Global Innovative Consulting offers a wide variety of
classes on various topics, such as:
*Risk Management using DFMEA (page3)
*Risk Management using PFMEA (page6)
*Introduction to FMEA (Failure Mode § Effects
Analysis) (page10)
*5S + X (1, 2 …) (page13)
*Introduction to Lean (page16)
*Quality Management System (QMS) (page19)
*Quality Audits (page22)
*Corrective Action Process and the problem
solving methods associated with it (page25)
All classes are taught by instructors
who have significant experience in
the subject matter.
Irrespective
of
how
many
employees will participate in our
training, your entire business will
benefit directly!
2 Days Risk
Management using
DFMEA (for advance users)
Why DFMEA does not work properly?
How to make it work sustainably in your
organization?
Class Objectives
•
•
•
•
•
•
•
Following points will be covered by this training:
The fundamental reasons companies fail to have a •
sustainable DFMEA development and how to
prevent them;
How to sustainably develop a DFMEA for a system
or sub-system; System analysis, Functional diagram
creation and the link with Product Requirements;
How to effectively fill-in the DFMEA template: the
reason this is an on-going pain for most
organizations and how to overcome this almost
with no additional effort or costs!
The obstacles teams will face in developing a
DFMEA and how to efficiently overcome them
including focusing the discussion on what really
matters spending no more than few seconds on any
rating;
How to use the information in the DFMEA to
improve product performance and reliability;
The interrelationships/benefits of DFMEA, Design
Validation Plan Report (DVPR) and Design
Verification Plans & Report (DVP&R);
The interrelationships between DFMEA and PFMEA
and how to link them effortlessly;
Suggested Attendees
This class is for users which are
familiar with DFMEA and have
been part of a team which has
developed at least one
DFMEA. Also more advance
users will benefit from this
training by learning new
techniques to improve the
performance and
manufacturability of their
designs as well as to bring the
lessons learned in their
organization.
Class duration
• The total duration for the class is
2 days. The class is
approximately 35% instruction
and 65% application exercises.
This training will introduce participants to the steps of Risk Management using the tool
of Failure Mode & Effects Analysis (FMEA) to define, manage, and reduce risks.
Although the focus of the training is FMEA, the link between FMEA and corrective
actions will be taught as well. Other risk management tools are also presented such as:
brainstorming, fish-bone diagrams, Cause and Effect diagrams, etc. Most importantly
the team will leave the course with a clear understanding of when it is best to use
each tool and how FMEA and corrective action are working together.
The FMEA training addresses each step of doing a FMEA, with exercises designed to
ensure maximum understanding of Design (D)FMEA.
The first day of this program includes training on tools used when doing a DFMEA, how
to do an effective DFMEA, and exercises to re-enforce understanding. Most
importantly we are also addressing the reasons why organizations fail to get most of
the benefits of DFMEA.
Day two involves having each company select a process to generate a DFMEA with
instructed guidance. During the DFMEA development process the participants will be
guided step by step to generate their specific DFMEA capturing all the lessons learned!
In this environment, each company’s DFMEA will have the most important items
addressed by the end of the second day.
After the DFMEA training, based on the lessons learned during the DFMEA
Why developing a PFMEA is a painful
experience and too often with no value
added for your organization?
How to fix this situation and ensure PFMEA
will add value sustainably in the future?
Class Objectives
Suggested Attendees
Following points will be covered by this
• Successful implementation of
training:
PFMEAs and control plans
• The interrelationships between DFMEA,
requires involvement from
process engineers, operations
PFMEA and Control Plans;
and quality control at a
• How to smoothly develop a PFMEA for a
minimum! Maintenance,
product of the class’s choice so they can
purchasing, SQM or any other
see the concepts applied;
department which is affected by
the decisions taken as a result of
• The obstacles teams will face in doing a
the PFMEA ought to participate.
PFMEA efficiently and how to overcome
Therefore it is advised that the
them including spending no more than
class be made up of
few seconds on any rating;
representatives from each of
these groups.
• How to use the PFMEA information for
process improvements (to decrease
Class duration
defects, increase productivity and
reduce downtime while optimizing the
• The total duration for the class is
utilization of the existing resources);
two days. The class is
• How to use PFMEA to manage
approximately 35% instruction
production risk for a project.
and 65% application exercises..
This training will introduce participants to the steps of Risk
Management using the tool of Failure Mode Effects Analysis
(FMEA) to define, manage, and reduce risks.
Although the focus of the training is PFMEA, other risk
management tools are also presented such as: brainstorming, fishbone diagrams, Cause and Effect diagrams, etc.
Most importantly a clear understanding of when it is best to use
each tool is also included in the training.
The PFMEA training addresses the particular steps of developing a
PFMEA, with exercises designed to ensure maximum
understanding of PFMEA and especially how to use the tool to add
value for your process development, reduce defects and prioritize
the improvement actions.
The first day of this program includes training on how to link the DFMEA with
the PFMEA including how to proceed when you do not have a DFMEA or the
DFMEA is not complete. Also in this day we will teach how to ensure you focus
on what really matters when you are developing the PFMEA and how to do it
sustainably. Most importantly we are also addressing the reasons why
organizations fail to get most of the benefits of PFMEA and how to address this
issue.
Day two involves having each company select a process or a product to
generate a PFMEA with instructed guidance. During the PFMEA development
process the participants will be guided step by step to generate their specific
PFMEA capturing all the lessons learned! In this environment, each company’s
PFMEA will have the most important items addressed by the end of the second
day.
After the PFMEA training, based on the lessons learned during the PFMEA
development, the trainer will suggest based on the feedback received from the
participants which processes need to be updated to ensure future
developments will benefit on-going from this training.
This written feedback is part of the training package and will be done at no
additional cost!
Introduction to Failure
Mode Effects Analysis
(FMEA)
Understand the basics about FMEA:
where does it come from, what is the
purpose, when and how to use it?
Class Objectives
Following points will be covered by this training: •
• Why bother developing an FMEA after all?
• What are the business benefits in doing an
FMEA?
• When and how do I have to do an FMEA to
ensure I optimize the benefit for the business?
• What is the meaning of the ratings and how can
I use the information to help me develop my
processes?
• What do I need to do to have a sustainable
FMEA development process? How to overcome
•
the FMEA to be seen as a deliverable?
• How can I maximize the usage of the
information in the FMEA?
• What is the link between FMEA and risk
management?.
• What is the link between FMEA and problem
solving?
• How can FMEA help business development and
help to increase revenues and market share? •
Suggested Attendees
Successful implementation of FMEAs requires a
thorough understanding of the principles which
are guiding the usage of the tool. A FMEA cannot
be sustainably maintained without the
involvement of all the departments which are
affected by the decisions taken, as a result of the
development of the FMEA. Furthermore FMEA is
like an “open book” showing almost everything
about a company’s expertize, capabilities and
commitment to quality. Therefore in order to have
a sustainable FMEA development process,
management support is a must!
In this training all middle managers and team
leaders should be involved at a minimum! Upper
management would benefit as well by getting
specific feedback on how to ensure the FMEA
development process is done sustainably. Aside
from the above, every other personnel who would
like to get a deep understanding about FMEA
should attend the class as well.
Class duration
The total duration for the class is one day. The
class is approximately 35% instruction, 35% open
discussions and 30% application exercises.
This training will introduce participants to the Failure Mode & Effects Analysis
methodology and most importantly it will highlight the enormous business
benefits that can be achieved when FMEA is done the right way and at the right
time!
The FMEA training addresses
• the principles which guide the developing of the FMEA,
• how was the tool developed,
• why it is used, and
• how can the companies benefit from it?
As part of the training, real life examples will be shown and discussed to ensure
maximum understanding of both Design FMEA and Process FMEA, as well as how
the two are linked together.
There will be detailed explanations about:
• why organizations fail to sustainably implement (D and/or P) FMEA and
• how to achieve the maximum benefits out of the FMEA, as well as
• how to overcome pitfalls in the FMEA development process.
An example will be provided at the end of the class showing the link between the
DFMEA and the PFMEA.
After the FMEA training, the trainer will suggest - based on the feedback received
from the participants - which processes need to be updated to ensure future
developments will benefit on-going from this training.
5S + X (1, 2 …) how to
get the most out of it!
What is 5S and why is it so difficult to have
a sustainable 5S process and how can a
business overcome this challenge?
Class Objectives
Suggested Attendees
Following points will be covered • To have the maximum
benefit of this training it is
by this training:
recommended
for
• Understand what 5S is all
management as well as
about and what can be actually
team leaders and employees
achieved when using it.
in key positions (those who
• What are the conditions
have been identified to have
needed to be fulfilled in order
the necessary commitment
for continuous improvement
to ensure 5S will become a
activities).
sustainable process?
Class duration
• How to implement 5S
optimally? Who should
• The total duration for the class is 4
hours. The class is approximately
participate and how should the
35% instruction, 40% examples
persons be selected?
and application exercises and 25%
open discussions
This training will clarify :
• how was 5S initially developed,
• what is actually the purpose of 5S,
• what is 5S,
• what are the pre-requisites to ensure a sustainable
implementation and
• how to implement 5S.
Due to a lot of misconceptions, 5S is not used as it
should, therefore the benefits are not realized and
subsequently the implementation degenerates in team
leaders asking their employees for compliance to some
pre-established rules.
This situation can be very easily overcome, once the
few simple steps on how to implement 5S in a
Introduction to Lean
What is lean, how to implement a lean
culture, the main reasons lean
implementation fails and what to do to
overcome them?
Class Objectives
Following points will be covered by this •
training:
• Understand Lean principles and what
are they all about.
• The main reasons why businesses fail
to implement lean! Some of the
reasons are … well… “ugly” but
nothing good comes without
realizing and accepting the need for
improvement!
• Answers to: ‘How to implement
Lean?’ Why is it so difficult? Is there
anything that can be done to make it
•
easier? Fortunately YES, it is!
• Specific suggestions where to start
the implementation and how to do it
optimally.
Suggested Attendees
Beginning with the CEO, continuing
with the board of directors and all
the way to middle management,
this training is primarily for you!
When it comes to Lean everything
begins and ends with you! Lean is a
way to do business; it is THE
profitable way to do business!
Therefore it is critical for you to get
a clear picture about what Lean is
all about before embarking on a
journey of this magnitude!
Class duration
The total duration for the class is 8
hours. The class is approximately
35% instruction, 40% examples and
application exercises and 25% open
discussions.
After the North American automotive crush in 20062008 timeframe, followed in parallel by the
unprecedented rise of Toyota, a lot of ideas and
conceptions about Lean have entered industries
worldwide.
Unfortunately too many businesses have tried to
implement Lean but failed and some of them failed
miserably! Why? What is actually Lean and why
Toyota managed to become ‘The Machine that
changed the world’, while the vast majority fail?
In this training we will clarify what Lean is all about:
the Lean principles, what is the ultimate purpose of
Lean and what needs to be done in order to
implement it sustainably.
Quality Management
System and ISO
requirements
What is it and why do we need it? How to
setup a QMS that will be sustainably
maintained?
Class Objectives
Suggested Attendees
Following points will be covered by this
• Primarily this training is
training:
for the management and
• Understand what a QMS is all about;
all Quality Engineers as
what are the elements of a QMS,
well as for the upper
where are they coming from and
management in case an
what is the relationship between the
initial certification for the
QMS and ISO?
ISO standard is needed.
• Clarify how to define a QMS; how
big, how many details, how wide and
who should be involved in building
it?
Class duration
• Provide solutions to optimally
implement a QMS and how to • The total duration for the class is 4
hours. The class is approximately
sustainably maintain it!
60% instruction, 20% examples and
• Specific suggestions where to start
application exercises and 20% open
discussions.
the implementation and how to do it
optimally.
Do you feel a cool chill penetrating your body when
you hear ‘QMS’ (particularly mentioned by a Quality
Director in the context of updating prior to a critical
external audit…)? If you participate in this training
you will never feel those chills again (sorry!). There is
no mystery or anything spectacular about any Quality
Management System!
As any QMS should have its roots in the requirements
of a standard, part of the training will be to
understand the ISO standard requirements and how
the QMS and ISO are interconnected! In this training
we will also show how the QMS should sustain the
business and not the other way around!
Quality Audits
What is it and how to add
value for your
organization with every
audit!
Class Objectives
Suggested Attendees
Following points will be covered by • Primarily this training is for the
this training:
mid management and all Quality
Engineers as well as Team
• Understand the reason audits are
Leaders. Upper management is
not liked in your organization and
needed if the ISO certification has
what you should do to change that!
been recently obtained or if in the
• How to effectively change the way
organization there are evidences
audits are perceived and to bring
that the audit process is seen as a
necessary “to do” checklist rather
engagement from the organization
than a fundamental value added
in the auditing process
activity.
• Provide solutions to make the
Class duration
follow-up sustainable!
• Specific suggestions where to start • The total duration for the class is
4 hours. The class is
to change the audit process to
approximately 60% instruction,
20% examples and application
become a fundamental value
exercises and 20% open
added activity for your business
discussions.
What comes to your mind when you hear that a
new Quality Audit is approaching?
When people are informed they are going to be
part of an audit, they tend to feel uneasy about it
and would rather avoid it.
Why almost everybody in almost all organizations
have at least a “not me” approach about audits?
Fortunately this situation can be easily changed
and people can be actively engaged in
participating to any audit your organization may
face!
In this training we will show why audits have such
a bad reputation and how to fix this issue.
Corrective Action Process
and the problem solving
methods associated with it
(A3 vs. 8D)
What method is best, when
and why?
Class Objectives
Suggested Attendees
Following points will be covered by
• Because of the significant
this training:
impact that this process
• Understand the reasons why corrective
actions only addresses the technical
has on the company’s
issues at best and falls short to satisfy
image, this training is for all
stakeholders and to bring further
management levels as well
improvements to the organization;
as all Quality Engineers and
• Learn
the
main
reasons
why
Team Leaders.
organizations experience reoccurrence
of the same issue after the corrective
action has been closed and what can be
Class duration
done to avoid this situation;
• Provide solutions to ensure the
• The total duration for the class
corrective action process is effective and
is 4 hours. The class is
to have the entire organization
approximately 50% instruction,
participating for the successful closure of
25% examples and application
every corrective action;
exercises and 25% open
discussions
• Learn the difference between the A3 vs.
8D and when to use one or the other.
When an issue (such as a field failure) needs to be solved and reported
officially, usually the ugly side of ‘delegation’ surfaces in almost any
organization.
Particularly when it is about 8D reports which will be read by ‘who
knows?’!
This is another situation that reveals the strengths as well as the
weaknesses of an organization.
Unfortunately too many of them are struggling with :
• the corrective action process,
• with the proper closure of the corrective action and
• with the implementation of a permanent corrective action.
To add salt to the wound this is the favourite playground for any
external auditor! Ouch!
In this training we will reveal the usual reasons a corrective action
process is falling short, sometimes way too short, to meet the necessary
expectations of auditors but most importantly to add value to your
business! We will show what needs to be done to have a solid corrective
action process implemented in such a way that brings solid business