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1. PRAVEEN B N
SOFT SKILLS MENTOR & TRAINER EXPERT

2. Awareness on
Industry Preparedness
Target Audience:
• Passing out Engineering Graduates
• New Joinees / Trainees
• For Beginners
Slide-2

3. About this training:
Today the manufacturing industry has grown to multiple folds with new innovation, technology,
Automation. Hence require Skilled ,semi-skilled, Highly skilled employees right from the day of
Hiring.
It is a big challenge for every industry to get 100% trained Qualified manpower & have to
spend time and money on Training initially to build the competence of every employee hired.
Day by Day the selection during interviews are becoming challenging both to the Employer
and to individuals aspiring for a job.
To bridge this gap of understanding this Awareness and training is nurtured in such a way
considering all aspects of need and expectation of the industry so as to get the candidate who
are at bare minimal aware of all the Industrial practices, terms, tools, etc before they get
hands on experience. So the content will make an individual confident on the industry
requirement & can contribute efficiently by knowing the basics & later on will have a faster
grasping ability on the job.
Preface:
Slide-3

4. CONTENTS:
Sr. no. Description Slide
no.
Topic-1 Basic Knowledge on industry/ Manufacturing-General Operational
Guidelines
2~7
Topic-2 Determine your Area of Interest 8
Topic-3 Terms and Definition used in Manufacturing /Industry 9~14
Topic-4 Manufacturing tools awareness 15~16
Topic-5 About Industrial Revolution 17
Topic-6 Market Demands & Expectations 18
Topic-7 About Industry 4.0 & Product Design Development cycle 19~27
Topic-8 Awareness on Management Systems 28~33
Topic-9 Industries Expectation from Freshers 34~37
Topic-10 Know yourself 38
Topic-11 Facing Interviews-Basics 39~40
Topic-12 Basics on Resume building & Career path 41
Slide-4

5. Topic-1: Basic Knowledge on industry/ Manufacturing-
General Operational Guidelines
A. Any Manufacturing Industry & Business either it be Electronics, Automobile,
Aerospace, Pharmaceutical, Textile, Food,Hotel etc adopts and follows a
 Common Standard operating procedures,
 Common terminology
 Common Industry practices-Process Approach
 Common Functional Guidelines
 Applicable Statutory and Regulatory requirements
 Standard HR Management guidelines
Its all about : “PROCESSESS”
Slide-5

6. Process Definition
•An activity using resources, and managed in order to enable the
transformation of INPUTS into OUTPUTS, can be considered as a process
•Process Approach to quality Management encouraged.
Processes – Understand the Interactions
Input
Output
Process A Process C
Process DProcess B
Resources Controls
EXAMPLES: INDUSTRIES HOSPITAL INSTITUTION BANKS/OFFICES
Slide-6
Topic-1: Basic Knowledge on industry/ Manufacturing-
General Operational Guidelines

7. KEY FOCUS
PRODUCT
DEVELOPMENT
CYCLE
VENDOR
MANAGEMENT
PRODUCTION
MANAGEMENT
LOGISTICS
MANAGEMENT
AFTER SALES &
SERVICE
MANAGEMENT
CUSTOMER
SATISFACTION
Slide-7
Topic-1: Basic Knowledge on industry/ Manufacturing-
General Operational Guidelines- INDUSTRY SUPPLY CHAIN

8. Topic-2 :Determine your Area of Interest
CONSUMER DURABLES
AUTOMOBILES
TELECOMMUNICATION
DEFENCE
AGRICULTURE
MEDICAL ASSISTANCE
CHEMICAL IND.
IT
DOMAIN & SCOPE:
Slide-8

9. 1.QUALITY?
ATTITUDE DISCIPLINE
PASSION
Topic-3 :Terms and Definition used in Manufacturing /Industry
Slide-9
Quality has been defined in various approach by many
Quality Guru’s , Professionals. A few are listed below
APPROACH-5
APPROACH-1
APPROACH-2
FIT FOR USE
MEET ALL THE CUSTOMER REQUIREMENT
FIRST TIME RIGHTAPPROACH-3
APPROACH-4 MEET THE SPECIFICATION FOR THE INTENTED USE
BELOW 3 ASPECTS ARE REQUIRED TO MEET QUALITY

10. • ABC Analysis: Means Activity-based costing An accounting system that assigns costs to a product
based on the amount of resources used to design, order or make it.
• Batch:Producing more than one piece and then moving the pieces to the next operation before they are
needed.
• Bench marking: A technique in which an organization measures its performance against that of best-
in-class organizations, determines how those organizations achieved their performance levels and uses
the information to improve its own performance. Subjects that can be benchmarked include strategies,
operations and processes.
• Bottle neck:A bottleneck is a point of congestion in a production system (such as an assembly line or a
computer network) that occurs when workloads arrive too quickly for the production process to handle.
The inefficiencies brought about by the bottleneck often creates delays and higher production costs.
The term comes from the shape of an actual bottleneck, or the narrow neck or mouth of a bottle.
• Cell production:Arranging machines in the correct process sequence, with operators remaining within
the cell and materials presented to them from outside.
• Continuous production:A method in which items are produced and moved from one processing step
to the next, one piece at a time. Each process makes only the one piece that the next process needs,
and the transfer batch size is one. Also referred to as one-piece flow and single-piece flow.
Slide-10
Topic-3 :Terms and Definition used in Manufacturing /Industry

11. • Cycle time:The time required to complete one cycle of an operation. If cycle time for every operation in
a complete process can be reduced to equal takt time, products can be made in single-piece flow. Also
see “takt time.”
• Cost of poor quality (COPQ): The costs associated with providing poor quality products or services.
There are four categories: internal failure costs (costs associated with defects found before the
customer receives the product or service), external failure costs (costs associated with defects found
after the customer receives the product or service), appraisal costs (costs incurred to determine the
degree of conformance to quality requirements) and prevention costs (costs incurred to keep failure and
appraisal costs to a minimum).
• Critical processes: Processes that present serious potential dangers to human life, health and the
environment, or that risk the loss of significant sums of money or customers.
• First in, first out (FIFO): An inventory management method in which the oldest materials put into
storage are the next materials taken out of storage for use.
• First pass yield (FPY): Also referred to as the quality rate, the percentage of units that completes a
process and meets quality guidelines without being scrapped, rerun, retested, returned or diverted into
an offline repair area. FPY is calculated by dividing the units entering the process minus the defective
units by the total number of units entering the process.
• First time right or First time quality (FTQ): Calculation of the percentage of good parts at the
beginning of a production run.
Slide-11
Topic-3 :Terms and Definition used in Manufacturing /Industry

12. • Lead time:The total time a customer must wait to receive a product after placing an order.
• Lean manufacturing/production: An initiative focused on eliminating all waste in manufacturing
processes. Principles of lean manufacturing include zero waiting time, zero inventory, scheduling
(internal customer pull instead of push system), batch to flow (cut batch sizes), line balancing and
cutting actual process times. The production systems are characterized by optimum automation, just-in-
time supplier delivery disciplines, quick changeover times, high levels of quality and continuous
improvement.
• Line Balancing
• Lot: 1) A defined quantity of product accumulated under conditions considered uniform for sampling
purposes. 2) Items constituting a defined quantity of uniform product for purposes of proceeding
collectively through a process.
• Lot, batch: A definite quantity of some product manufactured under conditions of production that are
considered uniform.
• Material requirements planning (MRP): A computerized system typically used to determine the
quantity and timing requirements for production and delivery of items to customers and suppliers. Using
MRP to schedule production at various processes will result in push production because any
predetermined schedule is an estimate only of what the next process will actually need.
Slide-12
Topic-3 :Terms and Definition used in Manufacturing /Industry

13. • Multiskill:Multiskilling of employees is an effective way for facility management companies to organize
jobs in way that improves profitability, flexibility and quality of service. ... In a simple sense, multi-
skilling is the design of jobs to enable people to perform two or more traditionally separate job functions.
• MTTR:Mean Time To Repair is the average time it takes to repair a system (usually technical or
mechanical). It includes both the repair time and any testing time. The clock doesn’t stop on this metric
until the system is fully functional again.
• MTBF:Mean time between failures (MTBF): The average time interval between failures for a
repairable machine, piece of equipment or product for a defined unit of measure; for example, operating
hours, cycles and miles.
• Plan-do-check-act (PDCA) cycle: A four-step process for quality improvement. In the first step (plan),
a way to effect improvement is developed. In the second step (do), the plan is carried out. In the third
step (check), a study takes place between what was predicted and what was observed in the previous
step. In the last step (act), action should be taken to correct or improve the process.
• Process Flow:A visual depiction, generally using symbols, of the flow of materials or information
through a process. Also called a process flowchart.
• Process Mapping:A type of flowchart visually depicting the steps in a process.
• Productivity: A measurement of output for a given amount of input.
Slide-13
Topic-3 :Terms and Definition used in Manufacturing /Industry

14. • Pull system: An inventory management system based on replenishing inventory based on use rather
than a schedule or forecast. Also see “kanban.”
• Quality:A subjective term for which each person or sector has its own definition. In technical usage,
quality can have two meanings: 1) the characteristics of a product or service that bear on its ability to
satisfy stated or implied needs; 2) a product or service free of deficiencies. According to Joseph Juran,
quality means “fitness for use”; according to Philip Crosby, it means “conformance to requirements.”
• Takt time:The rate of customer demand, takt time is calculated by dividing production time by the
quantity of product the customer requires in that time. Takt is the heartbeat of a lean manufacturing
system. Also see “cycle time.”
• Through put time:The rate the system generates money through sales, or the conversion rate of
inventory into shipped product.
• WIP:Items between machines or equipment waiting to be processed.
Slide-14
Topic-3 :Terms and Definition used in Manufacturing /Industry

15.  7 TOOLS OF QUALITY CONTROL
 “5S” CONCEPT
 KAIZEN
 TPM
 SIX SIGMA
 LEAN MANAGEMENT
 ISO SYSTEM IMPLEMENTATION
 PROBLEM SOLVING TOOLS
Slide-15
Topic-4 Manufacturing tools awareness

16. KAIZEN Journey
S: Standardize
D: Do
C:Check
A:Act
P: Plan
D: Do
C:Check
A:Act
S
DC
A
P
DC
A
P
DC
A
Conventional Approach
SYSTEM APPROACH METHODS
P
DC
A
P
DC
A
What is the difference between Continuous Improvement & Continual Improvement
Continuous Improvement Continual Improvement
Slide-16
Topic-4 Manufacturing tools awareness

17. Industry -1.0
The mechanical
Weaving loom,water &
steam power
Industry -2.0
First Production
Line,Mass Production
using Electrical
Energy
First Programmable
Logic Contol(PLC).Use
of Electronic & IT for
further information
(Computer &
Automation)
Industry -3.0 Industry -4.0
Based on Cyber
Physical systems
Driving real Objects with
information processing
Virtual objects via
information network (eg:
Internet).
18th Century 1970’s
Topic-5:About Industrial revolution
20th Century 21th Century
Slide-17

18. Rising Brand
Consciousness
Evolving
Regulations
New Operating
Models
Easier Consumer
Financing
Focus on
Green
Technology
Innovation in
Technology
Increasing
Premiumization
Growing Rural
Market
Increasing
Organized Retail
/E-Commerce
Favorable
Demographics
Younger, richer, urbanized
10 key drivers which impacts Indian Growing Market
Slide-18
Topic-6:Market Demands & Expectations

19. MODERN MANUFACTURING PRACTICES- INDUSTRY 4.0
Slide-19
Topic-7:About Industry 4.0 & Product Design Development cycle

20. Industry 4.0 is the current trend of automation and data exchange in
manufacturing technologies. It includes cyber-physical systems,
the Internet of things and cloud computing. Industry 4.0 creates
what has been called a "smart factory".
Industry 4.0-The fourth Industrial Revolution
Industry
4.0
Smart Products
Smart Mobility
Smart Grids
Smart Logistics
Smart Buildings
Slide-20
Topic-7:About Industry 4.0 & Product Design Development cycle

21. INDUSTRY 4.0 COMPRISES OF 4 CORE ELEMENTS
The Digital Enterprise Suite enables manufacturing
companies to streamline and digitalize their entire
business process, seamlessly integrating suppliers
into the mix.
Industrial Ethernet
PROFINET/PROFIBUS(Industrial Networking)
AS-Interface
 IO-Link
Industrial Wireless Communication
Industrial software
automation
Industrial communication
Industrial security
Industrial services
Is a approach that integrates or includes
security mechanisms with a comprehensive
understanding of automation can provide reliable
protection.
 Industry Services help make your machines and
plants more profitable and efficient throughout their
entire lifecycle using Digitization
Slide-21
Topic-7:About Industry 4.0 & Product Design Development cycle

22. How it functions
Slide-22
Topic-7:About Industry 4.0 & Product Design Development cycle

23. IOT CONCEPT
Slide-23
Topic-7:About Industry 4.0 & Product Design Development cycle

24. PRODUCT DESIGN DEVELOPMENT CYCLE
DESIGN
PLANNING
DESIGN
REVIEW
INDUSTRIAL
DESIGN / MOCK UP
DESIGN
INPUT
DESIGN
OUTPUT
DESIGN
VALIDATION
MASS
PRODUCTION
Slide-24
Design FMEA
Quality
Assurance
BOM,
Specification
Topic-7:About Industry 4.0 & Product Design Development cycle

25. Design brief:
By Marketing and Management
(Based on Customer and competition study)
Industrial Design Brief :
Design study:
Study of Trends (Based on Market survey,
Study of new products, Visit International /
Domestic exhibitions )
Sketches:
Sketches are made based on
Design brief & Design study
Rendering and Mock up :
Based upon dimensional CAD
Considering material/Finish
Slide-25
Topic-7:About Industry 4.0 & Product Design Development cycle

26. 3D development in PRO/E :
After approval of mock-up the inputs of
industrial design team is converted in to product
3D drawing using PRO/E
Structure design :
Internal architecture is built to provide the
strength to the shell and for the fitment of parts
Mechanical Design :
Assembly design :
Parts are assembled in the 3D form to check the
interferences.
Design Failure Mode & Effect Analysis:
-Discussion of design with Tool Room /
Process/ Production / R&D/QA
- Summarize all feedback/Problem
- Correction of 3D design as per feedback
- Final release of 3D for Mould making
• Reliability
• Strength
• Productivity
• Cost
• Mould complexity
Slide-26
Topic-7:About Industry 4.0 & Product Design Development cycle

27. Concept 3F Benchmarking:DESIGN STAGE:
Feel Fit
& Finish
Slide-27
Topic-7:About Industry 4.0 & Product Design Development cycle

28. ISO9001:2015 - Quality Management System:
Part of a management system with regard to quality
A QMS comprises activities by which the organization identifies its
objectives and determines the processes and resources required to
achieve desired results
The QMS manages the interacting processes and resources required
to provide value and realize results for relevant interested parties.
The QMS enables top management to optimize the use of resources
considering the long and short term consequences of their decision.
A QMS provides the means to identify actions to address intended
and unintended consequences in providing products and services.
ISO- THE INTERNATIONAL ORGANIZATION FOR STANDARDIZATION
Slide-28
Topic-8: Management System

29. Quality Management System
Policies and procedures
detailing how we do the work
Quality Control
Checks performed as we do the
work
Quality Evaluation
Checking to see that what
should be happening is
happening and it is all effective
Auditing !
QUALITY ASSURANCE
4/59 Slide-29
Topic-8: Management System

30. WHAT WE SHOULD DO
Step 1:Understand what you do & write down in detail every step.
Step 2:A well-designed and well-implemented Quality Management
system can and should eliminate
 Ineffectiveness
 Inefficiencies
 Problems
 Errors
 Inconsistencies
 Malicious Practices
 Uncertainties
 Bad Culture
IT’s ALL MATTER OF DISCIPLINE
Slide-30
Topic-8: Management System

31. ISO 14001
ENVIRONMENT MANAGEMENT SYSTEM
1/46
Slide-31
Topic-8: Management System

32. Why do we need ISO 14001?
ENVIRONMENTAL MANAGEMENT SYSTEM
A. ENVIRONMENTlAL ISSUES:
1. Population Increase
2. Global Warming(Climatic Change)
3. Air Pollution
4. Depletion of the Ozone Layer
5. Water Pollution
6. Ecosystem destruction
B.PRESSURE ON BUSINESS:
1. Managing Impacts
2. Legislation
3. Customer Pressure
4. Market Trends
5. Financial Issues-Insurance
6. Sudden and Accidental-Bhopal,chernobyl,Sandoz,etc
7. Graduals –Disposal of toxic waste,Leakages,Discharges,Release of fumes
8. The Public.the Media & Pressure Groups
9. Sustainable Development as a Business Driver
Slide-32
Topic-8: Management System

33. ENVIRONMENTAL MANAGEMENT SYSTEM (EMS)
EMS refers to the Management of an organization’s Environmental programs in a
comprehensive, systematic, planned and organized manner.
Achieving a balance between the Environment,Society and the Economy
A systematic approach to Environmental Management System can contribute to
Sustainable Development by:
 Protecting the Environment by Mitigating adverse Environmental Impacts.
 Assisting the Organization in the fulfillment of Compliance obligation(Legislative
Requirements)
 Controlling or influencing the way the organization’s Products and Services are
Designed,Manufactured,Distributed,Consumed and Disposed by Life cycle
Perspective which can prevent environmental Impacts at different stages.
 Achieving Financial and Operational benefits that can result from implementing
environmentally sound alternatives that strengthen the organization’s market position.
 Communicating Environmental information to relevant interested parties.
Slide-33
Topic-8: Management System

34. WHERE TO GO
Slide-34
Topic-9: Industries Expectation from Freshers

35. EACH ONE HAVE TO BE
HOW
Slide-35
Topic-9: Industries Expectation from Freshers

36. WHAT INDUSTRIES
& CORPORATES
LOOK AT
Slide-36
Topic-9: Industries Expectation from Freshers

37. SKILL DEVELOPMENT ENHANCEMENT
MIND
INNOVATION
Culture
Attitude,
Disciplin
e
,Passion
Self
Analysi
s
Mind
Innovatio
n
Morale
Basics of
Manufacturing
5S,3R &
Visual
Manage
ment
Statistical
Tools
Mistake
Proofin
gQuality
OEE
Technical
Trainings
Product
Knowledge
Process
Knowled
ge
Equipment
usage.
New
Techno
logical
update
s
Technical
Regulatio
n updates
Personality
Development
Present
ation
skill
Time
Manage
ment
Commu
nication
skill
Internal
Auditin
g skill
Professio
nal
Excellenc
e Training
Slide-37
Topic-9: Industries Expectation from Freshers

38. PERSONAL TRAITS
WHO AM I & WHAT I INHERIT
•LEADERSHIP QUALITIES
•POSITIVE ATTITUDE
•CALM NATURED
•HIGH PATIENCE
•ASSERTIVE
•SELF MOTIVATOR
•GOOD COMMUNICATION SKILL
•GOOD LISTENER
•GOOD INTERPERSONAL RELATIONSHIP
•GOOD PRESENTATION SKILL
•ZEAL – ENERGY
•TEAM WORK
•OPEN MINDEDNESS
Slide-38
Topic-9: KNOW YOURSELF:

39. BODY LANGUAGE:
PRESENTATION SKILL
DRESS CODE
POSTURE
EXPRESSION
CONFIDENCE
EYE CONTACT
CONFIDENCE ON TOPIC U CHOOSE
PREPARATION OF TOPIC
LAYOUT OF CONTENTS
KILL STAGE FEAR
PRACTICE IN FRONT OF MIRROR
TIME KEEPING
Slide-39
Topic-9: Facing Interviews-Basics

40. YOU HAVE TO DIRTY YOUR OWN HANDS
TO LEARN
Slide-40
Topic-10: Basics on Resume building & Career path
•1.NO PRE-
•
DETERMINED
• MINDSET
2.BE READY
FOR ANY
AREA
POST JOINING
REQUIREMENTS
•1.BASIC
• PRACTICES
•2.ABOUT
• THEIR
• PRODUCTS
3.TURNOVER
•4.MARKET
• SHARE
•5.LOCATIONS-
• DOM./INT’l
ABOUT
INDUSTRY
•1.YOUR
• FAVOURITE
• SUBJECT
• AREA
YOUR
EXPERTISE
1.ADD PUNCH
LINES;
2.HIGHLIGHT
KEY AREAS
RESUME WITH
SUBSTANCE

41. New Technology
More Contact to your branch related
Organization
Dedicate yourself to lifelong learning:
India: C City/Rural Region/Sub Urban
Service Industry
Develop Clear Sense of Direction: Always
Do what you Love to do: Identify Work Longer, Work
Harder:
TWO PATHS
Career Opportunities Entrepreneurship Potential
Slide-41
Topic-10: Basics on Resume building & Career path

42. THANK YOU
Slide-42

43. Slide-43
Questionnaire/ Test :
01.What are the common approach of Business have?
a. Standard Operating procedure
b. Process Approach
c. Follow Statutory and Regulatory Requirement
d. All of the Above 
Tick the appropriate answer:
02.”Process definition”,Tick the right one?
a. Carry out the given work
b. Convert the given resources
c. An activity which enables transformation of input to output 
d. Control the activity performed
03.Industry supply chain focusses mainly on?
a. Business growth
b. Customer satisfaction 
c. Profitability
d. High productivity

44. Slide-44
Questionnaire/ Test :
04.Area of interest focusses on?
a. Consumer Durables
b. Medical Assistance
c. Agriculture
d. All of the above 
e. None of the above
Tick the appropriate answer:
05.What is Cost of Poor Quality?
a. Failure of worker deliverying good quality work
b. Internal & External cost
c. Appraisal cost
d. All of the above 
06.What is FIFO term in Industry?
a. Fill in Fill out
b. Fixed input Fixed output
c. Frieght in Frieght out
d. First In First Out 

45. Slide-45
Questionnaire/ Test :
07.What is definition of Quality?
a. First time right
b. Attitude,Discipline,Passion
c. Fitness for Use
d. All of the above 
Tick the appropriate answer:
08.Tick which are the Manufacturing tools?
a. TPM 
b. Profitability
c. Six Sigma 
d. Production
09.What is PDCA in Kaizen approach?
a. Produce-Deliver-Compliant-Access
b. Plan-Do-Check-Act 
c. Present-Damage-Control-Action
d. Pre-Determine-Controlled-Activity
10Current Industrial Revolution is based on?
a. Industry 3.0
b. Industry 2.0
c. Industry 4.0 
d. Industry 1.0