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(Review Testimonial from ASQ-LA on Training Skills-pdf

 Ford Motor Company. Dearborn, Michigan
Ford Powertrain Operations has been doing business with Dr. Ranjit Roy and Nutek, Inc. since August of 1989. We were involved in purchasing the Qualitek-4 software site license for all Ford employees worldwide to automate our design of experiments. We have sponsored more than 20 onsite four day seminar/workshops training to cover 400 employees.

Dr. Roy's teaching of the Taguchi approach and his focus on the application method has provided a practical approach to meet our needs. Our use of the Qualitek-4 software automates experiment layout and perform complex calculations to speed our experiment designs with effective solutions. Dr. Roy's consulting services also been helpful to solve several challenging experiments. We look forward to continuing our relationship with Dr. Roy to assist Powertrain Operations in our continuous improvement efforts.

Larry Smith
Manager Strategy & Planning Department, Quality Office, Powertrain Operations, Ford Motor Company. Dearborn, Michigan.

 Boston Scientific                                          
Faced with the complex nature of our manufacturing process data analysis, we recently retained Nutek, Inc. to facilitate a few of our process problem studies. Based on methods prescribed and guided by the principal consultant, Dr. Ranjit Roy, I was able to identify process parameters that produced significant improvement in performance. More importantly, the unique structured approach to work with the project team allowed me  to methodically investigate and understand our process performance to a greater extent. Overall, my experience with Nutek, Inc. in study of our production problem has been highly satisfactory and cost effective.
 
In addition to application consulting service, we trained many of our engineering and quality professionals using the seminar by Nutek on Product and Process Design Improvement. Based on my experience,  the Nutek 4-day seminar with application workshop has done an effective/outstanding job of preparing me for immediate applications to projects. Using the methodologies taught in the class, I have been able to apply the skills and carry out many successful experiments.
Atul K. Garg, Ph.D.
Manager, Materials Engineering, Boston Scientific Corporation, 45 Barbour Pond Drive, Wayne, NJ 07470
 

  TI Group Automotive Systems LLC                   "Dr. Roy's unique approach breaks down many of the inherent barriers to understanding design of experiments and allows the participants to focus on the really important aspects. His structured approach to planning of the experiment leaves the trainee with a feeling of confidence that carries over to the immediate applications of the theory to the real life applications. As an added bonus, the Nutek's Qualitek-4 software for the Taguchi experiments provides a simple and effective approach to analysis of the experiment. This frees up the team to concentrate on solving the problem. All in all it's a great approach."

Tom Dold, TI Automotive North America, Warren, MI.

"This would be a great disciplines to structure our experimental studies related to vinyl siding fabrication line."  - Tom Gates, Certainteed Corp. Jackson, MI.


"DOE is expected to be an excellent technique for controlling variables in wood drying process. This seminar covered the background necessary for proceeding with the applications." - Dr. David Barrett, Professor of Wood Science, The University of British Columbia, Vancouver, Canada.

"By completing this seminar, I feel self-confident to use DOE in real environment such as manufacturing, design, and development." - Tadej Sircelj, Grosuplje, Slovenia.

"This has been an excellent experience for me. Use of the software to take care of all design situations and calculations of results, is most helpful" - Quality Manager, Pretium Packaging LLC. Muscatine, IA..

"The instructor maintained an excellent and understandable pace of instruction throughout the course."  - Quality Engineer, Valeo Climate Control, Auburn Hills, MI.

"Instructor is very knowledgeable in the subject and was able to relate to practical uses as well as theoretical bases for the analysis" - Vince Chacon, NASA Dryden Flight Research, Edward, CA.

"I have an immediate need to apply the technique to my projects, and this seminar helped me learn how to apply right it away." - Amir Jiwani, Application Engineer, Industrial Tools Inc., Oxnard, CA.

"Dr. Roy is an excellent instructor and can explain difficult concepts in an understandable manner. I feel I learned a great deal." - Rick Bauer, Cardinal FG, Menomonie, WI.

"The program is very informative and the instructor provided good examples to help us understand ideas by explaining it different ways." - Scott Oldani, Belleville Shoe Manufacturing Co. Belleville, IL.

"The structured discussions in experiment planning will be most helpful to my activities. Also the ability to translate improvement into dollars using the Loss Function is something very attractive." - Barbara Schiller, Eagle Ottawa, Rochester Hills, MI.

"The instructor is very knowledgeable and makes use of simpler examples to clarify finer concepts of the technique. I hope to use the technique for trouble shooting and problem investigation. " - Solvey Advance Polymers, Apharetta, GA.

"My application is in product testing and validations. This session gave me the ability to confidently dispel some of the misunderstandings and most economically layout my product performance & durability tests." - John Wajenski, Sr. engineer, Lockheed Martin, Owego, NY.

DaimlerChrysler

"In terms of being a reference for your services here in DaimlerChrysler, absolutely.  You did an excellent job with the training provided to the DaimlerChrysler Quality Institute.  From a measurement point of view, the participants scored the class 4.4 on a 5 point scale and 4.8 on satisfaction with the instructor.  These numbers speak for themselves on the quality of your services.

Just as important is the practical approach your company takes to Designed Experiments and Taguchi methods.  The emphasis on using the tool was greatly appreciated.

Please feel free to forward this letter to other potential customers within DC if they are looking for recommendations."

Mike Groszko, Manager - DaimlerChrysler Quality Institute

DaimlerChrysler

"Ranjit: It was very good to speak with you last week.

I specifically remember discussing with you after class your teaching skills. You have the gift to be able to communicate effectively, not all teachers
have that ability.

Your class was a great addition to my background training in Shainin Red X Strategies, Juran, Deming and Wheeler. I have also completed a 2 week class on DOE at the University of Waterloo for problem solving.

I found your class worthwhile and very informative and especially laid out well
for instruction. I wish you the best in your future endeavors.

Call me if I can be of help. "

A. C. (Chuck) Masterson, Black Belt Core Group, DCX Corporate Quality

[John Deere Industrial Equipment Division]
Dear Dr. Roy,

I would like to express our satisfaction for the excellent Design of Experiment seminar which you provided at the John Deere Dubuque Works this spring. At the conclusion of the seminar we received very good feedback on the level of instruction and in particular your enthusiasm and breadth of knowledge on the subject matter.

While positive feedback at the conclusion is important, the true test of a good class is whether or not the materials presented will change the way we do our business. I'm very happy to report that several engineers have incorporated the Design of Experiment approach into their engineering toolbox and have made decisions based upon its output. Because of our successful usage of the Taguchi-based design of experiment methodology, I like to extend to you an invitation for another seminar in Dubuque this spring.

Thank you for your service and look forward to seeing you again next year.

Brian J. Rauch
Manager, Advanced Research and Development, John Deere Industrial Equipment Division, Dubuque, Iowa.

[Ford Motor Company. Sharonville, OH]

Nutek has conducted several Design of Experiments - Taguchi Methods training sessions at Ford Sharonville Transmission Plant, the most recent in 1/93. We have received positive feedback from our employees and we are in hopes of retaining Nutek services for another class in 1994. The subject matter was taught in a clear and concise manner and our employees felt comfortable in asking you questions throughout the 32 hours of the class.

Our feedback indicates that the software portion of the class enhanced their ability to properly construct and execute a Taguchi DOE for optimum results. Our employees routinely use the software now when doing a DOE.

Personally, I want to thank the instructor to rearrange the schedule to accommodate our needs in conducting the last two classes. The training class was in demand and the attendees were able to accomplish their project goals within the planned time frame.

Jean D. Holcomb
Training ADministrator, Sharonville Plant, Powertrain Operations, Ford Motor Company

[Ford Motor Company. Dearborn, Michigan]
Dear Mr. Roy, Thank you for conducting the workshop sessions on applications of Parameter Design at our Quality Conference in Cleveland this year. The feedback has all been positive, the attendees found your session interesting and informative with good potential applications for them in future.

A. J. Tombrillo
UAW Co-Chairman, National Quality Committee, Casting Operations, Ford Motor Company
. 

[Manchester Plastics, Canada]

Dear Ranjit,

I would like to take this opportunity to thank you for the excellent instruction provided during the DOE course last month.

I have talked to most of the participants in person and read all the course evaluations and the response was very positive. Everyone felt that the course gave them a complete understanding of the Taguchi DOE methodology and most could immediately see an application in their day-to-day work.

I personally felt that you approached the subject (Taguchi DOE) in a very systematic way and therefore was easily understood. You provided excellent examples and exercises that allowed for a complete understanding of the subject. I would recommend this course to anyone who is missing this tool from their tool box.

Kevin Webster 
Quality Manger, Manchester Plastics, Gananoque, Ontario, Canada.

[Tri-State Quality Manufacturing Conference]

Dear Dr. Roy,

Congratulation on a most excellent presentation at this year's 49th Annual All-Day Quality Conference sponsored by American Society for Quality, Section 0905.

The post conference survey indicated that quality improvement was of far more interest than quality planning, or assurance. Whether due to this interest or other reasons, your presentation was voted the most valued presentation of the ten offered.

Many thanks for helping make our conference a great success.

Stepjhen Rowe, Ph.D
1998 Conference Chairman, Tri-State Quality Manufacturing Network, 

[Ford Motor Company. Dearborn, Michigan]
This is to verify that Dr. Ranjit K. Roy of Nutek, Inc. has completed the standard certification requirements for Ford Motor Company's Fairlane Training and Development Center (FTDC) in Dearborn, Michigan for the courses listed below. As a certified instructor, he has taught at FTDC facility in Dearborn, Michigan, USA and elsewhere at Ford manufacturing facilities since 1997.

List of courses that Dr. Roy has taught at FTDC:

  1. ISO/Q 9000 Overview
  2. Benchmarking Overview
  3. MS7S Quality System Training
  4. Threaded Fasteners (Taught in Mexico, Canada &US)
  5. Parameter Design (Taguchi Robust Designs)

Under the FTDC standard certification used in all Quality/Relibility/SixSigma/Ford Technical Education Program courses, all qualified instructors are required to go through .....

Roderick A. Munro, Ph.D.
ASQ-Fellow, CQRE,CQA,CQMgr, Manager of Training, FTDC, Ford Motor Company, Dearborn, MI.

LinkedIn Recommendations

Jose Mora, President, Atzari,Inc. has endorsed your work as Owner at Nutek, Inc..  Oct. 11, 2007

Dear Ranjit K.,

I've written this recommendation of your work to share with other LinkedIn users.

Details of the Recommendation:

"During my time at Stryker Howmedica Osteonics, I sent two of my Quality Systems engineers to learn Taguchi techniques. They came back very excited and said that that was one of the best courses they've ever taken and that Dr. Roy was an excellent teacher.

I later contacted Dr. Roy when I was Director of Manufacturing Engineering at Boston Scientific and he performed to excellent services for us:

(1) He provided on-site facilitation and consulting on a key process optimization issue and helped the team there make a breakthrough in understanding their process and how to improve it.
(2) He provided expert training to 16 of my engineers, all of whom went on to the Six Sigma program with the advantage of knowing this technique that is at the heart of Six Sigma.

Dr. Roy's clear, concise, patient, and amicable manner along with his expertise and highest levels of integrity made him a pleasure to work with. I have maintained contact with him and consider him a good friend."

Service Category: DOE Consulting
Year first hired: 2003 (hired more than once)

Quality Digest

[Excerpts from publication in Quality Digest/January 1999, Page 51]

Quality Software:  Simplified Taguchi DOE

Qualitek-4                                                                                  by Tim Knight

Taguchi's design of experiments methodology is a systematic evaluation of two or more input factors at randomized and varied levels for their contribution to product or process variation. The use of these methods truly leads to process understanding and characterization. Qualitek-4 by NUTEK effectively harnesses the power of Taguchi.

The package's capabilities include the use of L-4 to L-64 arrays. Two to 63 factors may be selected, with two, three and four levels to each factor. Data-analysis options offer the choice of standard or signal-to-noise analysis with choices of bigger, smaller or nominal-is-best categories for quality characteristics. The standard analysis identifies which factors affect the average response, whereas the signal-to-noise analysis consolidates several data points into one value that reflects the amount of variation present.

Getting started on experimental design is easy:

The manual design option presents a spreadsheet-style input screen that allows advanced users the choice of which array to use and the freedom of placing factors into the columns provided. By clicking the Set Interactions button, users can indicate which column represents the interactions of specified factors.

The automatic design option allows Qualitek-4 to select the array used and assign factors to the appropriate columns. This feature is a real timesaver, especially for users less familiar with DOE. The program prompts users to enter the critical design information into a dialog box that offers a number of multiple-level factors to choose from. I tried quite a few combinations of experimental designs and found that the software could suggest an array for each.

Both options can design simple experiments using only an inner array, and experiments that formally incorporate uncontrollable or noise factors into the outer array. In both design modes, Qualitek-4 assists users by suggesting possible interaction columns at the click of a button. Once a design is established, entering experiment trial results is an easy task. Qualitek-4 uses spreadsheet-style input screens here, too.

After entering results, users can analyze the data. This is where the software's true power emerges. The package does an excellent job of presenting results in a logical fashion with very detailed graphics available for selection.

Depending upon how many trials are entered, Qualitek-4 will perform a standard

or signal-to-noise analysis. The only difference is that standard analysis utilizes averages or, in the case of a single column of data, a single measurement point, whereas the signal-to-noise analysis is based on the signal-to-noise ratio.

To view the analysis data, users first must select whether the quality characteristic is bigger, smaller or nominal-is-best. The experimental results then show up on the screen, with the option to view a bar graph that compares the average or signal-to-noise ratio for each trial. If there are multiple data entries for each trial, each bar in the graph will have a shaded portion that represents the amount of associated variation present in that trial.

The next screen shows the main effects, with a column that represents the average effects. At this screen, users can view the interaction plots. The resulting tables and graphics are well-done; they are one of the software's best features. Another nice touch: All interactions may be generated automatically and viewed as graphs.

Next, the ANOVA table offers some good features. Qualitek-4 enables users to either manually pool the ANOVA results or it does it for them. The last screen, Optimum Conditions and Performance, is the basis for the confirmation experiment. Users can perform a what-if analysis by clicking on the Estimate button. By entering different levels of factors, the software will compute the expected performance levels for that combination.

Context help screens and online help are both done well. However, some additional Taguchi theory entries would be helpful. The user manual gives a good overview of the package's capabilities. Ranjit K. Roy, the software's author, also wrote A Primer on the Taguchi Method, available through the Society of Manufacturing Engineers. One criticism: For the price of the software, a copy of the text would be a nice addition to the supplied material.

Overall, I highly recommend this package. The interface, while simple, offers various experimental design options. The excellent data-analysis capabilities serve to ease the interpretation process. Roy has done an outstanding job of presenting Taguchi methods to all potential practitioners.

About the author: Tim Knight is the quality assurance manager for Chucking Machine Products, specialists in close-tolerance, ultra-precision machining