Program Overview
This training program is tailored for auto components industry. It bridges theoretical concepts with practical insights, focusing on critical aspects such as reliability metrics, failure analysis, and warranty cost optimization. Participants will explore tools like root cause analysis (RCA) and predictive analytics while engaging in interactive activities, including case studies and hands-on exercises. By the end of the training, attendees will be equipped to improve manufacturing processes, reduce warranty costs, and enhance product quality
Features
- Understand reliability metrics and their significance in product lifecycle management.
- Conduct effective failure analysis using tools like Fishbone Diagrams and predictive analytics.
- Develop strategies to optimize warranty costs and improve product quality.
- Apply analytics tools to prevent failures and enhance manufacturing processes.
Target audiences
- Manufacturing professionals across industries such as automotive, or industrial machinery.
- Quality assurance and reliability engineers.
- Production managers and supervisors.
- Professionals in warranty management or after-sales support roles.
- Professionals involved in product lifecycle management and failure analysis.
Curriculum
- 4 Sections
- 18 Lessons
- 2 Days
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- Warranty Management Strategies4
- 0.0Warranty cost drivers and their implications on profitability.
- 0.1Warranty claims data analysis and decision-making using analytics.
- 0.2Strategies to reduce warranty costs (proactive testing, supplier quality improvement, process optimization).
- 0.3Industry case study: How leading auto OEMs improved warranty management using analytics.
- Introduction to Product Reliability5
- 1.0Definition and importance of reliability in product lifecycle management.
- 1.1Key metrics: Mean Time Between Failures (MTBF), Mean Time to Repair (MTTR), Reliability Growth.
- 1.2Examples of reliability failures in the auto industry and their impact.
- 1.3Group discussion: Challenges faced by participants in ensuring reliability during manufacturing.
- 1.4Reliability Quiz: Short quiz to reinforce key metrics and concepts.
- Failure Analysis & Root Cause Identification5
- 2.0Common failure modes in auto components manufacturing.
- 2.1Root cause analysis (RCA) frameworks: Fishbone Diagram, 5 Whys, Fault Tree Analysis.
- 2.2Real-world examples of failure analysis in auto components.
- 2.3Predictive failure analysis using manufacturing analytics.
- 2.4RCA Case Study: Participants analyze a real-world warranty claim to identify the root cause of a failure.
- Application of Analytics in Product Reliability & Warranty4
- 3.0Overview of data analytics tools for reliability and warranty analysis (Pareto analysis, Weibull analysis, regression models).
- 3.1Predictive analytics in preventing failures and improving product quality.
- 3.2Real-world use cases: Predicting failure rates and improving manufacturing processes using data.
- 3.3Hands-on Exercise: Using sample warranty data, participants will analyze trends and propose predictive insights.
Instructor
