Manufacturing Fundamentals – 16 hours

Manufacturing Fundamentals is a practical, application‑focused training package designed to build a strong foundation in quality, Lean thinking, project execution, and core automotive best‑practice tools. The package helps teams develop shared language, consistent methods, and disciplined daily practices that improve plant performance and reduce preventable issues.
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Process Monitoring and Correction – 20 hours

Process Monitoring & Correction is a practical, action‑oriented training package designed to help teams detect issues early, maintain process stability, and implement effective corrective and improvement actions. The package builds capability in data‑driven monitoring, structured problem solving, daily verification, and continuous improvement so organizations can prevent repeat issues and strengthen operational performance. 
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Quality Planning – 20 hours

Quality Planning is a practical, prevention-focused training package designed to help teams anticipate risk, align cross‑functional work, and launch or change products and processes with greater confidence and consistency. The package builds capability in planning, measurement, risk analysis, and approval processes that reduce costly surprises and improve customer satisfaction. 
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Quality Core Tools Overview – 16 hours

Quality Core Tools Overview provides a clear, shared understanding of how Automotive Quality Core Tools work together as an integrated system. This course helps teams move from reactive problem-solving to a preventive, risk-based approach—improving communication, reducing risk, and supporting more consistent, successful product launches.
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Process-Failure Mode & Effects Analysis (P-FMEA) – 8 to 16 hours

P-FMEA teaches a structured method for anticipating problems and developing controls to prevent defects or failures. While FMEA is most fruitful as a proactive quality improvement tool implemented during product and process development, it can also be effectively applied as a continuous improvement tool after a product launch. Versions are available for AIAG 4th edition or the AIAG & VDA FMEA approach.
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Design-Failure Mode & Effects Analysis (D-FMEA) – 8 to 16 hours

D-FMEA can be a one- or two-day workshop or more. The two-day version permits more application exercise and includes discussion regarding the Process-FMEA and the relationship between the System-FMEA, D-FMEA and P-FMEA. D-FMEA training shows participants how to use the FMEA tool to identify activities that are potential risks in the design of a new product, process or service.  Versions are available for AIAG 4th edition or the AIAG & VDA FMEA approach.
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Layered Process Audits (LPA) – 8 hours

Layered Process Verification (or Layered Process Audits) is a supervisor and management tool to ensure that things important to quality are done right the first time. Periodic verification through observation and conversations remove the ‘assumption’ that work is happening as ‘expected.’ LPAs require various layers of supervision and leadership to verify processes, work instructions and error proofing on a scheduled basis, to ensure compliance with documented procedures and standards, and to regularly solicit employees for their improvement suggestions.
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Leadership’s Role in a Successful Layered Process Audit (LPA) – 4 hours

This half-day workshop equips plant leadership with insights into how Layered Process Audits (LPA) integrate with their existing operations, fostering a proactive problem-prevention mindset. Included is critical knowledge about LPA, essential implementation techniques, and tools to enhance the plant’s LPA system to achieve superior performance.
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Project Management – 16 hours

This two-day workshop presents a proven 8-step methodology, tools and techniques for project planning and control, including:  definition of the project and customer’s requirements, roles of the project team, determination and flowcharting of the project tasks, critical path scheduling and costing, quality aspects of critical tasks, risk management and project communications.  This workshop is helpful for anyone involved in project planning and execution, or event management.
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Process Improvement Essentials – 8 hours

Every work process can be improved. This adaptable training workshop teaches and applies a 4-step method along with straightforward but powerful tools and techniques, to help individuals and work teams improve their work processes.  The methodology of: 1) Gather, 2) Review, 3) Innovate and 4) Deploy (GRID) is applicable to any business or organization that wants to do more things, right the first time, in less time, or with less effort and cost.
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Advanced Product Quality Planning (APQP) – 8 hours

This workshop teaches a documented analysis that begins with thoughts concerning customer requirements that could go wrong and ends with defined actions that are implemented to help prevent and/or better detect problems.  This workshop provides key skills required for people involved with product design and/or process development of new programs.
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Production Part Approval Process (PPAP) – 8 hours

This interactive workshop is a high-level overview of PPAP submission elements with focus on the completion of the part warrant. PPAP outlines the process used for approval of production and service commodities, up to and including part submission.  The purpose of the PPAP process is to ensure that suppliers of components comply with the design specification and can run production consistently without negatively affecting the customer production line.
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Process Control Plan – 8 hours

This workshop will demonstrate the effectiveness of proper characteristic definitions and help establish controls to assure high productivity and product quality.  Process Control Plans provide a written summary of the methods, devices and practices used to control all product and process characteristics.  This workshop will help participants identify and define preventative and detection controls that will increase productivity, reduce variation and increase customer satisfaction.
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Geometric Dimensioning & Tolerancing (GD&T) – 16 hours

This workshop explains the benefits of GD&T along with the fundamentals including evaluation tolerances for size, form, orientation and location; how to determine correct datum usage and how it affects manufacturing and inspection; apply geometric tolerances to drawings and determine the virtual condition to ensure assembly.  Participants will be able to practice these concepts with class exercises and evaluations of sample drawings.
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Measurement Systems Analysis (MSA/GR&R) – 8 hours

The objective of the MSA curriculum is to provide participants with the analytical tools and methods necessary to create, use and maintain effective measurement protocols and devices.  This training can be customized based on the audience’s needs, but generally covers:  sources of measurement error, GR&R studies, measurement correlation, control charts to measure measurement systems over time, and handling non-replicable systems (e.g. destructive tests).
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Statistical Concepts / SPC – 8 hours

This training course in basic statistical tools and concepts used for manufacturing process control.  While it might be a refresher for some, the course is designed to help participants properly apply statistical tools and SPC in a manner that proactively improves quality and reduces the costs of non-conformance.  Learning occurs through instructor-facilitated teaching, discussions and team exercises that transfer knowledge and skills to the participants.
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8-Step Root Cause Problem-Solving – 8 to 16 hours

This course uses a proven approach to problem solving that will help improve operational and financial performance by identifying causes and implementing lasting solutions to significant or recurring problems.  Workshop results are best obtained when participants include individuals who are closely involved with the problem areas, collectively have a multi-faceted view of the current situation, and have management support to improve performance.
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Problem-Solving Using the A3 Method – 8 hours

This hands-on course equips individuals and teams with a simple, powerful approach to structured problem solving. Rooted in Toyota’s A3 thinking model, it empowers employees at all levels to address challenges head-on, eliminate root causes, and implement sustainable corrective actions that last.
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Problem-Solving Principles for Non-Technical Personnel – 8 hours

In this one-day training workshop, participants learn a practical approach to solving various business and process related problems.  A 5-step method captures a clear definition of what’s gone wrong, selection of the best of several possible solutions and then verification of the solution’s effectiveness.  By having a consistent approach and familiarity with various problem solving tools, individuals can efficiently and effectively work individually or together to solve problems and prevent them from recurring.
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Improve Outcomes with PDCA – 8 hours

The term “PDCA” (Plan-Do-Check-Act) is often misused, overstated or misunderstood – but can be used to improve planning and solve problems quicker. This training program will demystify how PDCA should be used and motivate employees to improve their individual, team and organizational performance beyond current levels.  This interactive workshop can be a standalone training event or part of a change effort engagement.
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Error Proofing – 8 to 16 hours

This course concentrates on manufacturing quality and cost reduction.  The training will enable participants to implement error proofing techniques that prevent defects by monitoring process conditions that would otherwise lead to problems.  There is a logical and chronological sequence of events from process errors to product defects.  Error proofing within this sequence ensures a high-quality outcome, reducing scrap, customer complaints and costs.
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Six Sigma – 8 to 16 hours

We offer various workshops that can be facilitated for Green Belt, Black Belt and general training in the Six Sigma approach to process improvement.  Our expert facilitators will bring knowledge and examples and guide participants in the proper application of the DMAIC (Define, Measure, Analyze, Improve and Control) process and extended Six Sigma quality improvement tool box.  For Green Belt and Black Belt training, advanced statistical techniques are covered, including: MSA, GR&R, SPC and DOE.
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Design of Experiments (DOE) – 16 hours

This course teaches Design of Experiments (DOE) techniques that permit participants to better control variation and make objective decisions to reduce problems.  Application of DOE translates into highly functional products and processes with improved quality and reliability. The workshop content is applicable for R&D, engineering and manufacturing personnel.  Material is technical in nature, but no prerequisites are required.
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ISO / IATF 16949: Foundations for Quality Management and Auditing Success – 16 hours

This course is perfect for anyone working with the ISO/IATF 16949 standard. Participants will learn the basic knowledge needed to manage and audit quality systems in the automotive industry.  This course is ideal for managers, internal auditors, and team members focused on compliance and improvement, and for leaders who want to learn how to use the system to drive better business results.
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ISO / IATF 16949 Internal Auditor Training: Hands-On Learning and Practice – 16 to 24 hours

This 2-day course covers the fundamentals of the ISO/TS 16949 Quality Management System and teaches participants to conduct effective “Automotive Process Approach” assessments.  An optional 3rd day covers Core Quality Tools from the IATF 16949 standard. The training emphasizes the “Risk is the Compass” method, focusing audits on critical business and quality risks. For maximum benefit, we recommend combining this course with on-site practice internal audits conducted in small groups. Participants apply their knowledge, receive feedback, and gain insights to improve their audit effectiveness.
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Training Enhancement and Mentoring Systems (TEaMS) – 8 to 16 hours

Our Training Enhancement and Mentoring System (TEaMS) will guide you to develop and deliver job-specific, flexible training that will allow your company and your workforce to reach and maintain its highest potential. We accomplish this by training you to enhance your front-line operator training, or by coaching and facilitating your designated mentors to develop best-in-class job training which will accelerate your workforce learning.
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Strategic Planning for Quality – 8 hours

This workshop begins with a facilitated discussion of how the organization is currently performing and what performance is needed in the near future.  Pre-work includes an analysis of the current state of process efficiencies and customer satisfaction (external and internal).  A gap analysis is performed and presented with possible plans of action, including practical considerations for improved outcomes, innovation, and strategies to increase engagement of employees.  This workshop is best suited for an organization’s top leadership.
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Manufacturing Quality Essentials – 16 hours

This two-day workshop explores key quality strategies including standardized work, Error Proofing Verification, 5-S workplace organization, visual management, Process Verifications and root cause problem solving.  Participants will discuss how to incorporate these strategies into the existing management system and daily employee behaviors.
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Manufacturing Quality Basics (covers BIQS / QSB) – 8 hours

This workshop equips participants with practical tools to improve manufacturing outcomes such as reducing errors, increasing productivity, and ensuring more predictable outcome. Key strategies covered include Error Proofing Verification, 5-S, visual management, standardized work, Layered Process Audits (LPA), and Fast Response. Through interactive activities, participants will learn how to apply these techniques effectively within their operations. The workshop emphasizes hands-on learning, enabling attendees to identify improvement opportunities and create actionable plans tailored to specific processes for immediate and lasting impact.
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Lean Principles – 8 hours

This one-day seminar will provide you with an understanding of Lean principals, concepts and tools that will help reduce inefficiencies and errors (waste) from your work.  Learning will occur through presentation, discussion and group activities.  When participants are in the same department or team, action items can be defined to begin to apply Lean concepts to existing workflow.
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SMED / Job Set-Up Error Proofing & Optimization – 8 to 24 hours

This engagement will be multiple days of both consulting and workshop training that will help you target three important areas of improvement:  quality (reduce defect ppm and PRRs), efficiency (reduce changeover cycle time, increase output and lower cost) and staff competency (provide your plant personnel with tools and techniques to replicate improvements across your plant).  We facilitate and consult with the client organization throughout each of three distinct phases on this engagement – Planning, Workshop and Verification of Results.
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5S & Visual Management – 8 to 16 hours

This one- or two-day workshop provides a systematic methodology for organizing, cleaning and sustaining an efficient work environment free of waste and barriers to productivity.  Visual controls support 5S by standardizing where things are stored and making problems visible.  While these are seemingly intuitive concepts, busy organizations do not always take the time to ensure 5S and visual controls are part of their formula for success.
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