Zero Defects through use of Statistical Techniques

Zero Defects through use of Statistical Techniques


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About The Event

What is your Quality tolerance? Ask yourself! Is it necessary to go for ZERO defects? Why is 99% or for that matter 99.9 % good enough? Is it possible to be hundred percent defects free? To prosper in today’s economic climate we must be dedicated to continual improvement. Continuous improvement may be defined as the attempt to better meet customer requirements and expectations by progressively reducing process variation and quality costs using appropriate statistical control and problem solving techniques. The higher the sigma value, the less the variation and fewer defects the process will have. Six Sigma is the new standard of excellence at only 3.4 defects per million opportunities (DPMO). Rolled throughput yield determines the probability of a product or service making it through a multi-step process without being scrapped or ever reworked.


 This workshop will cover some basic methods such as Check Sheets, Flowcharts, Pareto Charts, Histogram, Cause and Effect Diagrams, Scatter Diagrams, Stratification, Control Charts and Process Capability studies. Some advanced methods such as Quality Function Deployment and Design of Experiments etc. will not be covered. The value of continually reducing variation beyond traditionally accepted limits is important to understand. The economics of improving capability beyond specification limits is difficult to quantify. Use of statistical techniques need to be supplemented by 100% inspection of the product utilizing Poka-Yoke devices and accelerating feedback by self-checking and successive checking systems. Measurement systems are critical to proper data analysis and they should be well understood before process data are collected. For the purposes of this workshop it will be assumed that this system is under control and is not significant contributor to total variation.


The workshop objectives will be as follows:

  1.  Understand the importance of SPC
  2.  Understand the business impact of variation reduction
  3.  Understand the concepts of control and capability
  4.  Be variation aware in decision making and actions in the workplace
  5.  The value of improved process capability
  6.  A strategy for reducing variation
  7.  The problem solving process and tools
  8.  Z- Score relationship to six sigma
  9.  Taguchi Loss function
  10.  Role of Self Inspection and Poka Yokes 

The coverage and contents of the workshop will be as follows:

  1.  Introduction to Quality
  2.  Variation
  3.  Gathering and organizing the facts
  4.  Normal distribution
  5.  Statistical Process Control
  6.  Process analysis  and concepts of control and capability
  7.  Problem solving process and tools
  8.  Strategy for reducing variation and Taguchi Loss Function
  9.  Sigma Values and Rolled Throughput yield
  10.  Poka Yokes 

Participants’ Profile : The workshop will be very useful for engineers and managers from fuctions like design, manufacturing planning, production, maintenance and quality. 

Methodology: The program will be interactive. The program delivery will contain presentation, exercise, discussion based question and answers.


IITD Sr. Expert Faculty:

The workshop has been conceived, structured and will be conducted by Mr. Shanti, an ex Tata Motors senior executive who has conducted a number of successful training programmes on FMEAs for both Tata Motors engineers and managers as well as for its supply base and other organisations. He is a certified Quality Engineer from RWTUV and a trained lead assessor for QS9000.  Mr. Shanti Sarup is also expert in topics such as SPC, Seven Basic Tools of Problem Solving, Variation Control, Problem Solving Process, Predictable Quality and FMEA, etc. He has conducted programmmes on these topics, for Tata Motors, CII, IITD and a number of other organisations.



English & Hindi.

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