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.
As your manufacturing operations grow in size and in complexity, you can no longer rely on a few key people to keep an eye on everything that is happening. You need to put a system in place to ensure people do the right thing when nobody is watching them.
You also cannot rely on final inspection to catch all the problems. Paying many inspectors to do this is very expensive, and they will never be able to find 100% of problems. Instead, a good quality system will allow you to find more problems with fewer inspectors. This is a significant source of savings.
There are other side benefits as well:
|The need for a quality systemout of the factory||Inspection costs
Cost impact of catching problems earlier
|What is a system?||General concept
Production steps, risks, control points
|‘Go’ / ‘no-go’ gates||Using QC inspectors
Using production operators
The concept of mistake-proofing devices
What to do with rejected materials/products
|Watching trends||Internal auditing
The concept of statistical process control
|Fundamental documents||High-level flow chart
Process-level flow chart
Problem solving flow chart
|The role of leaders||What is a process “owner”?
Escalation in troubleshooting
We introduce new concepts and then immediately apply them to the trainees’ 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.
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.
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.
|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)|
|10:40-12:00||Internal failures||Concept introduction, examples and cost modelling, discussion with participants (application of the concept to their work)|
|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|
|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|
|Applicability and role of SPC (statistical process control) and preventative maintenance|
|13:30-14:00||Workshop observation||Observation of a machining of fabrication process, if applicable; outline of the ways SPC and maintenance could help|
|Applicability and role of operators training (including coaching from team leader and supervisor), and mistake prooﬁng|
|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|
Companies that set up a strong quality system can expect to reduce their costs of quality by at least 50%. They can also expect much higher grades on quality audits from their customers, which will help get and keep customers for whom quality is important (and who can generally pay a higher price).
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:
China Manufacturing Consultants
Phone: +86 755 8253 0056 (China)
Phone: +1 443 485 6415 (US)