DOE Workshop (2 days) 9&10 Oct, Pearl View Hotel, Prai

Course Outline –
Design of Experiment Workshop (2 days)
Venue : Pearl View Hotel , Prai

Date : 9 & 10 Oct 2007

Time : 9am~5pm

Fee : RM500 per person. (* special discount for group registration)

INTRODUCTION

DOE is now recognized as a key strategic element to help organizations remain competitive and profitable in today's business climate which demands consistency and quality.
A Design of Experiment (DOE) is a structured, organized method for determining the relationship between factors affecting a process and the output of that process.
It is a systematic methodology that dramatically improves industrial products and processes thus enhancing productivity and reducing costs. Input factors are varied in a planned manner to efficiently optimize output responses of interest with minimal variability.
This training provides a comprehensive exposure to the use of powerful DOE techniques for improving and optimizing any process. During this workshop, you will learn how to set up and run basic factorial and screening experiments; how to analyze experimental outcomes; identify significant effects on process performance and consistency; and identify factors for further study or implementation. Then, in a workshop environment you will design and conduct experiments.

Duration

2 days (9am-5pm)



OBJECTIVES

After the training, the participants will be able to:

· understand the advantages of using experimental design over trial and error methods
· set up and run basic factorial and screening experiments
· analyze experimental outcomes
· identify significant effects on process performance and consistency
· identify factors for further study
· optimize the output performance of a process or product
· use relevant techniques & tools for DOE implementation.
· correct the mistakes or overcome the problems encountered during DOE implementation.

WHO SHOULD ATTEND

This course is designed for those managers, engineers, & professionals who
intend to apply DOE for process optimization.
responsible for developing or improving products and processes.
No previous exposure to designed experiments is required.

COURSE CONTENT

Day 1 – 9.00 am – 5.00 pm
Module 1 : Introduction to DOE
· What is DOE?
· Why do a designed experiment?
· Try and error method and OFAT (One-Factor-At-A-Time)
· Types of experiment
· Steps for implementing DOE
· Practical examples
Module 2 : DOE Terminology
· Statistical assumptions for DOE
· Understanding on process variation & p value
· Sampling strategies
· Randomization
· Blocking
· Main Effects and Interactions
· Coded setting
· Un-coding the setting
· Introduction to ANOVA

Module 3 : Two factors factorial design
· Why do we need to use 2k factorial experimentation?
· 2k Vocabulary
· Steps for DOE Analysis
· 2k Standard Order Designs
· Calculating main effects
· Calculating interactions
· Adding Center Points
· Adding Blocking
· 2k Example and Exercise
· Interpretation of results and necessary actions

Day 2 (9.00am- 5.00pm)
Section 4 : Three-Factor Full -Factorial Design
· Graphical Interpretation of Effects and Interactions
· Statistical Concepts
· Determining Statistical Significance
· Interpretation of results and necessary actions
· Design and Analysis
· Practical workshop

Module 5 : Fractional Factorial Design
· Fractional Factorials
· Defining Relation
· Confounding
· Resolution
· Factor Assignment
· Interpretation of results and necessary actions
· Practical workshop
Module 6 : Introduction To Advanced DOE
· Advanced DOE
· Response Surface Methodology (RSM)
· Multiple Responses Optimization
· Taguchi method




Trainer profile:

1. Mr. Tony Lim
Tony Lim, Master of Science (USM, Penang)
Tony Lim is a certified quality auditor and is a Training Specialist by profession.
He is a multilingual facilitator with more than 5 years of consulting and training
experience in ISO 9000 quality management, six sigma deployment, statistical
process control and lean manufacturing. He has more than 15 years of
experience in quality system management, 5 of them as a quality manager for
one of leading MNC.
He has often been invited to conduct training for various manufacturing
companies in Asia Pacific Region.
His main accomplishments were setting up and implementing the ISO 9000
Quality Management System and Six Sigma Deployments for various
manufacturing companies.

2) Mr Roshidi Mat Rejab
Roshidi, Master of Mechanical Engineering (Old Dominion University, Norfolk, U.S.A in 1987)
Roshidi has spent more than 16 years in world leaders manufacturing environment as key person of operation team. Besides working in major international companies in Malaysia, he has also worked abroad; for instance at Intel,Phoenix plant, Arizona, U.S.A.(1988~1992).
Experiences and educations gained abroad lifted up his way of thinking towards a more global manner, as demonstrated in his performance at work.
Over the past four years, he has facilitated more than 100 practical workshops in Asia Pacific region dealing with principles of Lean manufacturing, overall equipment effectiveness, DOE, FMEA, value stream mapping, visual factory, Genba Kaizen, kanban systems, setup reduction, and total productive maintenance (TPM).

Project Management Training (2 days)

Project Management Training
Venue : Pearl View Hotel, Prai , Penang
Time : 9.00am~5.00pm
Date : 25 & 26 September 2007

Duration : 2 days

PLS CONTACT TONY 012-4921811 or email to proqual_training@yahoo.com.my for registration.

Overview – Project Management Training
In today’s fast-paced business world, organizations that practice sound project management principles secure competitive advantage over those that run the projects by experience alone. Project management is the application of knowledge, skills, tools, and techniques to a broad range of activities in order to successfully meet predetermined project requirements.

In this 2 days session, you will be introduced to the best practices of project management. With hands-on activities, you'll go from novice to expert and learn how to effectively manage all phases of a project. This course uses the structured project management framework of initiation, planning, execution, control, and formal closing, teaching you the steps that ensure project success. The course focuses on practical tools and techniques you can use immediately back on the job. Through class exercises and realistic simulations, attendees learn how the principles of project management are put into practice.

Course objectives
Upon completion of this course, the participants will be able
-Define basic terminology of project management
-Identify the project management life cycle
-Understand the project management knowledge areas
-Build a business case for project initiation
-Define project scope and stakeholder expectations
-Define roles and responsibilities for project stakeholders
-Build an effective project schedule
-Identify, analyze, quantify, mitigate, and manage risks
-Create project management plans
-Manage project change through formal change control processes
-Close a project

Who Should Attend?
Anyone seeking a structured project management method
Project managers/engineers currently experiencing difficulty keeping projects on the track.
Executives and supervisors who want a better understanding of the project management process.
Course Outline
Day 1 (9.00am-5.00pm)
1. Fundamental of Project Management
· What is a Project Management?
· Life Cycles
· Project Management Processes
· Project Management Terminology
2. Initiating
Project Scope Management
· Initiation
· Scope Planning
· Scope Definition
· Scope Verification
· Scope Change Control
Five Steps of Project Initiation
Stakeholder Analysis
Project Roles and Responsibilities
Sign-Off Process
Video examples – initiating the project successfully
3. Planning
Project Time Management
Project Cost Management
Project Quality Management
Project Human Resource Management
Project Communications Management
Project Risk Management
Project Procurement Management
Workshop


Day 2 (9.00am ~ 5.00pm)
4. Controlling and Closing
Project Controls
The Constraints Quartet
Focus on Past and Future
Project Meeting Tips
Key Principles for Control
Challenges
Activity Analysis
Expectations
Stakeholder Expectations
Project Environment
Expectation Control Elements
Project Manager vs. Expectation Gap
Organizational Style
Why do Projects Fail?
5. Closing Processes
6. Case Studies
7. Workshops


Trainer profile
Mr Roshidi Mat Rejab
Master of Mechanical Engineering
(Old Dominion University, Norfolk, U.S.A in 1987)
Roshidi has spent more than 16 years in world leaders manufacturing environment as key person of project management team. Besides working in major international companies in Malaysia, he has also worked abroad; for instance worked as project manager at Intel,Phoenix plant, Arizona, U.S.A.(1988~1992).
Experiences and educations gained abroad lifted up his way of thinking towards a more global manner, as demonstrated in his performance at work.
Over the past four years, he has facilitated more than 100 practical workshops in Asia Pacific region dealing with principles of Project Management, Lean manufacturing, overall equipment effectiveness, value stream mapping, visual factory, Genba Kaizen, kanban systems, setup reduction, and total productive maintenance (TPM).

Six Sigma Black Belt Training

How to redefine your company quality strategy? Part II

2.0 Interpreting Control Charts

2.1. Check for Instability

2.1.1 If the process is stable, leave it alone

2.1.2 If the process is unstable, check the chart pattern and find the assignable causes.

Tony Lim 24-Aug-07 Malaysia

How to redefine your company quality strategy? Part I

With technology and globalization changing the business environment at whiplash inducing speeds, quality strategy redefinition is a necessity. But before you take any action, you should find out your company’s existing strengths and capabilities.
Here some of areas for your consideration:
1.1 Study your existing SPC implementation :
Here are 5 levels of SPC implementation
Level 1 - SPC as wallpaper only, without proper training
Level 2 - SPC on X’s or Y’s with fully trained operators. Operators will understand the signals, but management will not empower them to stop for investigation. Operators will learn to ignore or disconnect the warning signals once production becomes the #1 priority.
Level 3 - SPC, with Corrective Action = Inspection. Short term containment equals auditing or 100% inspection.
Level 4 - SPC, with Corrective Action = Equipment Flag. Process is stopped or equipment automatically shuts down, so that defects will not move forward.
Level 5 - SPC, with Corrective Action = Countermeasure. Improvements are made so that defect cannot occur again.
Where are you ? Are at the best (level 5) or the worst (level 1).

1.2 SPC - should apply on procuss inputs instead of outputs
Most companies apply SPC to finished goods (Y’s) rather than process characteristics (X’s).
The full power of SPC methods to improve quality, increase productivity, and reduce cost can only be realized if the process inputs become the focus of our effort.

Tony Lim 23-Aug-2007

Part II - Response Optimization

In order to optimize the responses (Coil Res & Coil Mass), we should set the inputs at :

Coil Diameter 0.1975

Winding Tension 263.25

Tony Lim 20-Aug-2007 Malaysia

DOE - How to optimize the setting for two parameters? Part I

Case Study
•Mr John wants to determine the optimum setting for the wire diameter and winding tension.
•His goal is to achieve the target values of the two main responses, coil resistance and coil mass.
•Given spec are
–coil resistance, max spec is 5.985 ohm ,min spec is 5.415 ohm and target value is 5.80 ohm
–Coil mass, max spec is 0.4692 g , min spec is 0.4508 g and target value is 0.4650 g

How to optimize the setting for both inputs (wire diamtere and winding tension) in order to achieve the target values of responses?

Guideline (using Minitab):
•Stat>DOE>Factorial>Create Factorial Design
–2 factors, 2 levels
–Enter the data for both responses (Coil res & Coil mass)
•Stat>DOE>Factorial>Analyze Factorial Design
•Stat>DOE>Factorial>Response Optimizer
–Click Setup.
–Goal for both responses should be “target”.

Tony Lim 17-Aug-2007 1pm