PPIG can carry out a 1 day Manufacturing Capability Awareness Session that as a standard program, covers the following, but can be tailored to suit the specific needs of your organisation.


Manufacturing Capability an Introduction

Aim: To introduce the team to the process of Manufacturing Capability as well as some of the principle tool and techniques used.

The Introduction includes:

  • A breakdown of the day
  • A reflection Exercise
  • A Visualisation Exercise
  • Background
  • Objective Setting



Variation exists in everything: in our height in the colour blue and in the materials you use in your factory. PPIG will explain the two types of variation Natural & Special and will use SPC techniques to show how to measure and identify each type.

Areas included under Variation include:

  • The use of Fishbone Diagrams
  • Cause & Effect
  • The 5 A’s Exercise



Measurement is important in helping to turn opinions and assumptions into facts. If we can’t express what we know in the form of numbers we don’t really know much about it. In this section of the training the team will actually do some measuring.

Areas included under Measurement include:

  • Component width
  • Measurement discrimination
  • Operator Effect
  • Reproducibility
  • Replication Error
  • Repeatability
  • The use of Control Charts
  • Standard Deviation
  • Upper Control Limits (UCL) & Lower Control Limits (LCL)
  • Range & Mean Charts



With the knowledge that detrimental special causes need to be eliminated and that processes need to be in control, the team will now expand into Capability and will discuss the customer expectation and process capability with a view to producing ‘Good Quality’.

Areas covered under Capability include:

  • Brainstorming Who are the Customer & what are their needs
  • Specifications
  • Standard Deviation Exercise
  • Six Sigma


Problem Solving

Within the problem solving section the team will discuss some issues relating to the environment they are familiar with….your factory. The team will discuss the cause and effect of problem and will be encouraged to fix problems using techniques such as 5 Whys, Senses Make Sense and the 5 step Problem Solving Process.

Additional areas covered under Problem solving include:

  • Root Cause & Effect
  • Failure Mode Effect Analysis (FMEA)
  • Design of Experiment


Action Planning

The final activity for the day is for the teams to think about their work situations and how they could apply some of the tools and technique for their own benefit. PPIG can supply improvement sheet that the participants can fill in to help them remember then these can be shared as a group.

PPIG will encourage the team to meet again and discuss the progress of their action plans.