1. COST OF POOR QUALITY
Calculating the cost of poor quality allows an organization to determine the extent to which organizational resources are used for activities that exist only as the result of deficiencies that occur in its processes.

2. INTRODUCTION
Is your organization spending too much money on rework? Is your organization losing customers? Has your organization losing market share? If any of these things are true, your organization is spending money on failure. The way that you think about the various cost of quality can help you improve this failure focus. Cost of Poor Quality(COPQ) is an excellent continuous improvement management tool. COPQ can be used effectively to identify, prioritize and then track continuous improvement projects by breaking down quality costs into four standard categories of internal failure, external failure, appraisal and prevention.

3. At the end of the workshop, participants will be able to:
OBJECTIVES
At the end of the workshop, participants will be able to:
Understand what is COPQ.
The elements and definitions of COPQ.
Used tools and strategies to reduce the cost of non- conformance.
The benefits of thinking about COPQ.
COURSE DURATION
This is a 2 days highly interactive, entertaining and useful course running from 9.00 am to 5.00 pm

4. METHODOLOGY WHO SHOULD ATTEND ? Power point presentation
Participative and active discussion including
short exercise and case studies
WHO SHOULD ATTEND ?
Managers, Engineers, Supervisors, Leaders, and staff involved with COPQ.

5. Day 1 COURSE OUTLINE Internal failures cost. MODULE 2: Module 1:
How to define COPQ?
Opportunity to reduce real costs.
Understand quality cost.
Categories of quality cost.
Internal failures cost.
Scrap.
Rework.
Material review.
Down time.
MODULE 3
MODULE 4
External failures cost.
Warranty charges.
Product liability.
Freight cost.
Product recall.
Appraisal cost.
Receiving inspection.
Source inspection.
Final inspection.
Product testing.

6. Day 1 COURSE OUTLINE MODULE 5 MODULE 6 Prevention cost.
Quality planning.
Process control.
Training.
Preventive maintenance.
White collar COPQ.
Controller COPQ.
Software COPQ.
Plant administration COPQ.
Purchasing COPQ.
Marketing COPQ.
Personnel COPQ.
Industrial engineering COPQ.
MODULE 7
Controller COPQ.
Billing errors.
Incorrect accounting entries.
Payroll errors.

7. Day 2 COURSE OUTLINE Module 8: MODULE 9 Software COPQ. Crashes.
Deadlocks.
Incorrect input.
Plant administration COPQ.
Facilities redesign.
Overstaffing.
Equipment downtime/idle
MODULE 10
MODULE 11
Purchasing COPQ.
Line down cost.
Excessive inventory.
Premium freight cost.
Marketing COPQ.
Overstock.
Loss of market share.
Incorrect order entry.

8. Day 2 COURSE OUTLINE Module 12: Module 13 Personnel COPQ
Absenteeism.
Turnover.
Grievances.
Industrial engineering COPQ.
OSHA fine.
Shipping damage.
Relay out.
Paying contractors for poor quality.
MODULE 14
COPQ calculations.
COPQ workshop.

9. TRAINER PROFILE MR. IRMAN KANG
Mr. Irman Kang has a Master in Business Administration from Southern Pacific University, U.S.A. He is also a certified lead auditor for ISO9001:2000 and also a certified ISO/TS 16949:2002 Organization/Supplier Auditor.
Mr. Irman Kang also has a Certificate in Factory Management from Sanno Institute of Management, Japan. He also has a Certificate in Competent Toastmaster (CTM) from Toastmaster International, U.S.A. He also has a Certificate in Training (Train The Trainer) from PSMB.

10. TRAINER’S ACCOMPLISHMENT
Mr. Irman Kang is very experience in conducting APQP, PPAP, FMEA, MSA and SPC trainings. He is also very experience in conducting Internal Quality Audit trainings and also participated in a lot of IQA audits as well as suppliers’ audits.
He has also conducted numerous trainings on 5S, 7QC Tools, Lean Manufacturing, Effective Supervision, Effective Communication, Effective Presentation, Project Transfer Management, Train The Trainer and Stress Management.
Mr. Irman Kang has 28 years of working experience in Quality Management Systems, Quality Assurance and Operations. Also covering a wide range of industries from semiconductors, plastics, wire harness, assembly of connectors and light emitting diodes (LEDs).