How to Conduct an Internal Audit
Acquire the knowledge to audit your internal quality system to the requirements of the AISC certification standard. This course will present methods and techniques that can be used to maximize the benefits from your own internal audit to any quality management system. Implement these techniques in your own facility to train other internal auditors.

Statistical Process Control (SPC)

Introduction to Statistical Process Control (SPC) for operators

Designed for both managers and others responsible for the implementation of an SPC effort, this course defines and explores the relationship between collecting data and then using it appropriately for quality management. Basic statistics are included, as is a discussion of the use of the Bell curve. Duration: 8 hours. Prerequisites: None.

SPC control charting

In this course, operators and managers will learn the tools and techniques used to monitor and track information as part of statistical process control. Charting techniques for variable and attribute data are emphasized, and the course also covers basic diagnostic tools to supplement data analysis. At the end of the course the student will be able to: Distinguish between attribute and variable data; create fishbone, histogram, Pareto and scatter diagrams; create variable data charts in the form of X-bar and R; create and analyze data in the form of a P-chart; analyze charted data; calculate process capability in the form of CPK or PCR. Duration: 24 hours. Prerequisites: An understanding of 8th-grade math. Prior or concurrent attendance in the Introduction for Operators course is highly recommended. 

Pre-control in SPC

Pre-control is a simple charting technique for detecting process conditions and changes. This easy to use technique helps operators determine or prevent what may be causing defects within a process rather than the use of complex statistical charts, which rely on statistical significance. Pre-control focuses on controlling process conformance to specifications rather than process based control as defined by a normal curve. This class is for people on the shop floor who need to implement a mathematically valid charting technique without the use of complex math formulas or any prerequisite training. Users of the chart can begin plotting their process after only one hour of training. This process can also allow shop floor management to estimate process capability after running only five consecutive pieces. Duration: 2 hours. Prerequisites: An understanding of 8th-grade math. Prior or concurrent attendance in the Introduction for Operators course is highly recommended.

Train-the-trainer

Through this course, individuals who have been identified to train coworkers within the company can be given comprehensive knowledge in the use and application of SPC. Trainers are also given instruction on how to train (a separate discipline from mere technical mastery of SPC), and are also given in-depth instruction regarding how to determine which SPC application is required for any type of operation or method. Trainers are also taught to facilitate problem resolution teams and to instruct individuals in a classroom setting for SPC and problem resolution.  Duration: 24 hours. Prerequisites: Attendees should have a solid understanding of SPC techniques and process metric calculations, such as CPK, CPU, CPL, PCR, etc.; should understand the seven steps of problem resolution; have analytical capability ; and possess a patient disposition in working with teams or individuals. 

Facilitation for SPC implementation

After the SPC program coordinators and/or key resource personnel have been trained, ongoing sessions can facilitate items such as: overall roll-out of SPC applications; types of charts to be applied; who is to analyze data; how is the program to be monitored over time; etc. Typically, this series of sessions will begin 30 to 60 days after the initial SPC training for resource personnel. The heart of this process is a steering committee, which meets once a week to establish a solid SPC program. Once the program is implemented, they will then meet on a weekly, monthly or quarterly basis as determined necessary by the committee. Duration: per-meeting basis, typically for 30-60 days after a committee is established. Prerequisites: Staff trained in SPC basics. 

Design of Experiments (DOE)

Introduction for operators

Design of Experiments gives a company the leading edge over their competitors. Emphasis is placed on how to support a Design of Experiments from the shop-floor point of view. Participants will learn: terms and fundamentals associated with selected styles of DOE; how a basic DOE is set up; what is analyzed; and and methodologies to determine best-cost setting for future savings. This workshop is essential for anyone who is involved in investigating or improving needs to investigate or improve processes. Duration: 8 hours. Prerequisites: 8th-grade math skills. 

Intermediate DOE

Designed for students who need to have a solid understanding of Design of Experiments methodologies, the focus of this class is on mastery of different DOE styles such as full factorial, fractional factorial and Tagucci's Orthogonal Arrays. Analysis will be made utilizing basic formulas designed for easy, real-world applicability. Teaching is done through hands-on experimentation and analysis, and is ideal for anyone charged with taking processes “to the next level.” Duration: 24 hours. Prerequisites: Previous DOE experience or completion of the DOE Introduction for Operators class.

Implementing the Benefits of Quality Management Systems for Executives
Progressive managers know if they aren’t moving forward, they are falling behind! Establishing goals and objectives for quality in your company let’s you know if you are on a forward moving path. This session is designed to assist executive managers in understanding the need for goals in a quality management system. Executives will leave with clear personalized objectives and tools to measure and implement them.

How to Manage the Welding Process ½ day
Presidents, Vice Presidents and General Managers who have the ultimate responsibility for welding fabrication, often need a better understanding of the complex requirements of codes and specifications that govern the process. Using the AWS (American Weld Society) D1.1 Structural Welding Code Steel as a reference, this session will give participants the insights needed to make critical decisions. These decisions will result in a better welding program by managing the right balance between quality, economy and meeting production quotas. This session targets managers with process and financial responsibility.