Transforming Plant Standards into World-Class Shop-Floor Performance

APQP phases, timing and deliverables. PPAP levels, PSW & submission evidence with Customer-Specific Requirements.

7-step approach and structure. Severity, Occurrence, Detection & Action Priority (AP) linked with Control Plan.

Process flow to control strategy, special characteristics identification, and linkage with PFMEA & inspection.

Variation & control charts, Capability (Cp/Cpk & Pp/Ppk), Gauge R&R, and measurement-system decisions.

Pareto, Fishbone, Control Charts, 8D methodology, 5 Why root cause analysis, and CAPA closure effectiveness.

Vendor Quality System Evaluation, process risk assessment, and supplier performance improvement coaching.

Framework & assessment expectations, Labour, ethics, health & safety, environment, worker interviews & NC closure.

Working hours, attendance & overtime records, statutory documentation, grievance mechanisms & code of conduct.

Document checklist & evidence mapping, worker interview preparation, facility walk-through & gap identification.

Business ethics awareness, anti-bribery, responsible sourcing, confidentiality, and contractor reporting.

Supplier assessment criteria, Quality, EHS & social compliance review, audit planning, and follow-ups.

Leadership, people management, training needs analysis (TNA), competency matrix, and review systems.

HIRA / risk assessment & controls, emergency preparedness, incident investigation, and safety culture.

Aspect-impact assessment, operational controls, environmental monitoring, records & legal obligations.

Chemical SDS, segregation, spill response, PPE, hazardous waste manifests, and vendor controls.

Fire risk awareness, extinguisher & hydrant readiness, evacuation planning, mock drills, and response roles.

Machine guarding, LOTO awareness, material handling, ergonomics, and contractor safety monitoring.

Audit checklist development, evidence-based findings, legal gap reviews, and verification of corrective actions.

Eliminating 8 Wastes, value-stream mapping, 5S, Visual Management, Standard Work & Kaizen.

Yellow Belt foundation & Green Belt problem-solving approach for data-driven COPQ reduction.

Autonomous maintenance, planned maintenance, OEE optimization, and downtime reduction.

KPI boards, escalation protocols, layered reviews, accountability, and daily shift reviews.

Tracking OEE, rejection/rework rates, Cost of Poor Quality (COPQ), and straight pass rates (>99.5%).

Stress handling techniques, time management, prioritisation, and cross-functional team coordination.

Decision-making, delegation, conflict handling, performance coaching, and departmental leadership.

Department-specific training for Operations, Quality, HR, Maintenance, Stores, SCM, Accounts & Purchase.

New employee onboarding, Quality awareness, EHS emergency protocols, and SOP/WI alignment.

Internal Auditor, Process Auditor, and Facilitator skills development, including interview techniques.

Gap-based customized training, customer audit preparation, NC/CAPA closure workshops, and mock audit simulations.

Quality fundamentals, manufacturing basics, industrial safety, and career-oriented skill building.