Course Objectives:

By the end of this training, participants will be able to:

1. Introduction to Lean Principles in Quality Control

• Understand the fundamentals of Lean methodology and its role in quality improvement.
• Learn how Lean reduces waste, improves efficiency, and enhances quality control.
• Identify the eight types of waste (Muda) and how they impact quality control.

2. Implementing Lean Tools for Quality Control

• Learn how to apply Lean tools for quality excellence, including:
• 5S (Sort, Set in Order, Shine, Standardize, Sustain) for workplace organization.
• Kaizen (Continuous Improvement) for defect prevention.
• Value Stream Mapping (VSM) to identify quality improvement areas.
• Gemba Walks to detect quality issues at the source.

3. Lean Problem-Solving and Root Cause Analysis

• Understand root cause analysis (RCA) methods in quality control.
• Apply Lean Six Sigma tools, including:
• DMAIC (Define, Measure, Analyze, Improve, Control) for process improvement.
• Fishbone Diagram (Ishikawa) for defect analysis.
• Pareto Analysis (80/20 rule) for prioritizing quality issues.

4. Lean Manufacturing and Statistical Quality Control (SQC)

• Learn how Lean principles integrate with Statistical Process Control (SPC).
• Implement Process Capability Analysis (Cp, Cpk) to monitor quality variations.
• Reduce Defects Per Million Opportunities (DPMO) for Lean Six Sigma improvements.

5. Standard Work and Error-Proofing (Poka-Yoke)

• Understand the importance of standard operating procedures (SOPs) in Lean quality control.
• Learn how error-proofing techniques (Poka-Yoke) prevent defects and improve reliability.
• Apply visual management tools to detect and correct quality issues in real-time.

6. Lean Quality Control in Supplier and Vendor Management

• Implement Lean supplier quality management to reduce incoming material defects.
• Learn how Lean procurement strategies improve supplier reliability.
• Develop Lean-driven inspection and testing plans to enhance quality assurance.

7. Regulatory Compliance and Lean Quality Control

• Ensure compliance with ISO 9001, AS9100, API Q1, IATF 16949, and other industry quality standards.
• Integrate Lean with auditing processes to streamline regulatory inspections.
• Learn how Lean digital tools (ERP, QMS software) enhance compliance tracking.

8. Case Studies and Continuous Improvement for Quality Excellence

• Analyze real-world Lean quality control success stories.
• Develop continuous improvement action plans for sustained quality enhancement.
• Apply Lean culture strategies to engage teams in quality control excellence.

Target Audience

This course is designed for professionals involved in quality control, process improvement, and Lean implementation, including:

• Quality Control Inspectors
• Quality Assurance Engineers
• Supplier Quality Specialists

• Lean Manufacturing Specialists
• Production Managers
• Continuous Improvement Teams