Program Overview
This expert-led program is designed to help Lucas TVS professionals deeply understand the financial and operational impact of poor quality, build a culture of zero-defect manufacturing, and harness digital tools under the Quality 4.0 framework. Participants will explore real Lucas TVS scenarios — from stator/rotor lines to warranty returns — and learn how to trace root causes, prevent defects at source, and adopt technologies like IoT, AI, and cloud-based QMS for predictive quality management. With hands-on exercises, live case studies, and team-based action planning, this course aims to move the organization from reactive firefighting to a proactive, preventive quality culture.
Features
- Accurately identify and quantify the hidden costs of poor quality in operations
- Design and implement zero-defect practices using proven lean quality tools
- Apply Quality 4.0 technologies to address specific manufacturing pain points
- Build and execute a 90-day roadmap to initiate quality transformation in their departments
Target audiences
- Manufacturing & Quality teams
- Production Engineering teams
- Maintenance teams
- Process Improvement teams
Curriculum
- 4 Sections
- 21 Lessons
- 1 Day
Expand all sectionsCollapse all sections
- Cost of Poor Quality (COPQ)4
- 1.1Breakdown of COPQ: Internal failure, external failure, appraisal, prevention
- 1.2Automotive examples: Impact of COPQ on profitability, supplier scorecards, and OEM relations
- 1.3Explore hidden quality costs in stator/rotor lines, warranty returns, line downtime
- 1.4Group Exercise: Estimate COPQ for one real case (Lucas TVS data anonymized by the facilitator)
- Zero Defect Manufacturing – Building a Prevention Culture6
- 2.1Introduction to Zero Defect: Why it’s a necessity, not a goal
- 2.2Methods: Poka-yoke, Layered Process Audits, Autonomous Quality, Visual Controls, Andon Systems
- 2.3Analysis: Why current quality efforts fail to prevent — addressing people, process, and system gaps
- 2.4Case Study: Successful zero-defect practices from Japanese Tier-1 suppliers
- 2.5Where defects escape—Operator involvement, process capability, in-process detection gaps
- 2.6Group Discussion: “How can we move from fixing to preventing?”
- Enabling the Shift with Quality 4.0 Tools6
- 3.1What is Quality 4.0?
- 3.2Key pillars: Real-time defect tracking with IoT sensors; AI-based pattern recognition to predict quality drifts; Cloud-based QMS for instant traceability; AR/VR for quality training and remote audits; Blockchain for tamper-proof traceability
- 3.3Automotive Case: Bosch/Continental plants using AI for in-line defect prediction
- 3.4Readiness gap for digitization – legacy equipment, siloed systems, low data capture
- 3.5Group Exercise: One pain point (e.g., leak test, winding defects) and map a Quality 4.0 solution
- 3.6Discussion: Start small – how to run pilot with minimum investment
- Integration & Execution Plan5
- 4.1Synthesis: COPQ → Zero Defect → Quality 4.0 – Integrated model
- 4.2Framework: “Quality Maturity Ladder” – From firefighting to predictive quality
- 4.3Team Activity: 30-60-90 Day Action Plan for own department
- 4.4How to drive plant-level quality transformation with existing teams
- 4.5Pitfalls to Avoid: Common mistakes when implementing digital quality or zero-defect programs
Instructor
