Course Overview
Training and Learning (T&L) program for Foundation of HVM for an Engineer are necessary part of preparing new and current employees for the technical and cultural aspects of working in a high-volume manufacturing (HVM) operation or plant.
Every company has its own unique ways of performing tasks and handling day-to-day operations, and T&L can turn into a long, drawn-out process while everything is explained. Utilize this program to help your HVM operation employees maintain their focus, producing high quality products, world-class high productivity level and positive mind-set.
Who Should Attend?
- Unemployed graduates who have obtained SPM/Diploma / Degree
- School leavers aged between 18 to 40 years with school/exam certificate
- Retrenched workers aged between 18 to 55 years who are registered with Employment Insurance System (EIS)
Pre-requisite
Come with open-minded and ready to embrace change
Course Outlines
Day 1
Lean supply chain management is about promoting efficiency by removing unwanted or wasted components from a process. This process is most often applied to manufacturing, where supplies can be ordered as they’re needed rather than holding a lot of inventory as back stock.
- Learning Objective and key takeaways
- Mission, Vision, Goals – Ice breaking session
- Lean – The history
- Lean – Ground Rule (Make it simple!)
- What is Lean?
- Why Lean for HVM operation?
- What is Supply Chain?
- What is Waste?
- Muda, Muri, Mura
- 8 Types of Waste
- Wasted Human Talent
- Defects
- Inventory
- Overproduction
- Waiting time
- Motion
- Transportation time
- Over processing
- Lean house framework
- JIT
- Jidoka
- Stability
- Just in Time (JIT)
- Tact Time
- Cycle Time
- Lead Time
- Capacity
- Machine/Workstation capacity
- Production line/Cell capacity
- Bottleneck
- Throughput rate
- Utilization rate
- Planning
- Manpower planning
- Machines planning
- Build plan
- Ship plan
- Material planning
- Yield and Unyielded planning
- Inventory management
- Inventory costing
- Inventory count
- Inventory type
- 80:20 Rule (Analysis)
- Kanban concepts
- Pull system
- Basic types
- Andon system operations
- Standardize work
- Value Stream Mapping (VSM)
- Order to Cash
- Kaizen
- Workshop #1
Day 2 to Day 3
SPC or statistical process control is a statistically-based family of tools used to monitor, control, and improve processes. Statistical Process Control (SPC) training can be time consuming and frustrating because of the complex nature of the statistics underlying SPC control charts.
Basic SPC is a comprehensive online SPC training course for engineers, operators, and technicians that makes understanding and applying statistical process control (SPC) concepts easy.
- What is SPC?
- What are Process Variations?
- Introduction to Variation
- Measuring Variation
- Patterns of Variation
- Measures of Variation
- What is SPC Control Chart?
- What a Control Chart Looks Like
- Interpreting Control Charts & Taking Action
- Types of Control Charts
- Control chart variables
- Control chart pattern
- Why SPC is important in HVM?
- How the SPC process flow works?
- Identify defined process
- Identify measurable attributes of process
- Further control
- Who is the Person in Charge (PIC)?
- Case study # 1
- Case study # 2
- Workshop # 2
Day 4 to Day 5
Design of experiments (DOE) is a systematic, efficient method that enables scientists and engineers to study the relationship between multiple input variables (aka factors) and key output variables (aka responses). It is a structured approach for collecting data and making discoveries.
Use DOE when more than one input factor is suspected of influencing an output. DOE can also be used to confirm suspected input/output relationships and to develop a predictive equation suitable for performing what-if analysis.
- What is DOE?
- Why use DOE for HVM operation?
- DOE design principles
- Factorial concepts
- Randomization
- Blocking
- Replication
- Experimental Design Stages
- Plan
- Design
- Conduct
- Analyse
- Confirm
- Case study # 1
- Case study # 2
- Case study # 3
- SPC VS DOE
- Workshop # 3
Day 6 to Day 7
Eight disciplines problem solving(8Ds) is a method developed at Ford Motor Company used to approach and to resolve problems, typically employed by quality engineers or other professionals. Focused on product and process improvement, its purpose is to identify, correct, and eliminate recurring problems.
- What is 8D?
- 1D – Team Formation
- 2D – Problem Description
- 3D – Interim Containment Actions
- 4D – Root Cause Analysis
- 5D – Formulate Corrective Actions
- 6D – Validate Corrective Actions
- 7D – Preventive Action
- 8D – Team and Individual Recognition
- What is 8D Problem solving tools?
- Ishikawa diagrams also known as cause-and-effect or fishbone diagrams
- Pareto charts or Pareto diagrams
- 5 Whys
- 5W and 2H (who, what, where, when, why, how, how many or how much)
- Statistical process control
- Scatter plots
- Design of experiments
- Check sheet
- Histograms
- FMEA
- Flowcharts or process maps
- Benefits of 8D Problem Solving tools
- Importance of 8D Problem
- Solving tools in HVM operation
- Overview of the 8D steps
- 8D steps explanation with examples
- Case study # 1 / # 2
- Workshop # 4
Day 8 to Day 9
Tableau is a Business Intelligence tool for visually analyzing the data by makeing Big Data small, and small data insightful and actionable. The main use of tableau software is to help people see and understand their data.
Users can create and distribute an interactive and shareable dashboard, which depict the trends, variations, and density of the data in the form of graphs and charts.
- What is Tableau?
- Collection
- Exploration
- Merging
- Modeling
- Validation
- Reporting
- Why Tableau?
- Tableau workspace and various options
- Tableau Repository
- Tableau Dashboard
- Navigating in Tableau
- 3 Main Stages
- Import data
- Analyse data and create dashboard
- Share the results
- Tableau files and files type
- Demo
- Connecting with flat files
- Connecting with DB
- Connecting with server
- Conditional importing
- Connecting two data sources
- Editing a connection
- Data roles
- Data types
- Case study # 1/ # 2
- Workshop # 5
Day 10
Power Pivot is a data modeling technology that lets you create data models, establish relationships, and create calculations.
With Power Pivot you can work with large data sets, build extensive relationships, and create complex (or simple) calculations, all in a high-performance environment, and all within the familiar experience of Excel.
- Maximize the Power of PivotTable
A Quick Tour
- Determine What You Need to Know
- Identify the Source
- Creating the Pivot Table
- Working with Pivot Table Layout
Manipulating the PivotTable
- Rearranging the Layout
- Adding New Field
- Renaming a Field
- Formatting Numbers
- Changing Sorting Order
- Showing Top 10
- Refreshing Data
Digging Deeper
- Grouping Items
- Displaying Subtotals
- Hiding/Showing Grand Totals
- Formatting PivotTable
- Using Slicer
- Formatting Slicer
Beyond the Basics
- Creating Second Data Field
- Changing the Summary Function
- Displaying Numerical Value as a Percentage of the Total
- Creating a Custom Calculation
- More Function in Custom Calculation
More PivotTable Calculations
- Using Formulas
- Creating a Calculated Field
- Creating a Calculated Item
- Using GetPivotData Function
- Turn off GetPivotData Function
Optional Topics
- Creating PivotChart
- Publishing PivotTable to the Web
- Using Multiple Source Ranges