Ergonomics, environment, employee morale, identification of skill gaps
Interactive sessions using case studies, Exercises on productivity and Practical cases brought out by participants

Root cause analysis and problem solving techniques

Root cause analysis (RCA) is a class of problem solving methods aimed at identifying the root causes of problems or events.Root Cause Analysis is any structured approach to identifying the factors that resulted in the nature, the magnitude, the location, and the timing of the harmful outcomes (consequences) of one or more past events in order to identify what behaviours, actions, inactions, or conditions need to be changed to prevent recurrence of similar harmful outcomes and to identify the lessons to be learned to promote the achievement of better consequences.

The practice of RCA is predicated on the belief that problems are best solved by attempting to address, correct or eliminate root causes, as opposed to merely addressing the immediately obvious symptoms. By directing corrective measures at root causes, it is more probable that problem recurrence will be prevented. However, it is recognized that complete prevention of recurrence by one corrective action is not always possible.

Duration : Two day

  • Understanding the technique of Root cause analysis
  • How to implement the root cause analysis method
  • Application of the “5 Why” Technique
  • Problem solving techniques
    • Brainstorming
    • Force field analysis
    • Fish bone diagrams
    • Concentration diagram
    • Critical activity analysis
    • Check sheet
    • Pareto analysis
  • Introduction to the new 7 QC tools
Interactive group techniques that involve Case studies, Exercises on productivity and Practical cases brought out by participants

Market Intelligence

Market Intelligence, occasionally called business intelligence, is a branch of market research, involving collation and analysis of available and relevant information and data on specific markets.

Market intelligence typically involves collation of data from various sources such as company accounts, official statistics, data from trade bodies, interviews with business contacts, and research on consumer attitudes. Whereas market research is often considered a consumer-orientated discipline, market intelligence tends to offer a broader view of markets including business and sector data - such as market-sizing, -segmentation, and -share data.

Duration : Two day

The participants would be able to understand :
  • which distribution channels would best suit different products
  • The effect of indicative price points on your own financial productions model is critical
  • which routes to market would be most effective for a business structure
  • How a company sizes up against your competitors.
  • Which product line should be generated to understand different tastes and preferences
  • Understand different tastes and preferences
Hands on experiential techniques, simulations, case studies, group work