This course equips technical freshers and diploma holders with practical analytical and root-cause troubleshooting skills for Indian workers in domestic plants and collaborative manufacturing setups. Combining online learning with OJT, candidates learn to interpret shop-floor data, systematically investigate defects, and apply structured problem-solving methodologies without disrupting production flow.
- Foundations of Shop-Floor Data & Analytical Thinking
- 1.1 The Role of Data in Manufacturing: Moving from Intuition to Fact-Based Decision Making on the Line
- 1.2 Collecting Reliable Shop-Floor Metrics: Capturing Accurate Counts on Output, Rejections, and Downtime
- 1.3 Interpreting Visual Controls: Reading Andon Status Boards, Trend Charts, and Production Dashboards
- Japanese (TPS/JIT) & German (Industrie 4.0) Analytical Approaches
- 2.1 Gemba & Genbutsu Analysis: Going to the Real Place to Gather Unbiased Shop-Floor Facts and Data
- 2.2 The German Engineering Approach: Systematic Fault-Tree Analysis and Structured Technical Diagnostics
- 2.3 Poka-Yoke (Mistake-Proofing) Analytics: Analyzing Error Patterns to Design Permanent Mechanical and Process Safeguards
- Root-Cause Problem Solving Methodologies
- 3.1 The 5-Why Analysis Technique: Digging Deeply Beyond Symptoms to Find True Line-Level Causes
- 3.2 Ishikawa (Fishbone) Diagrams: Mapping Man, Machine, Material, and Method Variables During Breakdowns
- 3.3 Pareto Analysis (80/20 Rule): Identifying and Focusing on Vital Few Defect Sources on the Assembly Line
- Quality Metrics & Process Monitoring
- 4.1 Tracking Overall Equipment Effectiveness (OEE): Analyzing Availability, Performance, and Quality Ratios
- 4.2 Defect Categorization and Rejection Trend Analysis: Spotting Recurring Quality Anomalies Early
- 4.3 Process Capability Awareness: Understanding Control Limits and Detecting Variations Before Rejections Occur
- Submissions & Assessment
- 5.1 Practical Submissions: Completed 5-Why Problem-Solving Sheets, Fishbone Diagrams, and Rejection Trend Logs
- 5.2 Online Theory Examination: Scenario-Based Assessment on Data Interpretation, Root-Cause Logic, and Defect Analysis
- 5.3 Practical Viva / OJT Evaluation: Assessing Live Troubleshooting Logic, Explanation of Defect Data, and Corrective Action Execution
