1 Program.doc · Web viewAugust 2003. Program Outline & Participation Requirements. of. The Quality...

August 2003

Program Outline&

Participation Requirementsof

The Quality Control Training Course[QCTC]

18 February - 9 March 2004

Osaka, Japan

1. BACKGROUND OF THE PROGRAM:AOTS - the Association for Overseas Technical Scholarship - is a non-profit association run with Japanese

government subsidies from the Ministry of Economy, Trade and Industry (METI). Since its establishment in

1959, AOTS has been conducting various technical and management training programs in Japan for the people

of developing countries. The total number of participants in past AOTS training programs amounts to almost

107,000 from about 150 developing countries and regions. These former participants are playing very

important roles in industry and contributing greatly to the economic development of their respective countries.

At the request of former participants of AOTS training programs as well as the industrial and business circles

in developing countries, AOTS has been organizing various training programs to meet their needs for

successful industrialization.

The Quality Control Training Course (QCTC) was first organized in 1979 to enhance the quality management

ability at manufacturing companies in developing countries, and the 25th program will be held this year.

2. NUMBER OF PARTICIPANTS:30 participants

3. PARTICIPATION REQUIREMENTS:Participants should have the following qualifications in addition to meeting the other requirements specified in

the AOTS Scholarship Rules and Regulations.

(1) Participants should be, in principle, managers/staff who are responsible for the promotion of TQM/quality

control activities at manufacturing companies, with a basic knowledge of the seven QC tools.

(2) Participants should be, in principle, between 25 and 55 years of age, with three years or more of

professional experience.

(3) Participants should be university graduates and/or have equivalent professional experience.

(4) Participants should have a sufficient working knowledge of English.

(5) Participants should be healthy enough to undergo an intensive training program in Japan.

Notes:

(1) AOTS ex-participants who have recently been awarded an AOTS Scholarship and participated in an AOTS

training program in Japan are not entitled to apply for any program which starts within six months (183

days) after they have returned home from Japan.

(2) Family members are not allowed to accompany the participants to Japan.

(3) Participants shall not request AOTS to arrange, nor arrange by themselves, any additional programs, and

shall leave Japan and return to their home countries soon after the completion of the program.

4. APPLICATION PROCEDURE:Applicants should apply to AOTS by submitting the following documents to reach AOTS Head Office in

Tokyo no later than 21 O ctober 2003 .

(1) AOTS Training Application Form, Applicant’s Personal Record and Medical Check Sheet (AOTS official

form)

(2) 2 copies of a photo (4.5 cm x 3.5 cm)

(3) Brochure of the applicant’s company

(4) Photocopy of a passport, an election card, a driver’s license or any other identification document issued by

a public organization in the applicant’s country containing the applicant’s name in full, a photo of the

applicant and his/her home address

(5) Pre-Training Report (Page 12)

(6) Consent Form of Overseas Travel Insurance

The application documents will be forwarded to the AOTS Screening Committee, which will be held on 18

December 2003, for official approval of participation. Those who have successfully passed the screening

process will be notified when they receive the invitation documents.

5. OUTLINE OF THE PROGRAM:■ OBJECTIVES

The objectives of the program are:

(1) To acquaint participants with the practice of TQM (total quality management) in Japan, and

(2) To enhance participants’ capability in promoting TQM as a comprehensive system.

■ DURATION18 February – 9 March 2004 (3 weeks)

■ CONTENTSThe training course will focus on the following six important components of TQM practice in Japan.

-Daily management and management by policy (hoshin kanri)-New product development-Quality assurance-The production system-Human resource development-Problem-solving and continuous improvement (kaizen)

Studying these topics systematically, participants will come to understand the strengths of Japanese companies.

Participants will gain theoretical knowledge in the morning sessions and learn how to put such theory into practice in the afternoon sessions with case studies and simulations. The curriculum focuses on “what individual participants, as managers/staff promoting TQM/quality control, should do and how”, so that what they learn in the course will be immediately applicable when they return to their own companies.

The typical daily schedule consists of a three-hour morning session and a three-hour afternoon session. Some

evening sessions may be organized after dinner.

Please refer to the Tentative Schedule on page 3.

■ LANGUAGE

All lectures, discussions and company visits will be conducted in English or Japanese with translation into

English. The program documents and training materials will be prepared in English.

■ PROGRAM COORDINATORSDr. Yoshio KONDO, Ph.D.Professor Emeritus, Kyoto UniversityChairman, International Academy of Quality

Dr. Hideo IWASAKI

Professor, Department of Industrial Engineering, Kinki University

■ TRAINING LOCATION AND ACCOMMODATION

The program will be held at the following AOTS Training Center.

AOTS Kansai Kenshu Center (KKC)

7-5, Asaka 1-chome, Sumiyoshi-ku, Osaka 558-0021, Japan

Tel: 81-6-6608-8260 (Reception) Fax: 81-6-6690-2678

Tentative Schedule

The Quality Control Training Course [QCTC]

18 February – 9 March 2004 AOTS Kansai Kenshu Center (KKC)

Date Morning Session Afternoon Session

17 Feb.

(Tue.)(Arrival in Japan)

18

(Wed.)

Orientation

Opening Ceremony

LECTURE: Introduction to TQM-Quality, PDCA cycle

19

(Thu.)

LECTURE:Characteristics and Promotion of TQM-TQM Practice in Japan, QC Mindset and Viewpoint

CASE STUDY: QC Mindset-Group Discussion (GD) on kaizen example(s)

20

(Fri.)

LECTURE: Daily Management vs. Management by Policy(hoshin kanri)-How to promote daily management and hoshin kanri

CASE STUDY:Formulation and Deployment of Policy-Simulation of policy formulation and deployment using formatted charts

21(Sat.)

22 (Sun.) Self-planned training

23

(Mon.)

LECTURE:

New Product Development

-System for new product development

CASE STUDY: Formulation of “Required Quality Deployment” using QFD-Simulation of QFD and GD

24

(Tue.)

LECTURE: Promotion Procedures of Quality Assurance-Mechanism of and major tools for quality assurance

CASE STUDY:

Formulation of QC Process Charts

25

(Wed.)

LECTURE: Establishment of Production Systems -Production systems in Japanese companies

CASE STUDY:

Production Systems

26

(Thu.)

LECTURE:

Human Resource Development and QC Circles

-Importance of HRD and continuous improvement,

promotion of QC Circles

CASE STUDY:

Formulation of QC Circles Revitalization Plan

-Drawing cause and effect diagrams and tree diagrams

27

(Fri.)

LECTURE:

Process Control and Improvement

-Effective use of QC tools in the problem-solving

procedures

CASE STUDY:

Exercise on Process Analysis

28 (Sat.)

29 (Sun.)Day off

1 Mar.

(Mon.)

LECTURE:

Utilization of QC Techniques-Key points in using QC techniques for cause analysis

EXERCISE:Hands-on Exercise on Cause Analysis (QC Game)

2

(Tue.)

EXERCISE:Hands-on Exercise on Cause Analysis (QC Game) Presentation on Cause Analysis Exercise

3

(Wed.)

STUDY TOUR

COMPANY VISIT:

TQM Promotion

4

(Thu.)

COMPANY VISIT:

Case Study of the Production System at a Japanese Company

5

(Fri.)

VISIT:

Understanding Japanese Culture and Society

6(Sat.)

7(Sun.)Day off

8

(Mon.)

COMPANY VISIT:　Management by Policy (hoshin kanri)

COMPANY VISIT:　QC Circles

9

(Tue.)Overall Question and Answer Session

Evaluation of the Program

Closing Ceremony

10 (Departure from Japan)

(Wed.)

Remarks: (1) The above schedule is subject to change due to the convenience of lecturers and cooperating companies , or for

other unavoidable reasons.

(2) Several group discussion sessions may be arranged in the evening.

(3) Though Saturdays and Sundays are days off in general, lectures may be scheduled if deemed necessary.

6. ACCOMMODATION:During the training period, participants will be accommodated at an AOTS Kenshu Center. AOTS will provide

participants with accommodation in single rooms of the value of \8,700 per day with lunch, dinner and

breakfast. During the study tour period, participants will receive in cash \9,800 per day for accommodation,

and \2,700 per day for meals.

Please note that AOTS Kenshu Center Canteen will be closed on Sundays. The participant will receive \2,700

in cash per day for meals to cover this day.

Participants in principle are requested to arrive in Japan the day before the commencement of the training

program and leave Japan the day after the final day of the program.

7. TRAINING COSTS:1) Outline

AOTS training programs are financed by Official Development Assistance (ODA) subsidies from the Japanese

Ministry of Economy, Trade and Industry (METI) together with the Participation Fee (Contributions from

Participant) from the participants themselves.

Participants shall pay the Participation Fee (Contributions from Participant) in cash to AOTS after their arrival

in Japan.

The Training Expenses will vary in accordance with the actual airfare and participants’ staying days.

Therefore, the Participation Fee will be finalized after their arrival in Japan.

The estimate of the Training Expenses together with the Participation Fee is shown in Table 3 on pages 6-7.

Please note that the subsidy from the Japanese government will be applicable to the period between the day

before the commencement of the training program (17 February 2004) and the final day of the training

program (9 March 2004) in principle.

2) Breakdown

1. Training Costs

The Training Costs are the total amount of expenses incurred by a participant during the training

program. It is the sum of (1) Allowances for Course Participation, and (2) Cost of Course

Implementation.

(1) Allowances for Course Participation

International Travel Allowance

・Participants will purchase their own round-trip air tickets, for which there are no restrictions pertaining

to boarding class or flight route.

・The subsidy from the Japanese government will cover the actual airfare up to the AOTS’s standard

airfare limits, which amounts are shown in the estimates.

・Please refer to “Guidelines for Purchase of Air Tickets by the participant” on page 10 for the

arrangement and the method of reimbursement for details.

Initial Allowance

・AOTS will pay \20,000 in cash to participants.

Accommodation and Meal Allowance

・AOTS will provide participants with accommodation of the value of \8,700 per day including three

meals, while they stay at the AOTS Kenshu Center.

・However, for the arrival day, AOTS will provide participants with accommodation of the value of

\7,900 per day with dinner and breakfast at the AOTS Kenshu Center.

Personal Allowance

・AOTS will pay \1,200 per day in cash to participants.

Baggage Allowance

・AOTS will pay \6,750 in cash to participants.

(2) Cost of Course Implementation

The cost of Course Implementation is the cost to carry out an AOTS Management Training Program. This

does not include the Allowances for Course Participation. The amount, which is shown in Table 2 on this

page, depends on the duration of the course.

(3) Domestic Travel Allowance

AOTS will pay in cash to participants the cost of travel between the AOTS Kenshu Center and the

nearest international airport. The amounts are as follows:

Table 1 Domestic Travel Allowance

AOTS Kenshu Center Airport Amount (to & from)

KKC/Kansai Kenshu Center Kansai International Airport 1,720

2. Participation Fee (Contributions from Participant)

The Participation Fee, which consists of Contribution for Course Participation, Contribution for Course

Implementation and Contribution towards Administrative Costs, is the amount participants should bear.

(1)The Contribution for Course Participation for the participants from Less Developed Countries(LDCs) is

25% of the Allowances for Course Participation. The Contribution for Course Participation is not set up for

the participants from Least Less Developed Countries (LLDCs).

(2)The Contribution for Course Implementation, which is a part of the Cost of Course Implementation and

fixed as per Table 2, is used to organize the AOTS Management Training Program.

Table 2 Cost of Course Implementation and the Contribution for Course Implementation

Course duration Cost of Course Implementation Contribution for Course Implementation

3- week course 500,000 164,000

(3)The Contribution towards Administrative Costs is \1,800 per day for the participants from LDCs, \1,000

per day for the participants from LLDCs, and covers administrative expenses.

　　＊As for definition of LLDC by DAC, please refer to Table 4 on pages 8-9.


Table-3-1 Estimate of the Training Expenses and the Participation Fee (LDC)

（Bangkok/ Thailand – Osaka / Japan）

The Association for Overseas Technical Scholarship [AOTS]0


Table-3-2 Estimate of the Training Expenses and the Participation Fee (LLDC)

（Dhaka/ Bangladesh – Tokyo / Japan）



Table-4

Table of Standard Airfare Limits and LDC/LLDC for FY2003 (unit: Japanese Yen)As of 30 April 2003

Area CountryPlace of

Departure

Place of

Arrival

Standard

Roundtri

p Airfare

*LDC

/

LLDC


Departure

Place of

Arrival

Standard

Roundtrip

Airfare

*LDC

/

LLDC

Southeast Asia

Cambodia 　　 74,800 LLDC

Central

and

South

America

Argentina 　　 170,200 　

Indonesia 　　 61,200 　 Bolivia 　　 189,700 　

Laos 　　 71,800 LLDC Brazil 　　 211,200 　

Malaysia 　　 67,900 　 Chile 　　 198,600 　

Myanmar 　　 74,900 LLDC Colombia 　　 265,900 　

Philippines

Cebu 　 54,700 　 Costa Rica 　　 197,100 　

Manila 　 67,200 　Dominican Republic

　　 131,800 　

Thailand 　　 49,700 　 Ecuador 　　 211,100 　

Viet Nam 　　 93,900 　 El Salvador 　　 150,000 　

Northeast Asia

China Beijing Tokyo 45,600 　 Guatemala 　　 184,300 　

　 Nagoya 49,600 　 Haiti 　　 126,600 　

　 Osaka 47,000 　 Honduras 　　 150,000 　

　 Fukuoka 41,800 　Mexico

Mexico City 97,600 　

Chengdu Tokyo 57,400 　 Monterrey 108,600 　

　 Osaka 51,200 　 Panama 　　 197,100 　

　 Fukuoka 45,400 　 Paraguay 　　 198,600 　

Chongqing Tokyo 54,900 　 Peru 　　 164,200 　

　 Nagoya 49,200 　Trinidad and

Tobago　　 164,400 　

Dalian Tokyo 47,900 　 Uruguay 　　 198,600 　

　 Nagoya 43,600 　 Venezuela 　　 118,200 　

　 Osaka 40,800 　 Africa Algeria 　　 125,500 　

　 Fukuoka 34,800 　 Cameroon 　　 161,700 　

Guang

ZhouTokyo 45,700 　 Egypt 　　 64,300 　

　 Osaka 41,500 　 Ethiopia 　　 124,000 LLDC

　 Fukuoka 40,600 　 Ghana 　　 174,200 　

Hong

KongTokyo 39,700 　 Kenya 　　 134,400 　

　 Nagoya 39,700 　 Madagascar 　　 159,400 LLDC

　 Osaka 39,300 　 Mauritania 　　 123,200 LLDC

　 Fukuoka 34,800 　 Mauritius 　　 110,200 　

Qingdao Tokyo 47,000 　 Morocco 　　 127,200 　

　 Osaka 40,100 　 Nigeria 　　 342,000 　

　 Fukuoka 34,100 　 Senegal 　　 171,400

Shanghai Tokyo 41,800 　 South Africa 　　 93,400 　

　 Nagoya 36,000 　 Sudan 　　 166,600 LLDC

　 Osaka 32,400 　 Tanzania 　　 167,600 LLDC

　 Fukuoka 29,900 　 Tunisia 　　 89,700 　



Shengyang Tokyo 46,200 　 Uganda 　　 148,400 LLDC

　 Osaka 40,800 　 Zambia 　　 259,900 LLDC

Tianjin Tokyo 53,600 　

Zimbabwe 　　 157,600 　

　 Nagoya 47,300 　

MiddleEast

Bahrain 　　 149,900 　

　 Osaka 44,400 　 Iran 　　 95,400 　

Xiamen Tokyo 52,500 　 Jordan 　　 137,800 　

　 Osaka 45,600 Lebanon 　　 173,000


Departure

Place of

Arrival

Standard

Roundtri

p Airfare

*LDC

/

LLDC


Departure

Place of

Arrival

Standard

Roundtrip

Airfare

*LDC

/

LLDC

Northeast Asia

China

Xi'an Tokyo 49,600 　 Oman 　　 120,300 　

　 Nagoya 47,100 　Saudi Arabia

　　 153,500 　

Osaka 43,600 Syria 93,400

Fukuoka 37,400 Albania 148,500

Mongolia

Ulaanbaatar Tokyo 74,200 Bulgaria 126,100

Osaka 66,400 Czech Republic

83,000

Middle Asia

Uzbekistan 　 177,500 　 Hungary 　　 101,500 　

South Asia

Bangladesh 　　 100,800 LLDC Macedonia 　　 128,300 　

Bhutan 　　 125,000 LLDC Poland 　　 80,900 　

India

Bangalore 102,500 　 Romania 　　 93,600 　

Calcutta 75,500 　Slovak Republic

　　 122,100 　

Chennai 78,700 　 Turkey 　　 120,400 　

Cochin 　 109,700 　 Ukraine 　　 79,400 　

Delhi 　 79,200 　　Mumbai 85,700 　

Maldives 　　 147,800 LLDC

Nepal 　　 127,800 LLDC

Pakistan 　　 100,100 　

Sri Lanka 　　 82,300 　

Oceania

Kiribati 　　 168,800 LLDC

Palau 　　 95,500 　

Papua New Guinea 　 139,100 　

Vanuatu 　　 131,400 LLDC

　

[Remarks] LDC (Blank): Less Developed Countries LLDC: Least Less Developed Countries



Guidelines for Purchase of Air Tickets by the Participant

1. Arrival and Departure Dates:Arriving in Japan on the day before the commencement of the program and departing on the day after the closing day of the program or the nearest days to be allowed by the flight schedule within two days before and/or after the program.

2. Method of Reimbursement: During the training program in Japan, participants should present to AOTS their air tickets and submit official receipts of air ticket purchase for reimbursement. The sum of the following items (1) and (2) will be subsidized regardless of the method of air ticket purchase, flight route, or boarding class:

(1) Actual round-trip airfare within the Standard Airfare Limits which are shown in Table 4 on pages 8-9.(2) The departure tax, airport tax and other taxes indispensable to the usual flight route defined by IATA subject

to the submission of evidence.

3. Official Receipts:AOTS will check the air ticket and official receipt and calculate the actual yen value of the air ticket with the exchange rate on the date of the ticket’s issue.

1) AOTS can only accept official receipts duly issued by the issuer in which a breakdown of the total airfare isexplicitly described, such as airfare, tax (the departure tax, airport tax and other taxes indispensable to the usual flight route defined by IATA) and commission. It should also contain the name of the issuer’s representative, address, telephone number and facsimile number.

2) Neither Invoice nor Calculation Sheet will be accepted as the receipt. However, an Invoice/Calculation Sheetusing the letter-head of the air ticket issuer stating the word “Received” or “ Paid” and including the signature of the air ticket issuer may be accepted.

If any participant fails to submit an official receipt duly issued by the relevant airline company or travel agent, the participant will not receive any subsidy towards his/her airfare and will be required to pay the full amount of the Participation Fee in cash to AOTS.



8. FURTHER INFORMATION:Please contact:

AOTS HEAD OFFICENaomichi Yoshimura, Manager Overseas Administration DepartmentScholarship Administration DivisionThe Association for Overseas Technical Scholarship [AOTS]

30-1, Senju-azuma 1-chome, Adachi-ku, Tokyo 120-8534, Japan

Tel: 81-3-3888-8214

Fax: 81-3-3888-8242

E-mail: [email protected]

AOTS OVERSEAS OFFICES

1. AOTS Bangkok Office 2. AOTS Beijing Office

(General Manager) Mr. Shintaku Seizaburo14th Fl. SSP Tower 3, 88 Silom Rd., Suriyawong, Bangruk, Bangkok 10500Tel: 66-2-238-5233~4, 268-0784Fax:66-2-634-1200E-mail: [email protected]

(General Manager) Mr. Toshikazu KumazawaBeijing Fortune Bldg. Rm.610, 5-hao, Dong-Sanhuan Bei-lu, Chaoyang-qu, Beijing 100004Tel: 86-10-6590-8265, 8266Fax:86-10-6590-8267E-mail: [email protected]

3. AOTS Dhaka Office 4. AOTS Jakarta Office

(General Manager) Dr. AKM Moazzem Hussain

Rooms 31-32, 7th Fl., Eastern PlazaSonargaon Road, Hatirpool, Dhaka-1205Tel: 880-2-861-3856, 861-6379Fax:880-2-861-6379E-mail: [email protected]

(General Manager) Mr. Hideaki Otani2nd & 3rd Floor, Gedung Gajah, Jalan Dr. Sahardjo No. 111-FG, Jakarta 12810Tel: 62-21-835-0383, 835-1414Fax:62-21-830-1443E-mail: [email protected]

5. AOTS Kuala Lumpur Office 6. AOTS Manila Office

(General Manager) Mr. Takeshi Ichikawa52A, Jalan SS22/25, Damansara Jaya47400 Petaling Jaya, Selangor Darul Ehsan Tel: 60-3-77267273, 77267276Fax:60-3-77267269E-mail: [email protected]

(General Manager) Mr. Te ｔ suji Kawakami37th Fl., Robinson’s Equitable Tower, ADB Avenue Corner Poveda Road, Ortigas Center, Pasig City, Metro ManilaTel: 63-2-687-6112~4Fax:63-2-687-6115E-mail: [email protected]

7. AOTS New Delhi Office 8. AOTS Representative Officer for Vietnam


mailto:[email protected]


(General Manager) Mr. Shinichi MiyamotoFlat No.1307, 13th Flr., Gopaldas Bhawan, 28 Barakhamba Road, New Delhi 110001Tel: 91-11-23704122Fax:91-11-23704123E-mail: [email protected]

Mr. Nguyen Duc Hoec/o Dong Du Center, 43D/46 Ho Van Hue, Phu Nhuan Dist. HCMTel: 84-8-8477056, 8453782Fax: 84-8-8477528E-mail: [email protected]

Pre-training Report- The Quality Control Training Course-

[QCTC]Please fill in the following items by using a personal computer or similar equipment, or by handwriting in block letters. AOTS will duplicate and distribute it to lecturers and other participants as a reference material for the group discussion and the presentations to be held during the program.

1. Your name

2. Country

3. Name of company/ organization

4. Outline of your organization　

(preferably by attaching a brochure of the organization)

5. Your position

6. Your duties in detail　　



7. Present activities for quality improvement in your organization

　

　8. Most critical problem you are

now facing in your quality improvement activities

　9. Your expectations of the

program 　

1.

2.

3.

Name Country

QuestionnaireLevel of Comprehension

This questionnaire is not used as a criterion for the selection of participants but to adjust the program to the knowledge of participants. Please indicate the level of your comprehension by checking the appropriate boxes.

Level a : You can explain what it is to others. Or you have ever applied it in your work.Level b : You know what it is. Or you have ever learned it in school or by yourself.Level c : You do not know it well. Or you have never heard of it.

No. SubjectComprehension

No. SubjectComprehension

a b c a b c1 QC Seven tools 27 Orthogonal array

2 Pareto diagram 28 Multi-variant analysis

3 Histogram 29 Multiple-regression analysis



4 Cause & Effect diagram 30 Taguchi methods

5 Scatter diagram 31 TQC/TQM6 x-R control chart, x-Rs control

chart32 PDCA cycle

7 p chart, pn chart 33 QC circle

8 u chart, c chart 34 QC story problem solving

9 Stratification 35Quality deployment/Quality function deployment

107 Management tools for QC/New QC 7 tools

36 Quality table

11 Relation diagram 37 FMEA/FTA

12 Affinity diagram 38 Design review

13 Tree diagram 39 QC process chart

14 Matrix diagram 40 Work (operation) standard

15 Matrix-data analysis 41 Process capability

16 PDPC 42 Cost of quality

17 Arrow diagram 43Management by Policy (Hoshin kanri)

18 Normal distribution 44 Daily (work) management

19 Standard deviation 45 Cross Functional management

20 3-Sigma rule 46 Sampling inspection

21 SQC 47 AQL

22 Statistical test 48 MIL 105D

23 Statistical estimation 49 SPC

24 Analysis of variance 50 Bath-tub curve

25 Correlation analysis 51 MTBF/MTTR

26 Design of experiment 52 ISO 9000/9001/9002/9003/9004


1 Program.doc · Web viewAugust 2003. Program Outline & Participation Requirements. of. The Quality...

Documents

Transcript of 1 Program.doc · Web viewAugust 2003. Program Outline & Participation Requirements. of. The Quality...