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2 DAY ON SITE QUALITY IMPROVEMENT TRAINING COURSE

REDUCING COSTS THROUGH INCREASING QUALITY

CMC quality improvement training by increasing quality

Presentation of China Manufacturing Consultants

Founded in 2012, CMC includes a team of more than 20 full-time consultants and trainers. Our staff have at least 10 years’ experience driving change in Chinese organizations. They are keenly aware not only of successful management techniques that are applicable to manufacturing organizations, but also have significant implementation experience in China.

As an organization our mission is to work as the facilitators of lasting change in Chinese companies, allowing firms to become more efficient and profitable. 

Presentation of China Manufacturing Consultants

Context

Context

As a manufacturer, you know that you need to keep your good customers. So your staff inspects and tests product quality. Sometimes a quality issue is caught before shipment, and you need to sort, re-work, and sometimes re-process some products.

In spite of those efforts, there are still cases where your customers complain about quality. They might charge it back to you, or switch to one of your competitors.

Inspections and testing, re-work, customer complaints… All of these cost you money. Do you know how much? Maybe it would make sense to adjust the inspection & testing budget up or down?

Can some quality issues be caught the very moment they start to appear, without the need for inspectors? In that case, your costs of quality will decrease a lot. Discover techniques and tools the best manufacturers use to improve their quality AND reduce their costs.

The Content Of This 2 Day On-Site Training Course On Cost Reduction In A China Factory

Type of cost Category name Most common cost components
Losses due to quality problems out of the factory  External Failures Penalities from Customers
Urgent re-production
Lost customers, or lower orders
Lawsuits and bad reputation
Losses due to quality problems in the factory Internal failures Rework on defects
Disruption of production planning
Scrap (wasted material)
People and/or machines waiting
Catching quality problems Appraisal Product QC inspection
In-line testing stations
Laboratory testing
Avoiding quality problems Prevention Design for manufacturing
Statistical process control
Preventative maintenance
Work instructions + training for operators and supervisors

Training style

We introduce new concepts and then immediately apply them to the trainee’s work environment. We spend some time on the shop floor, observing and discussing potential improvements. This way, the training content is immediately applied and trainees understand it in a deeper way.

Trainer

CMC Trainer Hank L

South China

Hank L.

20+ years manufacturing experience in various industries, including top management roles (plant manager, quality manager) at both Duracell and Honeywell in China. Experienced and trained in ISO9001, ISO 14001, ISO/TS 16949, and HACCP.

CMC Trainer Cindy J

Shanghai Area

Cindy J.

Product director for a branch of Li & Fung group, then general manager of a 1,000 people factory. Implemented ISO9001, TL9000, and ISO14001; strong experience developing FMEAs and control plans. 

Organisation

Day 1.

Time Topic Approach
09:00-09:30  Introduction Getting to know participants, introduction of the training
09:30-10:30 External failures Concept introduction, examples and cost modelling, discussion with participants (application of the concept to their work) 
10:30-10:40 Break  
10:40-12:00 Internal failures Concept introduction, examples and cost modelling, discussion with participants (application of the concept to their work) 
12:00-13:30 Lunch break  
13:30-15:00 Workshop observation Observation of testing & inspection activities at end of line, and of a few production activities. If applicable, observation and analysis of an internal failure case. 
15:00-15:30 Discussion about internal failures Brainstorming about the way to address internal failures, introduction of the concepts of correction vs. corrective action 
15:30-16:00 Appraisal Concept introduction, cost modelling related to the factory’s situation 
16:00-16:30 Discussion about appraisal Brainstorming about options to make appraisal more efficient 
16:30-16:45 Summary Wrap up of the day, reminder about main concepts and takeaways

Day 2.

Time Topic Approach
09:00-09:15 Reminder Reminder about main concepts and takeaways from previous day 
09:15-10:30 Prevention Overview of the most common types of prevention activities, and typical costs & benefits that can be expected 
10:30-10:40 Break  
10:40-12:00 Process control
& maintenance
Applicability and role of SPC (statistical process control) and preventative maintenance 
12:00-13:30 Lunch break  
13:30-14:00 Workshop observation Observation of a machining of fabrication process, if applicable; outline of the ways SPC and maintenance could help 
14:00-15:30 Training
& mistake-proofing
Applicability and role of operators training (including coaching from team leader and supervisor), and mistake proofing 
15:30-15:40 Break  
15:40-16:10 Workshop observation Observation of an assembly process, if applicable; outline of the ways training and mistakeproofing could help 
16:10-16:45 Summary Wrap up of the day, reminder about main concepts and takeaways

Typical benefits Of Training In Cost Reduction In A China Factory

Total costs of quality amount to 20-40% of a factory’s sales. By applying preventive measures and following the approach described by our trainers, a factory can reduce its total costs by 10-20% after about 12-18 months of work.

Deliverables

  • Template for corrections and for corrective actions will be given to participants.
  • After the training, the participants will be able to use that template and guarantee they follow the right approach.
  • An example of procedure for deciding whether to re-work some products and/or stop production will also be handed to trainees.
  • The content of the PPT slides will be handed to the company. This way, the participants will be able to ‘refresh’ the concepts a few months later.

Pricing

- The training session is spread over 2 days, in your factory

- Minimum 12 attendees

- If your factory is more that 2.5 hours away from Shanghai centre or dongguan centre, additional travel expenses will apply

CMC operate all over China map

Optional service

Some manufacturers feel the need for ongoing coaching of their team as they apply the concepts from our trainings. A good solution is to have one of our consultants come once a week for several months to reinforce the concepts and help apply them in a real situation.

Contact us for more details:

Contact us for more details:

Moon Li
China Manufacturing Consultants

创觅咨询(深圳)有限公司

深圳市福田区福田街道深南大道与彩田路交界西南星河世纪大厦A栋1106J

Email: moon.li@cmc-consultants.com
Phone: +86 755 8253 0056 (China)
Phone: +1 443 485 6415 (US)

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CMC quality improvement training by increasing quality