Manufacturing, Engineering and Technology Manufacturing and Assembly

Manufacturing Assembly Operational Problem Solving Training

SAQA US 116284 | NQF 4 | Credits 10 | Duration 7 Days
From $1,523 per delegate

Description

This course equips manufacturing assembly personnel with systematic problem-solving techniques to identify, analyse, and resolve operational issues. Participants will learn to apply root cause analysis, corrective actions, and continuous improvement methods to enhance productivity and quality in assembly environments.

Learning Outcomes

  • Apply structured problem-solving methodologies (e.g., PDCA, DMAIC) to manufacturing assembly issues.
  • Analyse operational problems using root cause analysis tools such as fishbone diagrams and 5 Whys.
  • Evaluate potential solutions and select appropriate corrective actions based on impact and feasibility.
  • Implement corrective actions and monitor their effectiveness in the assembly process.
  • Demonstrate effective communication and teamwork during problem-solving activities.

Target Audience

This training is designed for assembly line operators, team leaders, production supervisors, and quality assurance staff involved in manufacturing assembly operations.

Prerequisites

None — open enrollment.

Course Outline

Day 1: Introduction to Problem Solving in Manufacturing Assembly

Objectives:
• Understand the importance of structured problem solving in manufacturing assembly.
• Identify common problems in assembly operations.
• Describe the role of a problem solver and relevant SAQA unit standard requirements.
• Explain the basic problem-solving process (PDCA).

Topics:
• Overview of manufacturing assembly processes.
• Common assembly defects and inefficiencies.
• Introduction to the PDCA (Plan-Do-Check-Act) cycle.
• Roles and responsibilities of team members.
• Safety and quality considerations.
• Introduction to root cause analysis concepts.
• Documentation basics for problem solving.

Day 2: Problem Identification and Data Collection

Objectives:
• Apply techniques to identify and define problems clearly.
• Collect relevant data using appropriate methods.
• Use check sheets and data logs effectively.
• Distinguish between symptoms and root causes.

Topics:
• Problem definition techniques (5W2H).
• Data collection planning.
• Check sheets, tally charts, and data logs.
• Sampling methods in assembly.
• Visual management for problem spotting.
• Pareto analysis for prioritisation.
• Introduction to process mapping (SIPOC).

Day 3: Root Cause Analysis Tools

Objectives:
• Apply cause-and-effect diagrams to identify potential causes.
• Use the 5 Whys technique to drill down to root causes.
• Construct and interpret a cause-and-effect diagram.
• Validate root causes with data.

Topics:
• Fishbone (Ishikawa) diagrams.
• 5 Whys method.
• Combining 5 Whys with fishbone.
• Validation of root causes through data.
• Scatter plots and stratification.
• Case studies: assembly line defects.
• Group exercise: root cause analysis on a real scenario.

Day 4: Generating and Selecting Solutions

Objectives:
• Generate potential solutions using creative and structured techniques.
• Evaluate solutions based on feasibility, cost, and impact.
• Select the best solution using decision matrices.
• Plan implementation steps.

Topics:
• Brainstorming and nominal group technique.
• Solution evaluation criteria.
• Decision matrix (Pugh matrix).
• Cost-benefit analysis.
• Risk assessment for solutions.
• Implementation planning (action plans).
• Mistake-proofing (Poka-Yoke) concepts.

Day 5: Implementing and Verifying Solutions

Objectives:
• Execute the implementation plan effectively.
• Monitor the implementation process.
• Use data to verify if the solution resolved the problem.
• Document results and lessons learned.

Topics:
• Implementation steps and communication.
• Run charts and control charts for verification.
• Before-and-after comparisons.
• Standardisation of new processes.
• Updating work instructions.
• Handling implementation challenges.
• Verification report writing.

Day 6: Advanced Problem Solving and Team Facilitation

Objectives:
• Apply advanced tools like FMEA and fault tree analysis.
• Facilitate a problem-solving team effectively.
• Handle conflicts and ensure participation.
• Integrate problem solving with continuous improvement systems.

Topics:
• Failure Mode and Effects Analysis (FMEA).
• Fault Tree Analysis (FTA).
• Team facilitation techniques.
• Communication and conflict resolution.
• Linking problem solving to Kaizen and Lean.
• Case study: complex assembly issue.
• Role-play: facilitating a problem-solving session.

Day 7: Practical Integration and Assessment

Objectives:
• Demonstrate competence in the full problem-solving process.
• Complete a practical problem-solving project.
• Present findings and recommendations.
• Prepare for final assessment.

Topics:
• Recap of all tools and processes.
• Practical project: solve a simulated assembly problem.
• Presentation of project results.
• Peer and facilitator feedback.
• Final written assessment.
• Portfolio of evidence compilation.
• Course evaluation and certification.

Practicals

No practicals for this training.

This course is made up of exercises and case studies delivered alongside the theory — no separate practical sessions are required to complete it.

Summatives

Each delegate is assessed continuously throughout the course and a final summative test at the end.

Daily Exercises — 30%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 30% to the final total.

Final Test — 70%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 70% to the overall mark.

Final Total
Component Out of Weight
Daily Average (multiple choice) 100% 30%
Final Test (multi-answer multiple choice) 100% 70%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Daily Average 30% + Final Test 70%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
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Wed 09 Sep 2026 Thu 17 Sep 2026 Virtual Spring 2026 $1,523 Register
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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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