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Course 5: Management Tools: Product & Process Design 225

Product and Process design require much planning. This course reviews elements for consideration for both. On the product side, review the fundamentals of QFD, concurrent engineering, and DFM. On the process side, continue the review of error proofing, heijunka, kanban, automation, flow, standards and suppliers.

Course Outline
  • Objectives
  • Toyota Production System: A House of Quality
  • Concurrent Engineering
  • Quality Function Deployment
  • Design for Product Life Cycle
  • Design for Manufacture
  • Design for Assembly and Design for Environment
  • Kaizen Events
  • Assessment Tools for Kaizen Events
  • Planning Tools for Kaizen Events
  • Mistake and Error Proofing
  • Poka Yoke Applications and Devices
  • Sensible Automation
  • Kanban
  • Heijunka
  • Quick Changeover and Setup Reduction
  • One Piece Flow
  • Cellular Flow
  • Supplier Development
  • Cross Docking
  • ISO and Other Quality Standards
  • Summary

Course Objectives
  • Describe the parts of Toyota's house of quality.
  • Describe concurrent engineering.
  • Describe quality function deployment.
  • Describe the product life cycle.
  • Describe design for manufacture.
  • Distinguish between design for assembly and design for environment.
  • Describe a kaizen event.
  • Describe assessment tools for kaizen events.
  • Describe planning tools for kaizen events.
  • Describe poka yokes.
  • Describe poka yoke applications and devices.
  • Describe jidoka.
  • Describe kanban.
  • Describe heijunka.
  • Describe single minute exchange of dies.
  • Describe one piece flow.
  • Describe cellular flow.
  • Describe supplier development.
  • Describe cross docking.
  • Describe ISO and other quality standards.