CII Naoroji Godrej Centre of Manufacturing Excellence

Workshop on
Problem Solving using Shainin DOE Techniques
9 – 10 March 2018
Context
 In the present day scenario, we need to develop problem solving and continuous improvement experts in the Organizations
to compete at a Global level and to meet the demands of the customers in-terms of Quality, Cost and Efficiency. These
experts should have the skill of identifying opportunities for improvement and executing the improvements in a structured
manner.
 For most technical problems, there will be lot of opinion based judgmental decisions taken regarding the root cause(s) for the
problem. Every function like product design, process design, production, vendors connected with the problem will try to take
a stand saying that their functions are not responsible for creation of problem and generally will try to put the blame on the
other functions. This deadlock can be resolved only through proper data based tools for investigation of root cause(s) for the
problem.
 Shainin DOE techniques are very user-friendly tools that can be used for shop floor problem troubleshooting and to pin-point
the exact cause(s) for the problem or validate the confirmed cause(s). It does not involve huge data collection and can be
done by workmen and supervisor for troubleshooting daily technical problems
 This will help to create a healthy culture of Structured data based trouble shooting in the Organization

Objectives

 To impart the skills in correctly understanding the technical problem, identify the suspected cause(s) for the problem and
selection of right Shainin tools depending on the problem and process nature
 How to understand the problem using Phenomenon analysis
 Once the tool is selected, explain in depth in a prescriptive way on the following 3 steps
o Data collection
o Data analysis
o Conclusion on whether the suspected cause(s) are confirmed or eliminated
 Based on the confirmed cause(s), how to identify whether problem is due to Product/Process design or it is due to
manufacturing variability
 How to validate the confirmed cause(s)

Contents
 How to Identify Problems for Solving using Shainin methodology
 Splitting Generic Problems into Specific Problems
 Classification of problems into 4 categories
 Introduction to Shainin techniques. Brief overview of the following tools
ISO Plot, Paired comparison, Product/Process search, Component search, Modified Component search, Multi-vari analysis,
Variable search, Monte-carlo simulation, B vs C

In this workshop, the following techniques will be discussed in detailed, since for most of the problems, these techniques are
applicable
T1 - Paired comparison, T2 – Product/Process search, T3 – Component search, T4 – B vs C
Methodology
 Selection of problem and categorization of problems will be explained using the case studies from the following
processes
a) Machining b) Injection moulding c) Pressure die casting d) Assembly e) Welding f) Cold and Hot forging and all other
manufacturing processes
 Selection of Shainin tools will be explained using live problems
  Data collection, analysis and conclusion will be explained using hands-on exercises
 Entire program will be based on continuous interaction with the participants to ensure that they understand the tools
and can apply them in their work place
 Detailed discussion on two manufacturing case studies will be done on Feb 3rd
 E-mail and telephone support for participants who need help after the program on deployment, provided they take the
initiative to do projects after the program and are in touch with the faculty.
Target Audience

Function Positions

Production Production in-charge, Factory head

Quality Quality Engineer, Quality Manager

Manufacturing Engineering Manufacturing Process Engineers, Manufacturing Process Managers

Corporate / Support Functions Continuous Improvement Engineers / Managers, Quality System Implementers

Faculty :
Mr Ramnarayan is a Bachelors in Mechanical Engineering and a Post Graduate Diploma in Business Administration. He graduated
in 1991 from PSG College of Technology, Coimbatore, India. He worked with Lucas-TVS, Chennai from 1991-
1996 and with Omnex Inc., USA from 1996 – 2003 as Country head. He is now running his own consulting
company named World Class Manufacturing Solutions from 2003 till date.

He is a Six Sigma Master Black Belt & is using Shainin DOE techniques extensively for solving manufacturing problems for the last
27 years in various assignments. He has improved upon the techniques through the various problems solved. Mr Ramnarayan has
been involved in solving over 5000 manufacturing problems covering various products and processes. He also has trained over
10,000 people throughout India on problem solving techniques. Some of the organisations with he is / was involved are Tata Steel
- UK & Jamshedpur Operations, Bosch, Wanxiang Ltd, Shanghai, GM Shanghai, Brakes India, Amara Raja Batteries, Kirloskar Oil
Engines, Cadbury, Titan – Watch Division, Titan – Precision Engineering Division, Sriram Pistons, Sundaram Fasteners, Rane TRW,
Automotive Axles, TE Connectivity, EPCOS, Piaggio, Johnson & Johnson, Lucas TVS, etc.

Dates/Schedule of Sessions: 9 – 10 March 2018

9 March 2018 Registration- 9:15am to 9:30am
9 – 10 March 2018 Sessions - 9:30am to 5:00pm
Venue: CII Naoroji Godrej Centre of Excellence, Godrej Station-Side Colony, Opposite Railway Station, Vikhroli (East), Mumbai –
400079

Participation Fees: (on non-residential basis)

Type of Organisation Fees per Participant

CII Members (Large & Medium) Rs.11000/- (+ Service Tax as applicable)

CII SSI Members Rs.8500/- (+ Service Tax as applicable)
Non Member Companies Rs.12500/- (+ Service Tax as applicable)

Fees include participation, course material (hard copies), working veg lunch and tea / coffee. Advance payment of fees is to be
drawn in favour of “Confederation of Indian Industry”.

Discount
5% on 2 nominations from an organization.
10% on 3 or more nominations from an organization.

Participation fees is non-refundable/ non-adjustable against any other programme of CII, but change in nomination(s) is
accepted.

Registration: Prior registration for participation by the sponsoring companies is necessary. Number of admissions will be limited
to 25.
Certificate of Participation will be given to all the participants who attend the programme fully.
Nominations & Enquiries:
Rupali Salunkhe
CII Naoroji Godrej Centre of Excellence
Godrej Station-Side Colony Tel : (022) 2574 5146 / 5148
Opp Railway Station, Vikhroli (East) Email : rupali.salunkhe@cii.in / ciicme@cii.in
Mumbai – 400 079

CII Naoroji Godrej Centre of Manufacturing Excellence

Workshop on
Problem Solving using Shainin DOE Techniques
9 – 10 March 2018
We nominate the following manager/s to attend the Workshop
Name Designation Tel / Email id
1
2
3
4

Our Cheque / Demand Draft dated __________ No. _________ for Rs. ________________ drawn in favour of
“Confederation of Indian Industry” is enclosed.

Name : _____________________________________________ Designation : __________________________________

Organisation :______________________________________________________________________________________

Address : __________________________________________________________________________________________

__________________________________________________________________________________________________

CII Membership No : ___________________________ Telephone : ____________________________________

Fax : _____________________________________________ Email : __________________________________________

Signature & Stamp of the Nominating Authority : ________________________________________

 Participation fee is non – refundable / non-adjustable against any other programme of CII. However change in
nomination(s) is accepted.
 Workshop is non – residential.