Join Engineering Masters Today! CusumAcademy

Join Today ENGINEERING MASTERS

All the lessons, tools and tricks that allowed me to stand out while being the youngest person in the room.

What is included with Engineering Masters?

All the following subjects are taught as part of Engineering Masters.

Minitab Masters

A proven way to Dominate the Minitab Software and create DOE, Regression, Gage R&R, Process Capability and Sample Size Studies.

Validation Masters

Create Perfect IQ, OQ and PQ Validations in the Medical, Automotive and Aerospace Industry. Design Project validation Plans, Calculate sample size requirements and execute with confidence!

Injection Molding Beginners

Ready to Join the Plastics Injection Molding Industry? Learn Scientific Injection Molding and Apply it to your medical, automotive and aerospace industry!

Lean Six Sigma Masters

Optimize your process and reduce variation with DMAIC. Learn Root cause analysis tools and implement process improvements with ease using an A3 documentation flow.

JMP Statistical Masters

Not all Companies use Minitab for statistical Analysis! JMP is another great tool to learn. Run Gage R&R, Capability studies and DOEs with JMP!

Excel Masters

All Engineers need to be competent in Excel since most Company databases will export data to CSV. Clean, extract, and group your data automatically, use VLookUp, Pareto Chart graphs, Histograms, Data Validation and More!

Quality Control Engineers

Learn the basics of being a quality Engineer. How are departments structured, common manufacturing terms, what are NCR's, audits, how to provide feedback during a non-conformance and more!

CAPA/NCR Masters

Learn How to Document Corrective Actions and Preventive Actions in Regulated Industries. Use practical examples and download templates to document your own showing how to document your own CAPAs and NCRs.

ISO13485 Medical Device Manufacturing

Learn What ISO13485 is, how it applies to medical device manufacturing, and how to answer interview questions so you can join the medical device manufacturing field!

Industrial Production Forecast Masters

Learn to forecast industrial production demand in the future so you know exactly how much product to build and how much raw material to request.

Warranty and Reliability Analysis

Create Product Warranties and product life expectancy studies with accelerated Aging. This is a great course for design quality engineers.

Statistical Process Control Masters

Apply Statistical Process Control in your own manufacturing process, create your own control charts and know exactly when to take action!


Don't need this many lessons? Check out our other course options which include select lessons only.

Mastering Statistics and Minitab Executing Process Validations Join Engineering Masters

What is the Engineering Masters Full Content?

All the following lessons are included, video lesson length is included in the table in minutes.

Quality Engineer Content: The definitive Guide to being a Quality Engineer in the Medical Manufacturing Sector
How is a Medical Manufacturing Company Structured? What is the Main Role of Quality Control and How are Medical Products Classified based on Risk? 8:53
What are the Most Common Manufacturing Processes you should know? What is Injection Molding, Extrusion, RF Welding, Multivac Tray Sealing and Urania Pouch Sealing? 11:46
What Quality Departments Exist and what does each department do? Incoming, Quality Control, Quality System, Complaints, Audits and CAPA Department 14:39
How are Products transformed in a regulated industry? What are Raw Materials, Subassemblies and Finished Goods? How is product tested? When do we reject a Lot and how do we document the Non-Conformance? 13:23
Keys for Success starting Out, Knowledge Check, and Recommended Future Learning Based on your career future 8:39

CAPA Masters Content: Learn How to Document CAPAs In Regulated Industries
Introduction to the CAPA Process: What is the Corrective and Preventive Action Process? 4:15
How does a CAPA and a Non-conformance Differ? Review the NCR Template 5:17
How to Escalate from a Non-Conformance into a CAPA? What is the CAPA Process Flow and Root Cause Analysis? Learn to use the 5 Why's Tool and Ishikawa Diagram 8:16
How are CAPAs Implemented and How is effectiveness tested? Creating the Timeline Template 4:42
What Happens if a CAPA Fails? CAPA Review Boards 3:27
Practice Documenting your Own CAPA with our Online Simulator! 8:09
How to use Control Charts and Scatter Plots for Issue Analysis within the CAPA Process? 6:55
Exam: Review the Complete CAPA Process with this quick online Exam 2:09
Closing Comments and Recommended Future Learning. 1:03
Extra Lesson: Complete CAPA from start to finish for a Moisture inside sealed Pouch issue 19:39

ISO13485 Training for Quality Engineers: Learn to explain what ISO13485 requires. Latest Course Published June 2022!
Introduction to Medical Manufacturing ISO13485 9:55
Clauses 1 and 2 Scope, Key Terms and Reference Documents 8:21
Clause 3 Definitions you need to know. Lifecycle, Device, Evaluation and Risk 7:09
Clause 4 Quality Management Systems. General Requirements and Documentation 13:22
Clause 5 Management Responsibility, Commitment, Focus, Quality Policy, Quality Objectives and Management Reviews 7:52
Clause 6 Resource Management and Work Environment 2:46
Clause 7 Part 1. Production Planning and Customer Processes 6:34
Clause 7 Part 2. Product Design and Development. Verification, Validation and Interpreting KPO Requirements 13:21
Clause 7 Part 3. Purchasing Controls, Verification of Purchased Products, Sterilization and Product Identification 16:39
Clause 8 Measurement Analysis and Improvement Activities. Understanding Preventive and Corrective Actions 8:14
Interview Recommendations, Common Questions and Closing Comments 7:54

Problem Solving with the 8D Method: Become an expert at solving complex manufacturing problems with a proven step-by-step system.
Introduction to the 8D Root cause Investigation Method 8:22
D0 Stage: Identify Symptoms 9:11
D1 Stage: Define Team Members Roles and Responsibilities 15:43
D2 Stage: Define the Problem using the 5W/3H Tool 10:02
D3 Stage: Implement Containment Actions 1:52
D4 Stage: Root Cause Investigation Using FishBone Diagrams, Engineering Studies and other forms 32:56
D5 Stage: Implementing Permanent Corrective Actions (PCA) 1:42
D6 Stage: Demonstrating Effectiveness of Corrective Actions 2:40
D7 Stage: Implementing Permanent Preventive Actions 3:33
D8 Stage: Closing your project and Congratulating your team 3:36

Curriculum and Job Search Preparation Content
Quick Guide for Junior Engineer Job Postings Text
Quick Guide for B Level Engineering Positions Text
Recommended Minimum Reading Before a Manufacturing Interview. Review Key Process Outputs, Common Terms and possible quality metrics Text
How to use the 7 basic quality tools? - Guide and Templates in Excel Text

Minitab Masters Content: Learn How to use Minitab for Validations, Manufacturing and Quality Control
Minitab Basics: How to use the Minitab Interface, How to create Graphs and What are the most basic Statistical Studies I must know? 43:47
Minitab Hypothesis Tests: What are 1 Sample-Z, 1 Sample-T, 1 Poisson Rate and ANOVA Hypothesis tests? How do we calculate how many samples to take for each engineering study? 62:41
Minitab Normality and Ppk: How to calculate Process Capability, determine how many defects per million parts we expect on this process, what to do when data is not normal and what is data Transformation? 44:15
Minitab Regression: How are Machine Parameters Optimized with Regression Studies? What is a Linear, Quadratic and Cubic Regression? 44:45
Minitab Gage R&R: How are Measurement Machines validated using Minitab? What is repeatability and reproducibility? What is a Gage R&R and Kappa Test Study? 46:54
Minitab Design Of Experiments: What is a Design of Experiments? What are Fractional, Factorial, Response Surface, Mixture and Screening type DOEs? How are Process Parameter Windows made with Minitab? 70:11
Minitab: Control Charts. What are Control Charts? Which Control Chart should I use based on the data set that I have? 35:38

Sampling Plan Masters Content: Learn How to use ANSI Z1.4, Z1.9 and C=0 Sampling Methods for Process Control
1- Course Introduction, Table of Contents and Verified Vs Validated Processes 7:18
2- Sampling by Attributes and Variables 4:36
 3- Exercise: Variable or Attribute Sampling? 2:44
 4- Attribute Based Sampling with Z1.4 and MIL-STD-105 9:28
 5- Exercise: How many samples to take following Z1.4? 3:45
 6- Calculating AQL Values using Minitab and Understanding Producer Risk Alpha 10:08
 7- Exercise: Sampling with Minitab using Z1.4 3:40
  8- Introduction to RQL and Beta: Rejectable Quality Levels 1:55
  9- Exercise: Identifying RQL, AQL, Alpha and Beta Values 1:35
 10- Calculating RQL values of Z1.4 Sampling Plans using Minitab 18:11
 11- Conclusion: Calculating RQL Values of Z1.4 using Minitab 4:14
  12- Exercise: Calculate RQL values of Z1.4 Sampling plans using Minitab 7:34
  13- ANSI Z1.4 Single Based Sampling and Double Based Sampling Plans 7:55
  14- Calculating RQL Values with Minitab for Double Based Sampling Plans 5:49
  15- Exercise: How Many samples for Double Based Sampling Plans? 2:46
   16- ANSI Z1.4 Normal, Tightened and Reduced Inspection Rules 6:38
   17- Analyzing Normal, Tightened and Reduced Inspection Plans with Minitab 5:01
   18- Exercise: How many samples to take for Normal, Tightened and Reduced Inspection Plans? 4:29
   19- Introduction to C=0 Attribute Sampling Plans 11:43
   20- Exercise: Create C=0 Sampling plans that are equivalent to ANSI Z1.4 Plans 2:54
   21- Analyzing the difference between ANSI Z1.4 and C=0 sampling plans. Is one of them better? 7:28
   22- Why Don't all companies use C=0 Sampling plans? 5:26
   23- Exercise: Creating C=0 Sampling plans that are equivalent to ANSI Z1.4 using Minitab 9:13
   24- CRITICAL LESSON: Why you can't just switch from ANSI Z1.4 to C=0 without analyzing the manufacturing line first 5:31
   25- Introduction to Variable Based Sampling Plans using ANSI Z1.9 14:57
   26- Exercise: How many samples to take for ANSI Z1.9 Variable Sampling? 4:25
   27- ANSI Z1.9 Double Specification Sampling Plans 10:46
   28- Reducing the Number of Samples from ANSI Z1.9 using Minitab 8:20
   29- Exercise: Reducing the Number of Samples from ANSI Z1.9 using Minitab 9:11
   30- Congratulations on Finishing this course. Closing Comments 0:43

Validation Masters Content: Learn Know How To Validate In Regulated Industries Using IQs OQs PQs
Why are Validations required and what is the usual Process Validation Flow? 24:12
Validation Plan. What is a Project Validation Plan? How does it differ from other documents? What is the Project Timeline and how do we coordinate resources between departments? 31:04
Installation Qualification IQ. What are Installation Qualifications? What is challenged during an IQ? How do we create IQ Protocols and Reports? 31:06
Operational Qualification OQ. How do we create a process parameter window for testing during an OQ Validation? What is an Engineering Test Report? How do we calculate how many samples we need for the OQ validation? How to create an OQ Protocol and Report? 39:23
Performance Qualification PQ. What is a PQ Validation? What sections does this document have? How do we determine how many samples we need for the PQ Validation? How to create the PQ Protocol and Report? 25:32
Practice Time! Complete Step by Step Validation from ETR to OQ to PQ in 1 Hour! 48:31

Lean Six Sigma Masters Content: Learn how to Identify Defects and Fix Them using the DMAIC Approach
Introduction What is Lean Six Sigma and how can I use it at work? 8:34
Lean Six Sigma: Define Stage. How to Create an A3 Project Charter? 9:09
Lean Six Sigma: Measure Stage. Tools for obtaining Raw Data 6:06
Lean Six Sigma: Analyze Stage. How to use Pareto Charts to Review our Data 8:18
Lean Six Sigma: Improve Stage. How can we Implement our Project? 9:17
Lean Six Sigma: Control Stage. How to keep the project within the validated state 5:28

Statistical Process Control (SCP) Masters with Minitab: Create and Interpret Control Charts
Introduction to Statistical Process Control. What is SPC? 6:35
SPC Examples 1 and 2 With Minitab. Implementing Xbar-R Control Charts 10:57
SPC Example 3 With Minitab. Implementing I-MR Control Charts 5:04
SPC Example 4 With Minitab. Implementing P-Charts for Pass/Fail SPC Operations 8:36
Clarification SPC Vs Validations, Closing Comments and Recommended Future Learning 6:22

Industrial Production Forecast Masters: Learn to Forecast Future Demand with Minitab
Introduction: What are Forecasts? What are Actual Values, Fit Values and Accuracy Metrics? 3:25
When are Forecasts Used? How do Forecasts differ from Regression Analysis? Creating Time Series Plots 3:07
Creating Forecasts With Minitab for Historical Sales Data and Demand. Analyzing the Model with MAPE and MAD Accuracy Metrics 3:47
How to Forecast with Minitab using Seasonal Type Data and Winter's Method? Closing Comments 6:30

Warranty and Reliability Analysis with Minitab: Learn how to execute Accelerated Aging Studies!
Introduction to Reliability Analysis and first Exercise: Calculate a Tolerance Interval for Warranty Claims 10:55
Second Exercise: Calculating Tolerance Intervals for Upper Bound Quality Requirements 4:38
Third and Fourth Exercise: Accelerated Aging Studies for estimating product warranty 20:06
Important Clarification regarding Normal and Non-Normal Data, closing comments and recommended future lessons 4:34

Excel Masters Content: How to Extract useful data from Excel Databases at work?
How to use Conditional Formatting, Mathematical Functions, Counters and eliminate duplicate records from data sets? 34:27
How to use Conditional And Logical Formulas, Data Types, Cell Manipulation Techniques and review Financial Projects? 30:45
How to Manipulate Text Cells to Extract useful pattern data? How to use Pareto Charts and Pivot Tables for analysis? 13:46

Scientific Injection Molding Course. Learn a high-impact skill that is in high demand and is very well paid in the medical manufacturing sector.
Introduction - Molding Use, Engineering Salaries, Importance. Plastic Types and Machine Types 9:29
What are the Injection, Pack/Hold, Screw Recovery and Cooling phases of part creation? What are Injection Molds and molding Screws? What are the most common machines and cooling solutions used in the industry? 8:17
Scientific Injection Molding Basics. What is Scientific Injection Molding? How can I determine what type of machine I have and how can I calculate Plastic Density? 12:43
What is Cavity Identification? How can I execute a Mold Water Flow Study? How is Shot Size and transfer Position calculated? 13:04
How is a Machine Turned on? What is a Dry Run Test? How are Melt Temperature Studies, Clamp Tonnage Calculations and Pressure Drop Studies Made? 13:44
How are Mold Clamp Tonnage optimized? What is a Mold Balance Study? How is Injection Back Pressure Optimized and what is Screw Recovery Delay? 10:31
What is the Rheology Curve Study? How is Pack/Hold Pressure Optimized in scientific Injection Molding? 8:57
What is a Gate Freeze Study? How do we use Design of Experiments DOEs in Scientific Injection Molding to optimize Machine Parameters? Final Scientific Molding Recipe Summary 14:42

JMP Statistics Masters: For Companies that use JMP instead of Minitab
Module 1 - Fundamentals JMP 16 19:13
Module 2 - Hypothesis Test JMP 16 34:28
Module 3 - Normality Test Distribution Identification and Capacity Cpk Ppk JMP 16 26:11
Module 4 - Correlation and Regression Linear Quadratic and Cubic JMP 16 16:16
Module 5 - Validation Measurement Equipment Gage RR Kappa Test JMP 16 24:43
Module 6 - Design of Experiments Factorial, Response Surface, Mixture and Screening! 49:28

Online Simulators Made Exclusively for Cusum Academy Students
S1. DOE Linear Urania Simulator. We use this simulator during Regression Training and DOE (Design of Experiments Training) It teaches students how to statistically demonstrate if there is a relationship between two process variables and an output. This is the first step toward demonstrating basic competency as quality and manufacturing engineers.
S2. Quadratic Response DOE Urania Simulator. In production things don’t always work out as planned (Or How the textbook says). This simulator introduces quadratic responses and teaches students how to identify them and optimize processes that don’t behave linearly.
S3. Mixture and Gage R&R Destructive Simulator. When optimizing raw materials Engineers commonly use mixtures. This type of DOE is different from the previous ones and this simulator teaches students how to approach and optimize a mixture process. It also teaches them how to validate a destructive type Gage R&R.
S4. Gage R&R Caliper Simulator. Measurement System Analysis involves both destructive and Non-Destructive Testing. The Previous Mixture Simulator focused on Destructive Testing. This caliper Simulator focuses on non-Destructive Testing.
S5. Molding Machine DOE Simulator. When using new machines engineers usually feel lost. This simulator demonstrates that you can apply a DOE to any process no matter how complex or inexperienced the engineer might be.
S6. Gage R&R Weight Scale Simulator and Validation Simulator. Packaging and Shipping issues commonly occur when pass/fail inspection machines are not setup properly. This simulator teaches engineers how to identify minimum and maximum specifications limits that guarantee product quality. In this case they setup the alarm limits for a machine so it can identify when packages are missing or have excess material.
S7. Accelerated Aging Study With Car Engine Simulator. This car engine simulators teaches R&D departments how to determine edge of failure points in their products. For example: By running a car engine for a minimum number of miles in a stress test they can extrapolate when the car will fail in normal use conditions.
S8. Control Chart and Preventive Maintenance Simulator. Corrective Actions and Preventive Actions look to eliminate defects before they occur. This simulator tasks students with identifying machine alarms so maintenance changes the machine blades before defects are generated.
S9. Problem Solving LED Simulator Problem Solving. consists on detecting the correlation between your machine parameters and part defects. This simulator tasks students with identifying ideal assembly parameters to meet 3 Separate Quality Inspections.
S10. The CusumMx Engineering Validation Challenge. This Simulator trains them in the proper way to coordinate department resources, plan samples, request quality inspections, redact their own validation plans and create process parameter windows.

Don't need this many lessons? Check out our other course options which include select lessons only.

Mastering Statistics and Minitab Executing Process Validations Join Engineering Masters

Learn from the Minitab Master QE NPI Andres Ruelas!

Andres Ruelas is a world renowned Minitab Master who has peresonally developed all the lessons included in Engineering Masters using first hand experience of what Engineers really need to succed as Quality and Manufacturing Engineers. Learn from the Best to Become the Best!



We are Always Happy to Help!


Emails can be sent to info@cusum.mx You can include explanations of your engineering issues and even example Minitab and Excel files. Macro Excel files and/or executable files will not be opened for safety reasons.

All information is kept private and confidential, we will never use shared data in any of our exercises. Emails are answered Monday - Friday from 8AM to 3PM. Emails received Saturday and Sunday are answered during the Monday Workday.

Have any question about our Services?

Email us to info@cusum.mx

Quick 5 Minute Minitab and Lean Six Sigma Tips

Lean Six Sigma is all about Process Variation

We want to make every day interesting and teach you something new that might be useful for your job. Today we are looking at the main principle of Lean Six Sigma: The process Standard Deviation.

Lean Six Sigma
Create Your Own DOE using Historical Data

When I was just starting out, I wanted to make DOE's (Design of Experiments) for all the machines I had under my supervision. Obviously, this is very expensive and time consuming. I was young and very ambitious.

Minitab
Help is Always Available

When I was just starting out, I was fortunate enough to have great friends and mentors who always provided me with great insight and direction when I wasn't sure how to solve a problem.

Email Support
Interval Graphs and Boxplots, Which is Which?

Dominating Engineering Validations IQ, OQ and PQ in Regulated Industries. Create Project validation Plans, Calculate sample size requirements and execute with confidence!

Minitab
Why We stopped using Cpk for Validations.

For people unfamiliar with Cpk it's a quality metric commonly used to determine if we should accept or reject a process validation.

Minitab
Learn How to Create Gage R&R Studies!

The act of confirming that your measurement equipment is adequate for your operation is called Measurement System Analysis (MSA). Learn how to execute a Gage R&R Study from scratch!

Minitab