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Description

Operational Quality in Production: Cutting Scrap and Holding Standards

Two days to tackle poor quality where it is actually created, at the workstation

  • 2 days — 14 h
  • In-person or virtual
  • Foundation
  • Up to 6 participants

Scrap and rework are treated as an unavoidable part of the job. Defects are detected at the end of the line or, worse, at the customer's site. Work instructions exist, but each operator works in their own way depending on seniority. Actions agreed in quality meetings never reach the shop floor.

These 14 hours focus on the workshop and the workstation. Participants learn to identify sources of variation, to make work instructions reliable through simple devices, to react quickly to a detected defect and to sustain results through supervisory routines. The programme addresses daily execution, not the design of a quality management system.

Learning objectives

  • Identify sources of variation and poor quality at a production workstation
  • Quantify the losses caused by scrap and rework on a line
  • Make work instructions reliable through error-proofing devices
  • Organise immediate response when a defect is detected
  • Lead daily quality follow-up with your team

What makes this programme different

A defect log built and analysed for a described production line
Error-proofing devices designed workstation by workstation by participants
A five-minute daily quality briefing prepared and rehearsed on the shop floor

Programme

1Where Poor Quality Is Created

Looking at the workstation

  • Sources of variation at a production workstation
  • Scrap, rework and hidden losses
  • Approaching the cost of poor quality on the shop floor
  • Recording and classifying defects on a line

2Making the Workstation and Work Instruction Reliable

Making the right action easy

  • Work standards and genuinely usable work instructions
  • Error-proofing devices and poka-yoke solutions
  • Workstation organisation and housekeeping
  • Start-up conditions and first-piece validation

3Reacting Quickly to a Defect

Acting before the batch leaves

  • Detection as close as possible to the workstation
  • Stop and escalation rules for supervisors
  • Rapid cause analysis at the machine
  • Immediate actions and protecting the customer

4Sustaining Results Over Time

The daily role of supervision

  • Quality indicators displayed on the shop floor
  • Daily performance briefing with the team
  • Workstation audits and compliance with the standard
  • Involving operators in improvements

Who is it for

Team leaders, supervisors, quality technicians and lead operators in production workshops.

Prerequisites

No prerequisites

Dates & locations

36 scheduled dates between November 2026 and December 2027. Seats are confirmed in the order enquiries are received.

November 2026

December 2026

January 2027

February 2027

March 2027

April 2027

May 2027

June 2027

September 2027

October 2027

November 2027

December 2027

None of these dates suit you? We open additional sessions on request, and any programme can be run privately for your team.

Practical details

Before the programme
Online positioning questionnaire. Your development objectives are shared with the trainer, who tailors the practical case studies to your context.
Teaching methods
Theoretical input, workshops and practical case studies. Digital course materials and method sheets provided.
Assessment
Multiple-choice tests and role-play exercises. Assessment of learning at the start and end of the programme, with immediate and 60-day follow-up evaluations.
After the programme
One year of access to the e-learning platform. Self-assessment of the skills acquired and a 30-day follow-up session with your trainer.
How to register
Registration online or on the basis of a quotation.
Lead time
11 working days after confirmation of registration.
Accessibility
Accessible to people of determination. Contact our accessibility coordinator to design a suitable solution: contact@mpf-academy.ae
Start dates
Rolling intake: in addition to the scheduled sessions, this programme can start on request.