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Excel Toolkit Minimizing Manufacturing Cost & Defects Management, Lean Six Sigma Intermediate to Advanced

Training Duration : 2 Days

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Target Audience: Production Managers/Executives; Operations Managers/Executives; Finance Managers/Executives; and anyone involved in the areas of reducing cost and manufacturing defects. Basic Excel knowledge is required.

About the Course:

Manufacturing Defects are flaws or irregularities in products arising from errors in Production. When the manufacturing process goes awry, the resulting products may fail to meet the manufacturer’s own design specification standards. If such a product escapes the manufacturer’s quality controls, its flawed condition may lead to its failure during use, to an accident, and possibly to an injury to the user or another.

In general,manufacturers and other suppliers are liable for injuries caused by manufacturing defects in products that they sell. Increase in Defects will lead to increase in the organization’s operating cost. Small defects and manufacturing variations can become costly for any company. Several companies have begun implementing different lean manufacturing approaches to reduce manufacturing variations and defects.

Some of the common methods include Six Sigma, Total Quality Control, and the 5 “S”Methodology.Most of the common methodologies in the market require a tool that allows Managers and Executives to perform data collection,measure and analyze the Defects data quick. Microsoft Excel has become a tool that some of these methods recommends.The sample templates have been widely distributed to assist the manufacturing people in their data collection and data analysis.

However, most of the users still do not have sufficient knowledge of the latest functionalities in MS Excel. Financial budgeting can be easily done when Management is able to see real figures being transformed into analytical results with the power of MS Excel.

Training / Course Outline:

1. COST REDUCTION THROUGH EFFECTIVE DEFECTS MANAGEMENT

What are Manufacturing

Defects Urgency of Cost Reduction

Improving productivity through Defects Management

2. METHODOLOGIES OF DEFECTS MANAGEMENT

Cost Reduction by Design

Lean Production Overhead

Cost Economies of Scale

Product Line Rationalization

Supply Chain Management

Quality Cost Total Cost management

3. PERFORMANCE MANAGEMENT

Financial vs. Non-Financial

Measures Cost Drivers Key

Performance Indicators (KPI)

4. CRITICAL PRODUCTION FACTORS THAT CONTRIBUTE TO DEFECT 

Quality related costs

Cost of reworking

Scrap during Production

Manufacturing Effectiveness

Bottleneck Management Cycle

Time Reduction

5. COST RISK ANALYSIS

Cost Estimating Process

Cost Estimating Methods

Cost Models based on historical data

6. CHART FOR DEFECT ANALYSIS

Various cost related charts in Excel Analyzing the Charts / Graphs for smart financial decisions

Application of Statistical Analysis

7. MEASURING MANUFACTURING PROFITABILITY WITH MS EXCEL TOOLS

Effects of the Defects on overall

Manufacturing Cost on P&L

Statement Analyzing the P&L to identify the impact of higher Manufacturing Defects

Performing further analysis using Advanced Excel functionalities

Making financial decision by reading the P&L

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