New 6 Core Tools

By LEANAE L Excellence – Analyse | Design | Transform

The New 6 Core Tools program by LEANAE L Excellence is a comprehensive quality and product development framework designed to ensure robust processes, risk prevention, and consistent product quality.

This program equips professionals with practical knowledge and hands-on skills to manage product realization, prevent failures, and meet customer and regulatory requirements effectively.

Advanced Product Quality Planning (APQP)

APQP is a structured project management methodology used to develop and launch products that consistently meet customer requirements.

• Structured product and process development approach
• Five-phase APQP framework with defined deliverables
• Early risk identification and error prevention
• Cross-functional planning and execution

Failure Mode and Effects Analysis (FMEA)

FMEA is a proactive risk assessment tool used to identify potential failure modes, analyze their impact, and define actions to prevent or reduce risk.

• Identification of potential failure modes
• Evaluation of severity, occurrence, and detection
• Risk prioritization and mitigation planning
• Improved product and process reliability

Control Plan (CP)

A Control Plan defines critical process controls required to ensure consistent quality throughout production.

• Identification of key process and product characteristics
• Monitoring and control methods
• Reaction plans for process deviations
• Compliance with quality and customer standards

Measurement System Analysis (MSA)

Measurement System Analysis (MSA) evaluates the reliability and accuracy of measurement systems used in decision-making.

• Assessment of measurement variation
• Gauge repeatability and reproducibility (GR&R)
• Bias, linearity, and stability analysis
• Improved data credibility for Six Sigma and quality initiatives

Statistical Process Control (SPC)

SPC uses statistical methods to monitor and control process performance and ensure process stability.

• Control charts for variables and attributes
• Early detection of process variation
• Root cause identification
• Continuous process improvement

Production Part Approval Process (PPAP)

PPAP is a standardized process that demonstrates a supplier’s capability to consistently produce products meeting customer specifications.

• Documentation of product and process compliance
• Validation of manufacturing readiness
• Repeatable and reliable production assurance
• Customer confidence and approval

Training Methodology

• Each Core Tool is delivered through 4-day focused training sessions
• Practical examples, case studies, and real-world applications
• Assignments after every session to reinforce learning
• Hands-on practice to build independent competency
• Final test and performance assessment

Certification

Participants who successfully complete the training, assignments, and final assessment will receive an International Certification from LEANAE L Excellence.

This certification validates practical capability in applying the New 6 Core Tools for quality assurance, risk prevention, and operational excellence.

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7 QC Tools (Seven Quality Control Tools)

By LEANAE L Excellence – Analyse | Design | Transform

The 7 QC Tools are fundamental problem-solving and quality improvement tools used to identify, analyze, and eliminate the root causes of process issues across all industries.

At LEANAE L Excellence, the 7 QC Tools are taught as practical, data-driven techniques that support continuous improvement, defect reduction, and process stability—regardless of sector or function.

What are the 7 QC Tools?

The seven basic quality control tools form the foundation of effective problem solving and quality management:

• Check Sheet
• Histogram
• Pareto Chart
• Cause and Effect Diagram (Fishbone)
• Scatter Diagram
• Control Charts
• Flow Chart

These tools enable teams to visualize data, identify patterns, and make informed decisions for sustainable process improvement.

Key Benefits of 7 QC Tools

• Structured and logical problem-solving approach
• Effective root cause identification
• Data-based decision making
• Reduced defects and process variation
• Improved quality and operational performance

Who Should Attend?

• Anyone interested in learning systematic problem-solving techniques
• Engineers across manufacturing and service industries
• Managers and team leaders
• Quality professionals and supervisors
• Professionals involved in root cause analysis and continuous improvement

MSA – Measurement System Analysis

By LEANAE L Excellence – Analyse | Design | Transform

Measurement System Analysis (MSA) is a structured methodology used to evaluate the accuracy, precision, and reliability of measurement systems that support quality and process decision-making.

At LEANAE L Excellence, this course introduces participants to the principles and practical application of MSA techniques for both attribute and variable measurement systems, in alignment with the Measurement Systems Analysis reference handbook and industry best practices.

What is MSA?

MSA examines how much variation in a process is contributed by the measurement system itself. It ensures that data used for analysis, control, and improvement is accurate, consistent, and trustworthy.

• Attribute and variable measurement system evaluation
• Gauge Repeatability and Reproducibility (GR&R)
• Bias, linearity, and stability studies
• Improved confidence in data-driven decisions

Course Benefits

• Ensures reliable measurement data for Six Sigma and quality initiatives
• Reduces decision-making errors caused by poor measurement systems
• Supports effective process capability and control studies
• Strengthens APQP and new product introduction activities

Who Should Attend?

• Professionals involved in gauge and inspection system design
• Engineers responsible for process measurement and validation
• Quality and manufacturing professionals supporting APQP
• Teams conducting early process studies for new product launches
• Continuous improvement and Lean Six Sigma practitioners

FMEA – Failure Mode and Effects Analysis

By LEANAE L Excellence – Analyse | Design | Transform

The FMEA (Failure Mode and Effects Analysis) course by LEANAE L Excellence is designed to help organizations identify potential risks early, prevent failures, and improve product and process reliability.

Guided by the principle “A stitch in time saves nine”, FMEA enables teams to proactively recognize problems before they occur and address them using structured, data-driven techniques.

What is FMEA?

Failure Mode and Effects Analysis (FMEA) is a systematic risk assessment methodology used to identify potential failure modes in products, processes, or services, analyze their effects, and define actions to eliminate or reduce risk.

• Early identification of potential failures
• Evaluation of severity, occurrence, and detection
• Risk prioritization and preventive action planning
• Improved product quality and process robustness

Course Content

• Introduction to FMEA and risk-based thinking
• Types of FMEA – DFMEA, PFMEA, and Process Risk Analysis
• Failure modes, effects, and root cause identification
• Severity, occurrence, and detection rating methods
• Risk Priority Number (RPN) and Action Priority (AP)
• Defining preventive and corrective actions
• FMEA linkage with APQP, Control Plans, and Continuous Improvement

Skills Covered

• Structured risk assessment and analysis
• Proactive problem prevention techniques
• Root cause analysis and critical thinking
• Cross-functional team collaboration
• Integration of FMEA into business and quality systems

Who Should Attend?

• Professionals involved in product, process, or service development
• Individuals responsible for business or process improvement initiatives
• Managers planning to implement FMEA within their organization
• Quality, engineering, and operations professionals
• Cross-functional team members supporting risk prevention activities

SPC – Statistical Process Control

By LEANAE L Excellence – Analyse | Design | Transform

Statistical Process Control (SPC) is a data-driven methodology used to monitor, analyze, and control process performance through statistical techniques.

At LEANAE L Excellence, SPC is applied as a powerful tool to ensure process stability, consistency, and continuous improvement, enabling organizations to deliver specification-conforming products with minimal waste, rework, or scrap.

What is SPC?

SPC uses statistical tools to distinguish between common cause and special cause variation in processes. By continuously monitoring process behavior, organizations can take timely corrective actions and prevent defects before they occur.

• Real-time process monitoring and control
• Early detection of process variation
• Reduced defects, rework, and scrap
• Improved process capability and predictability

Business Benefits of SPC

• Consistent product and service quality
• Reduced operational costs and waste
• Improved productivity and efficiency
• Enhanced decision-making using data
• Stronger compliance with quality standards

Who Should Attend?

• Business executives seeking process control and performance improvement
• Engineers, managers, and supervisors working on the shop floor
• Middle and senior management responsible for operational control
• Quality professionals involved in quality management systems
• Individuals participating in internal audits and process governance

5S – Workplace Organization & Visual Management

By LEANAE L Excellence – Analyse | Design | Transform

The 5S program by LEANAE L Excellence is a powerful visual management and workplace organization methodology designed to improve efficiency, safety, quality, and profitability.

More than just cleanliness, 5S builds a structured mindset that encourages teams to observe processes, identify waste, standardize best practices, and continuously improve the way work is performed.

What is 5S?

5S is a systematic framework that focuses on creating and sustaining an organized, efficient, and visually controlled workplace. It emphasizes the use of simple yet effective tools to eliminate waste, improve workflow, and enhance value creation.

• Sort – Remove unnecessary items
• Set in Order – Organize for efficiency and flow
• Shine – Clean and inspect the workplace
• Standardize – Establish consistent practices
• Sustain – Maintain discipline and continuous improvement

5S promotes collaboration, accountability, and a culture of waste identification and elimination across all levels of the organization.

Course Content

• Introduction to Lean and visual management
• Detailed understanding of the 5S principles
• Workplace observation and waste identification
• Visual controls, floor marking, and standard work
• 5S audits, scorecards, and sustainment strategies
• Linking 5S with safety, quality, and productivity

Skills Covered

• Workplace organization and visual management
• Waste identification and elimination
• Process observation and evaluation
• Standardization and discipline building
• Team collaboration and continuous improvement mindset

Who Should Attend?

• Employees from any organization or function
• Factory and shop-floor professionals
• Students and fresh graduates
• Quality management trainers and practitioners
• Quality management executives seeking refresher training
• Safety, facility, and workplace management executives