I am hoping someone out there may be able to help with a training exercise related to PPAP. We are at the beginning of deploying this throughout our internal operations and will be conducting many training sessions on this. I am looking for an interactive (game?) exercise that engages audience and demonstrates the methodology/benefit of p-map, pfmea, msa, Cpk, Control plan. something other than a powerpoint presentation. We have full access the mfg facility and can easily and quickly get applicable process data if needed. I am assuming that with the abundancy of PPAP and 6-sigma training on the market, that something fun and engaging like this already exists. Anybody got any tricks up their sleeve?

Turn the training into a game show, complete with tossing out little Tootsie Rolls to people who give the right answers.

:nope::nope::nope:

You can't. It's terminally boring!:lmao::lmao:

:nope::nope::nope:

You can't. It's terminally boring!:lmao::lmao:
Andy, you stole the words right outta my mouth. PPAP and fun are mutually exclusive concepts. But, if you are forever optimistic, like our good friend Jennifer, you may be able to make it a little less painful!:mg:

Andy, you stole the words right outta my mouth. PPAP and fun are mutually exclusive concepts. But, if you are forever optimistic, like our good friend Jennifer, you may be able to make it a little less painful!:mg:

"Ah! You remembered to put inthe IMDS number! Great! Here's a Snickers bar!":biglaugh:

I know it is a serious question, but the concept hurts my brain. It's like making tax filing training fun.

Over the past few years, I have been asked quite a few times if I would train in PPAP but I just wouldn't do it with the exception of a small one for the local ASQ section.

It just too boring. Which form to fill out and how to fill it out - yuck! I enjoy delivering process FMEA or even GD&T and I can have fun with those but not PPAP. Anyone who is going to take a PPAP seminar, take lots of coffee prior to the training since it is going to be a long. long day.

Just face facts, PPAP is our pennance for being quality professionals! :lol:

I just finished putting together 3 PPAPs this week. zzzzzzzzzzzzzzzzzzzz

I just finished putting together 3 PPAPs this week. zzzzzzzzzzzzzzzzzzzz

Wow - what did you do Ralph? You must have ticked someone off pretty bad to have had to do that!

Wow - what did you do Ralph? You must have ticked someone off pretty bad to have had to do that!

They are equally as fun to receive and review......:sleep:

Unless they send a histogram in with Cpk data for precision machined parts for a capability study. Then there is a spark of intrigue when I reject that as invalid statistical data and control. :frust:

Just face facts, PPAP is our pennance for being quality professionals! :lol:

Can't live with 'em, can't live without 'em....

Andy, you stole the words right outta my mouth. PPAP and fun are mutually exclusive concepts. But, if you are forever optimistic, like our good friend Jennifer, you may be able to make it a little less painful!:mg:I got optimistic at the idea of pelting some engineering managers with anything.

I got optimistic at the idea of pelting some engineering managers with anything.

Ah, I get it! The subject is no less painful to learn, but you get the fun of releasing some of than pent up (internal customer) disatisfaction? Good thinking!

Ah, I get it! The subject is no less painful to learn, but you get the fun of releasing some of than pent up (internal customer) disatisfaction? Good thinking!You win the prize! :naughty: I ate a Tootsie Roll in your honor.

This morning's news included a segment about how physical activity can enhance students' learning ability. So it occurred to me the training activity could include some ducking/catching of flying goodies.

I'm only half kidding...

Actually, I've used the candy method in training too. I did a lot of it when we were just implementing the system. I'd do department training classes and then at some later date, when they were a captive audience for a refresher or some other training, I'd come in and "quiz" them. The person who volunteered the answer got the candy.

Actually, I've used the candy method in training too. I did a lot of it when we were just implementing the system. I'd do department training classes and then at some later date, when they were a captive audience for a refresher or some other training, I'd come in and "quiz" them. The person who volunteered the answer got the candy.I once found a cleanliness violation in a slide show that was proudly being given by Safety, to show how we've been engineering safety into processes to reduce injuries. I pointed it out to them, then the next day I left a sack of candy with the safety people to give to whomever in the factory noticed the violation. No one did, until the Safety guy prompted them by saying: "There is a problem in this slide... the first person to spot it gets candy." Then, people's minds were jolted from the mist and they pointed, yelling: "Glove!"

My point is, it doesn't take long before trainees' minds will lose their acuity. It helps to be prompted and a piece of candy as reward isn't just for kids. It's a benign way to break the monotony of the moment.

A good training presentation is at least one part theater. Participative theater is even better.
:2cents:

thank you all for feedback, but challenge is initial training will be given to VP, directors, and plant mgrs - will need something a little more structured than throwing candy at them - they know the concepts, but haven't come from industires with the discipline to actually make these tools effective and beneficial. ie. they haven't seen them work yet and there is a little skepticism about whether they are worth the resource drain or not. We have 50% internal yields and dont use any of these. They will help improve if used correctly and mgmnt supported. I strongly believe they just need a simple 1-2 hr exercise that simplifies the utilization of the tools and improves whatever they are doing during the 'game' - problem is I aint got the game!

Well, it may be that if you want to have fun with them, show them how it is working now without these techniques, and do the old Dr Phil bit: "How's that working for you". Then show how the tools will get them on the same page with the customer and get your processes well documented and controlled, and the improvement that should be seen afterwards. The key is APQP makes you think about the process and product ahead of time, rather than the old school approach of sliding a print across the table to a set-up guy, and have him spend a week trying to make the part - only to be able to make it right once and never again. MSA makes you think about using the right gages based on statistical verification rather than shop floor urban legend. SPC helps control the process to keep from adjusting it non-stop. The book will not help you if you are doing precision machining, but for normal processes it is pretty good. PPAP book gets you on the same page...or nearly so...that your customer is on. If you use this bullet point style of presenting the benefits, and then add some details of the actual processes - maybe in process flow chart rather than bullet points - it may keep them awake for a while....:sleep:

No guarantees...

Well, as much as I might want to pelt this kind of group in particular with things, maybe it wouldn't have the desired effect with these people.

They aren't looking for fun. As Bob said, flow charts instead of a blah-blah-blah presentation could work, and I would suggest some practical examples to pass around so they know what it looks like when done right. And don't forget the "What's in it for me" message, hopefully beyond "Because the standard tells me so." Dig up some benchmark examples of how it helps, is worth the time and effort. Use the language of money if you can. That will keep their interest up.

I am not sure how much time or resources you have for this, but you might want to toss in video vignettes of current state examples, like what an operator's response to "How do you know if the gage you are using is the right one?" or the response by a set-up person on "What information do you have when you start a new job?". It's just a thought - although it may end up looking like a safety film - you know, where they drive the lift trucks off the dock...:tg:

Bob's mentioning a video was good - it was actually one of the examples included in the book The Heart of Change (http://www.theheartofchange.com/). The video was described as very effective - only it was used as a way to show everyone the inefficiencies by just allowing them to step outside their shells and see what was going on from an observer's viewpoint.