This 1 day training program on the “Soft” TQM Concepts focus on Manufacturing Staff and Operators to equip Participants with a better understanding TQM and its practices and to understand why being responsible for Quality is so important as a mechanism to safe guard to Customer for receiving a Defect as well as to comply to Quality procedures..
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Quality in Manufacturing for Production & Manufacturing
1. DELL, Penang 17 & 24 Jan 2016
The Importance of Quality in Manufacturing
Dell Asia Pacific Sdn. Bhd.
Plot 76, Kawasan Perusahaan Bukit
Tengah, 14000, Bukit Mertajam, Pulau
Pinang, Malaysia. Tel 04-508 7119
2. International Educational Leadership Speaker.
Provides consultation on Lean and leads Kaizen,
TPM, Cellular system & Moonshine set up.
A multi skill Innovator with Mechanical background
that adopts Green Living and rode 18,290km thru 24
Countries over 5 months from Penang to London on
a 125 CC Kapcai.
Founder of Tim’s Waterfuel, an alternative HHO gas
supplement using Water that adds power, millage &
reduce Co2 emission on automobiles.
An NGO Community worker for Prison, Drug
Rehabilitation and Crisis Relieve & Training (CREST)
Malaysia, an organization that respond to Crisis &
Flood.
Timothy Wooi
Add: 20C, Taman Bahagia,
06000, Jitra, Kedah
timothywooi2@gmail.com
Certified HRDF Trainer & Principal Consultant for Lean Management
and a Kaizen Specialist with 30 over years working experience.
TRAINER’S PROFILE
3. Quality plays a major role in today’s manufacturing
environment.
Understanding Customer
needs and monitoring
process behaviors and
variation to safe guard
Customer from receiving a
defect is key in assuring
Quality.
Superior Quality, reduce Cost
and on-time Delivery (QCD)
The Importance of Quality in Manufacturing
4. Course Objective
This 1 day training program focus on the on the “Soft”
TQM Concepts to provide and equip Participants with
a better understanding TQM and
its practices and to
understand why TQM is so
important as a mechanism to
ensure Quality to Customer,
as well as to comply to
Quality procedures to ensure
Quality being delivered to
Customer.
The Importance of Quality in Manufacturing
6. Class outlines:
The “Soft” Side of TQM resulted in the identification
of nine (9) key principles most commonly found in
Quality Management.
1) Total Employee Involvement
2) Continuous Improvement
3) Continuous Training
4) Teamwork
5) Empowerment
6) Top-management Commitment
and Support
7) Democratic Management Style
8) Customer/Citizen Satisfaction
9) Culture Change
The Importance of Quality in Manufacturing
7. 2. “Hard” TQM Practices in Quality Management
covers: Techniques,
tools and systems;
Statistical Process Control;
ISO 9000 series;
Pareto Analysis;
Matrix Diagram;
Histograms;
Tree Decision Diagram;
Critical Path Analysis;
Fishbone or Ishakawa
Diagram.
Both are philosophy and sets of management guiding
principles for managing an organization.
The Importance of Quality in Manufacturing
8. Class outlines:
TQM in Production Manufacturing focused on (5) key
principles 1,2,4,8 & 9 from the overall (9) Quality
management as below; .
1) Total Employee
Involvement
2) Continuous Improvement
4) Teamwork
8) Customer/Citizen
Satisfaction
9) Culture Change
The Importance of Quality in Manufacturing
9. 01/31/16 9
I build it,
You inspect
I inspect,
You build
Quality is Everyone’s responsibility
10. Benefits
Participants will gain the followings at the completion
of the program:
allows understanding of Customer needs and to be part
of the team in a total organizational approach responsible
for Quality and..
to equip Participants with
importance of delivering a
Quality Product in
Manufacturing improve
organization’s processes,
products and services.
The Importance of Quality in Manufacturing
12. What does the word ‘Quality’ means to you ?
Delighting .. 1st
meet, then exceed and 3rd
make you
happy!
The Importance of Quality in Manufacturing
13. Meeting the required standards of Satisfaction
In 21st
Century, Quality is everybody’s responsibility in
“ Delighting the Customer ” through continuous Innovation
improvement in meeting upon agreed specifications”
14. Craft Manufacturing
• Late 1800’s
• Car built on blocks in the barn as workers
walked around the car.
• Built by craftsmen with pride
• Components hand-crafted, hand-fitted
• Excellent quality
• Very expensive
• Few produced
The Wasteful FactoryThe Wasteful Factory
15. Mass Manufacturing
• Assembly line - Henry Ford 1920s
• Low skilled labor, simplistic jobs, no pride in work
• Interchangeable parts
• Lower quality
• Affordably priced for the average family
• Billions produced – all identical “ You can choose any
color as long as its Black ”
The Wasteful FactoryThe Wasteful Factory
16. • Cells or flexible assembly lines
• Broader jobs, highly skilled workers, proud of product
• Interchangeable parts,
even more variety
• Excellent quality mandatory
• Costs being decreased through process improvements.
• Global markets and competition.
The Lean FactoryThe Lean Factory
Lean Manufacturing
17. The Origin of Lean Manufacturing
Pioneered by Taichi Ohno and Toyota Company in the 70’s.
New paradigm to simultaneously improve quality reduce cost
and reduce delivery time (QCD) from start of order.
Coined “Lean Manufacturing ” in 1990 by James Womack and
Daniel T. Jones in the book “The Machine that Changed the
World”
Allowed Toyota to penetrate
the American market by
delivering superior quality
at an affordable price.
Toyota Production System
initiated a revolution in
manufacturing strategy
18. Just in Time
What is needed
When is needed
exactly right Amount
• Continuous Flow
• Pull System
• Level Production
(Heijunka)
Jidoka
“Built in Quality”
• Manual / Automatic
Line Stop
• Labor-Machine
Efficiency
• Error Proofing
• Visual Control
Flexible, Capable,
Highly Motivated
People
Standardized Work
Total Productive Maintenance
Robust Products & Processes
Supplier InvolvementOperational
Stability
Lean MethodologiesLean Methodologies
TOYOTA PRODUCTION
SYSTEM
Best Quality - Lowest Cost - Shortest Lead Time
Shortening Production Flow by Eliminating Waste
5S’ WASTE elimination as Foundation of Lean
19. Best Quality - Lowest Cost - Shortest Lead Time
Shortening Production Flow by Eliminating Waste
Just in Time
What is needed
When is needed
exactly right Amount
• Continuous Flow
• Pull System
• Level Production
(Heijunka)
Jidoka
“Built in Quality”
• Manual / Automatic
Line Stop
• Labor-Machine
Efficiency
• Error Proofing
• Visual Control
Flexible, Capable,
Highly Motivated
People
Standardized Work
Total Productive Maintenance
Robust Products & Processes
Supplier InvolvementOperational
Stability
Lean MethodologiesLean Methodologies
TOYOTA PRODUCTION
SYSTEM
20. 21st
Century: Global Competition
The globalization of trade has exposes local
industries to new Competitive pressures.
Old View: Cost + Profit = Price
New View: Price – Profit = Target Cost
Order Qualifiers in a Global Market:
Superior Quality, Competitively Priced, Quick Delivery
Order Winners in a Global Market:
Products and Services that are valued by the customer.
21. Characteristics of World Class
Manufacturers
Delivery
CostQuality
Customer-Value Focused
Lean Production System
L e v e l P r o d u c t i o n
JIT
JIDOKA
5S / V i s u a l M a n a g e m e n t
Relentless R e m o v a l o f W a s t e
LEAN PRODUCTION
SYSTEM
Mechanic
Material
Machine
Standard
Work Takt
Time
SWIP
Operational
Availability
1 piece
Flow
Pull
system
Kaizen Methodology
Cost + Profit = Price
Price – Profit = Target Cost
22. CONTINOUS IMPROVEMENTCONTINOUS IMPROVEMENT == KAIZENKAIZEN
IMPROVEMENTIMPROVEMENT
WITHOUTWITHOUT
ENDINGENDING
In Japanese,
KAI
Change
ZEN
Good
KAI ZEN=
Change for
better
The small, gradual, incremental changes
applied over a long period can be add up for a
major impact on business in the future.
Qualifiers of 21st Century & Skills
23. Why Kaizen
To continuously eliminate waste without removing the
value added activities in the process
Processing
Transportation
Waiting
Movement
MUDA
Take
all
FOUR
I need
ONE!
DefectsDefects
Over Production
InventoryInventory
Qualifiers of 21st Century & Skills
25. TQM is the mutual co-operation of everyone in an
organization and its associated business to produce
products and services, which meet and exceed the
needs and expectations of customers.
Two important aspects
that comprise TQM
management are:
1. Soft TQM Concepts and
2. Hard TQM Practices.
The Importance of Quality in Manufacturing
27. TQM is a long-term approach that views continuous
improvement in an Organization and not as a
short-term goal.
It aims to radically
transform the organization
through progressive
changes in the attitudes,
practices, structures and
systems.
Soft TQM Concepts
28. TQM transcends the product quality approach, involves
everyone in the organization, and encompasses its
every function:
administration,
communications,
distribution,
manufacturing,
marketing,
planning,
training,
etc.
Soft TQM Concepts
29. Who wants what...
Customer Needs &
Expectation
Low Cost
High Quality
Availability
Company needs &
expectation
Profit
Repeat Business
Growth
Cash !!Cash !!$
Value !!Value !!
The Money Business Now!The Money Business Now!
30. 1. “Soft” TQM in Manufacturing focus on:
Total Employee Involvement;
Continuous Improvement;
Teamwork;
Customer/Citizen Satisfaction;
Culture Change.
The Importance of Quality in Manufacturing
31. Employee Involvement
Employee involvement can be defined as:
The direct participation of staff to help an
organization fulfill its mission and meet its
objectives by:
applying their own ideas
expertise, and efforts
towards
solving problems and
making decisions.
The Importance of Quality in Manufacturing
32. 1) Total Employee Involvement1) Total Employee Involvement
The “total” element of
TQM implies that every
organizational member is
involved in quality
improvement processes in
the “distribution of
intelligence” for resolving
problems.
TQM, involves everyone in an organization.
Increase employees’ participation in the overall quality
strategy brings an increased flow of information and
knowledge.
33. 2) Continuous Improvement2) Continuous Improvement
Continuous improvement is a method for
identifying opportunities for streamlining work and
reducing waste.
The practice by the
popularity of Lean / Kaizen
in manufacturing and
business.
It is now being used by
thousands of companies all
over the world to identify
savings opportunities.
36. Continuous Improvement using Kaizen Methodology
Shop Floor Kaizen
Equipment and
Facility Kaizen
System
Kaizen
ProgressionRadical Change – Kaikaku
Kaizen Workshops
Daily Improvements – Standard Work
People Based
System
2) Continuous Improvement2) Continuous Improvement
38. These practices prevent
defective items from
continuing and assures
Quality.
““Do it right the 1Do it right the 1stst
timetime””
Build Quality into ProcessesBuild Quality into Processes
2) Continuous Improvement2) Continuous Improvement
In a Lean factory. Production is responsible to
build Quality in its product.
Operators are required to
perform their work to the
Quality standards before
passing on next process..
39. Total Quality Approach
““Stop the Line” AuthorityStop the Line” Authority
2) Continuous Improvement
Operators are given ‘Stop line authority’ whenever
abnormalities are detected in Production.
They then feedback the
non conformance to the
Engineering & QA group
to come up with a
countermeasure.
40. 40
POKA-YOKEPOKA-YOKE Ways of Preventing Mistakes
1. Shutdown the process
2. Feedback to Engineering
dept for countermeasure
and to implement.
3. Ask for Mistake Proof
devices in process to prevent
Human error.
When an error is predicted or detected, Production
can stop Defects by:
2) Continuous Improvement
41. Total Quality Approach
TQM Quality CirclesTQM Quality Circles
2) Continuous Improvement
Quality Assurance work with Production in Quality
Circles to understand root cause of defect and assist
Production for countermeasures.
QA then use Quality tools
to improve the system
prevent the defect
repeating.
This assure that only
Quality products leaves the
Company.
42. Total Quality Approach
2) Continuous Improvement
QA with Production feedback to Engineering Dept.
(ED) cause of Defect for early detection.
Jidoka - AutonomationJidoka - Autonomation
ED then study ways of
incorporating ‘Human
Intelligence’ into equipment
to detect abnormalities and
stop automatically
whenever defects occur.
43. Total Quality Approach
Poke Yoke – Mistake ProofingPoke Yoke – Mistake Proofing
2) Continuous Improvement
ED then study and design Mistake proofing devices to
prevent Defects caused by ‘Human Error’ that requires
human skills and ‘remembering of process steps’
Example:
A cast part must
have a hole drilled in
it in order to be used
in assembly.
47. Elimination of Defect using PDCA approach starts
with Step iii) Check (use 4W +1H to assist)
1.What is the defect and What causes it?
2. Where does the
Defect occur ?
3. When the Defect
occur?
4. Who causes the
Defect
5.How does the Defect
Occur ?.
2) Continuous Improvement2) Continuous Improvement
49. Step iii) Plan
After defining the improvement points, Make a plan
to implement them.
Questions to consider:
What steps should be
done to achieve the
plan?
When to finish this
plan?
Once the plan is established, implement it with a
completion time frame.
2) Continuous Improvement2) Continuous Improvement
50. Step iii) Plan
This is again divided into 3 steps
1st
Identifying the problems
in the current process. Find
a countermeasure to
solving problems and not
just finding the solutions.
This avoids future recurrence - the primary goal of
Continuous Improvement.
2) Continuous Improvement2) Continuous Improvement
51. Step iv) Do
When the improvement actions are implemented
successfully as well as the target is met, do the
following-
Review the improvement
activities learn lessons.
Standardize the
improvement in the process
and follow.
Update the Quality as well
as the Standard Process
documents.
Determine when and where to make changes in the next
project.
2) Continuous Improvement2) Continuous Improvement
52. Definition: cooperative or coordinated effort on the
part of a group of persons acting together as a team
or in the interests of a common cause.
to increase performance,
employee unity and
company culture.
Companies that must frequently
develop new ideas or products
using a project-based approach
assemble teams in order to
diffuse responsibility.
4) Teamwork
The Importance of Quality in Manufacturing
53. 3) Teamwork3) Teamwork
Teamwork an important outcome and a condition
for continuous improvement are generally viewed
as more powerful and effective work entities than
individuals.
Teams should include
employees from all the
hierarchical levels, layers, and
from all the departments of the
enterprise to make work more
flexibly and to develop mutual
trust among members.
54. At Google, during a
‘Kaizen,’employees
typically work in small
teams of only three to six
people.
This gives productivity than
with larger groups.’
Work in many small, diverse teams for projects.
3) Teamwork3) Teamwork
The result is an empowered, flexible organization with
small teams pursuing hundreds of projects,
an approach that
55. …a frequently used marketing term is a measure of
how products and services supplied by a company
meet or exceeds Customer expectation.
….is defined as "the
number of customers, or
percentage of total
customers, whose reported
experience with a firm, its
products, or its services
(ratings) exceeds
specified satisfaction goals
4) Customer/Citizen Satisfaction
The Importance of Quality in Manufacturing
56. Customer satisfaction … the driving force to
improve performance to both Customers: external
(clients, government regulatory bodies, the public)
and internal (employees, different departments)
Both external and internal
Customers have needs.
TQM stresses the
importance of satisfying
those needs.
444) Customer/Citizen Satisfaction444) Customer/Citizen Satisfaction
57. 4) Customer/Citizen Satisfaction4) Customer/Citizen Satisfaction
A happy (or satisfied) customer
often doesn’t say anything or
tells just a few friends, but an
unhappy (or dissatisfied)
customer tells many more
people to warn them.
“A happy customer tells a friend; an unhappy
customer tells the world”
The exact words (and number of people told) vary, but the
adage became popular in the mid-1980s, when the
American Management Association conducted a business
study of the phenomenon.
58. Organizational culture affects and alters employees’
actions and perceptions of all aspects of their work
in order to include quality.
Culture acts as a
force for cohesion in
organizations and
therefore can support
or inhibit the process
of change towards
TQM application.
The Importance of Quality in Manufacturing
5) Culture Change
59. 5) Culture Change5) Culture Change
Change
… defined as making a
difference in something
compared to an earlier state,
transforming or converting
something, or simply
becoming different.
Culture
…. is a way of life of a group of people - the behaviors,
beliefs, values, and symbols that they accept,
generally without thinking that are passed along by
communication and imitation from generation.
60. Culture Change
…..modification of a society through innovation,
invention, discovery, or contact with other societies
5) Culture Change5) Culture Change
It is the transformation of
pass down older beliefs,
values, and symbols
without much thought to
those that work in current
environment ,time and
technological change.
61. Successful TQM implementation is dependent on the
existence of a total quality culture among everyone.
The Importance of Quality in Manufacturing
Research indicates that,
positive elements for
example:
common accepted vision,
accepted responsibilities,
customer focus and‐
group cohesiveness,
much still needs to be done to pave the way for a
total quality culture.
63. What to Expect in the Future
• Training
• Communication
• Elimination of Waste (NVA)
• Continuous Improvement
• Visual Factory
• More efficient layouts
• Roles & Responsibilities
• More involvement / ownership
• Long term GROWTH!!
The Importance of Quality in Manufacturing
64. & The Trainer
For further enquiries, please contact us:
Iverson Associates Sdn Bhd
No.52-1, First floor, Bayan Bay, Persiaran Bayan Indah, 11900
Bayan Lepas Penang.
T: 04 641 2760, 638 3179 | F: 04 641 2761
E: sales-pg@iverson.com.my | W: www.iverson.com.my
This training course is facilitated by IVERSON & conducted by its
Trainer Timothy Wooi, a LEAN Consultant and certified Kaizen
Leader with 30 over years of Hand-On exposure driving Lean &
Kaizen Improvement Projects.
We provide Technical Consulting services on TPM, Kaizen, Quick
Changeover, Cellular system set up, Production Line Balancing,
Factory Layout Planning and Small Group Activities.
We also conduct Team Building & Lean Production Training
Course Series.
Hinweis der Redaktion
The way things usually are today. This can apply to almost any department, take engineering and Maintenance for instance. Instead of I run it you fix it. It would be I design it, you fix and vise versa.
Time & Motion studies - Fredrick Taylor
Interchangeable parts - Eli Whitney
The term “Lean Manufacturing” originated at the Toyota Motor Company with Taaichi Ohno. It was popularized in American factories in large part by the Massachusetts Institute of Technology study of the movement from mass production to lean production as described in “The Machine that changed the World” by James Womack. The goal if this manufacturing philosophy is to eliminate waste in the production system, thus yielding greater throughput and reduced operating costs.
The Toyota company of Japan faced many obstacles following the end of World War II. In order to compete the company had to produce vehicles with limited resources in materials, manpower and machinery. The would also have to differentiate themselves from the stream of American auto products by providing superior quality in order to survive in the market place. The creators of the TPS discovered that if they concentrated on time, rather than directly on cost, they could defeat the trade-off between cost and quality. In other words, by focusing on “constantly reducing the time from order to delivery,” they could make a better (higher quality) product quicker and at lower cost.
Taiichii Ohno and the staff at Toyota Motor Company developed an entirely new production system that simultaneously reduced cost, improved quality and reduced delivery time. Their production system allowed Toyota to penetrate the US auto market by providing high quality, affordable cars that appealed to the American consumer. American Auto Industry was slow to adapt and Chrysler was pushed to the brink of bankruptcy as a result.
In 1990 two professor’s from MIT introduced American business to the Toyota Production System in their book “The Machine that Changed the World”. The authors coined the term “Lean Manufacturing” as the newest evolution in manufacturing. Since that time most of the US auto industry has adopted “Lean Manufacturing” as their manufacturing strategy. In many other industries including electronics, computers and now aerospace, Lean Manufacturing has become the proven method for competing in a global market.
Lean Manufacturing concepts as practiced in the Toyota Production System is the only method proven to simultaneously make major reductions in defects, cost and lead-time.
Until recently consumers in much of the world might be been fairly satisfied with their own country’s poor workmanship, long delays and high prices, but the elimination of global trade barriers have made products like Toyota Cars, Dell Computers, Nokia hand phones and Sony electronics available everywhere. More than ever customers have options and are demanding superior quality, competitive prices and quick delivery to qualify for their consideration. To win a customers goodwill businesses must not only meet those minimum criteria, they must also provide extra features and services that the customer values.
Today manufacturers are faced with a squeeze to reduce cost while simultaneously reducing defects and delivery time.
Prior to global competition most manufactures viewed costs as fixed. Sales Price was determined by adding a suitable profit margin to incurred costs. Cost increases were passed on to customers as higher prices.
To survive in a global market manufacturers must adopt a new view that focuses on reducing costs to make a profit. Companies can no longer pass on costs increases to the customer, they simply have too many other options. Prices are determined by market conditions and a company must focus on the variable it can control, its cost structure.
World Class manufacturers can be distinguished from more traditional competitors through three distinct characteristics:
World-Class manufacturers are customer-focused. They understand that value to the customer includes superior quality, competitive prices and shortening deliver times. In addition these companies distinguish themselves by constantly seeking to provide other products or services their customers find valuable. These companies look at the current market pricing and products being offered by competitors then ask how much cost they can take out by full application of lean methods. What is the waste-Free Cost of the Product?
All World-Class manufacturers apply a lean production system modeled after the Toyota Production System. There production systems strive to maximize efficient use of resources (manpower, materials, machines) by relentlessly eliminating waste.
Finally all World-Class manufacturers continuously improve by applying Kaizen Methodology. These companies develop a learning organization with workforce engaged in continuous improvement. For these companies the creativity of people’s minds is the real strategic advantage.
Kaizen event is as much as important as other activities because it is the builiding block of all LEAN Prod. Methology.
Lean production is founded on the idea of KAIZEN or Continous Improvement
Defects, rework, and scrap add cost and represent waste that must be eliminated. Lean factories apply a Jidoka to detecting and eliminating the sources of defects. As a result lean factories simultaneously reduce cost and improve quality.
Traditionally manufacturing relied on Inspection to detect defects before reaching the customer. Although this approach may result in high quality for the customer, it does nothing to eliminate the source of the defect and the associated costs. In a lean factory equipment is designed to detect abnormalities and stop automatically whenever defects occur. Operators in a lean factory are trained to stop the production line whenever they note anything suspicious. These practices prevent defective items from continuing into the production process and preventing the waste that would result from producing a series of defective items. Another advantage of these practices, it immediately signals the detection of abnormality so that the root cause can be quickly determined and eliminated
Stop the Line Authority – In a lean factory every operator is an Inspector, responsible for the quality of their own work. Operators are trained in evaluating quality and are given the authority to stop the production line. Operators must never accept or pass on a known defect. The ratio of Inspectors to operators in a lean factory is very low. The title Inspector is reserved for highly-trained specialists using specialized equipment.
Jidoka – Autonomation – means giving machines the ability to detect when a defect is created and stop immediately. As a result only one defective product is made and the source of the problem can be investigated. Jidoka frees the operator from watching the machine, now one operator can monitor many machines (reducing cost). By giving machines the ability to perform simple repetitive tasks, then human can focus on problem-solving and improvement.
Poke Yoke translated from Japanese means mistake-proofing: Modify the production system so that abnormalities cannot occur, as opposed to detecting abnormalities which have already occurred. Mistake Proofing eliminates the possibility for a defect from occurring. If mistakes aren’t made in the first place, then we don’t have to spend extra time and money fixing them.
Example: A cast part must have a hole drilled in it in order to be used in assembly. The original jig required that the operator carefully orient the part on the drill press table in order to ensure a proper fit during the assembly process. Taking advantage of the “L” shaped slot on the part, a piece of angle iron has been attached to the drill press table which matches the slot in the part, allowing the part to be loaded only with the correct orientation.
What we have here is a pretty fundamental relationship. Each party wants something; the customer and Cascade.
The essential ingredients that make the whole thing go are:
Value to the Customer
Profit to Cascade
These are the two fundamentals that MUST be there for a company to grow and thrive. If only one side of this flow takes place, the company will soon be out of business;
if the customer does not receive adequate value
if the company doesn’t make sufficient profit
As for value to the customer, what determines if the customer is getting good value?
Answer: Desired product and features at low cost.
As for Cascade, what determines how much profit you make?
Answer: Sales Price - Cost to produce
Transition to next slide
Key Points:
In today’s competitive environment, price and lead time can no longer be dictated to the market.
The market demands shorter lead times AND lower prices.
The market demands ever improving quality.
AND the market DEMANDS higher variety!
These things are being done every day.
The question is HOW, not IF, it can be done.
Eliminating process wastes,such as defects, through implementation of Poka-yoke efforts, will result in more repeatable and reproducible processes.
Thus, processes will be more efficient and be more cost effective.
Lean Manufacturing relies on continuous improvement or “Kaizen” as the engine for cost reductions and quality improvements. All world class manufacturers apply some form of improvement methodology to their processes and equipment. These companies have developed a culture of learning and improvement. Problems are seen as an opportunity for improvement NOT to blame or punish people.
Kaizen involves the people who perform the work. Individuals are encouraged to take part in designing and managing their own jobs through application of standard work.
Improvement may be dramatic, over-night transformations of the work place, often called a Kaikaku.
Or more often as week-long kaizen workshops focused on rapid improvement in a smaller area.
Even daily improvements are kaizen. Standardization is the foundation for improvement. In a lean factory Standard Work are the tools used to define the efficient flow of people and materials and is the basis for continuous improvement.
Typically kaizen workshops are focused on the shop floor. Waste on the factory floor can often be quickly eliminated with simple solutions. As inventory is reduced equipment and facility reliability problems become problems to attack with Kaizen.
After the factory has become lean, it is time to focus on the system of suppliers and customers to lean out the total flow.
Defects, rework, and scrap add cost and represent waste that must be eliminated. Lean factories apply a Total Quality Approach to detecting and eliminating the sources of defects. As a result lean factories simultaneously reduce cost and improve quality.
Traditionally manufacturing relied on Inspection to detect defects before reaching the customer. Although this approach may result in high quality for the customer, it does nothing to eliminate the source of the defect and the associated costs. In a lean factory equipment is designed to detect abnormalities and stop automatically whenever defects occur. Operators in a lean factory are trained to stop the production line whenever they note anything suspicious. These practices prevent defective items from continuing into the production process and preventing the waste that would result from producing a series of defective items. Another advantage of these practices, it immediately signals the detection of abnormality so that the root cause can be quickly determined and eliminated
Stop the Line Authority – In a lean factory every operator is an Inspector, responsible for the quality of their own work. Operators are trained in evaluating quality and are given the authority to stop the production line. Operators must never accept or pass on a known defect. The ratio of Inspectors to operators in a lean factory is very low. The title Inspector is reserved for highly-trained specialists using specialized equipment.
Jidoka – Autonomation – means giving machines the ability to detect when a defect is created and stop immediately. As a result only one defective product is made and the source of the problem can be investigated. Jidoka frees the operator from watching the machine, now one operator can monitor many machines (reducing cost). By giving machines the ability to perform simple repetitive tasks, then human can focus on problem-solving and improvement.
Poke Yoke translated from Japanese means mistake-proofing: Modify the production system so that abnormalities cannot occur, as opposed to detecting abnormalities which have already occurred. Mistake Proofing eliminates the possibility for a defect from occurring. If mistakes aren’t made in the first place, then we don’t have to spend extra time and money fixing them.
Example: A cast part must have a hole drilled in it in order to be used in assembly. The original jig required that the operator carefully orient the part on the drill press table in order to ensure a proper fit during the assembly process. Taking advantage of the “L” shaped slot on the part, a piece of angle iron has been attached to the drill press table which matches the slot in the part, allowing the part to be loaded only with the correct orientation.
Continuous Improvement in product quality is accomplished through application of root cause analysis and statistical process monitoring. Workers are educated in the use and application on the seven quality tools. Often small teams of employees (called Quality Circles) are assigned responsibility for analyzing the root cause of defects.
Control examples : polarized electrical plug, gas pump nozzle, car transmission must be in park in order to start engine.
Warning examples : disc brake pad noise when pad becomes thin, alarm for car lights left on after engine is turned off.
Defects, rework, and scrap add cost and represent waste that must be eliminated. Lean factories apply a Total Quality Approach to detecting and eliminating the sources of defects. As a result lean factories simultaneously reduce cost and improve quality.
Traditionally manufacturing relied on Inspection to detect defects before reaching the customer. Although this approach may result in high quality for the customer, it does nothing to eliminate the source of the defect and the associated costs. In a lean factory equipment is designed to detect abnormalities and stop automatically whenever defects occur. Operators in a lean factory are trained to stop the production line whenever they note anything suspicious. These practices prevent defective items from continuing into the production process and preventing the waste that would result from producing a series of defective items. Another advantage of these practices, it immediately signals the detection of abnormality so that the root cause can be quickly determined and eliminated
Stop the Line Authority – In a lean factory every operator is an Inspector, responsible for the quality of their own work. Operators are trained in evaluating quality and are given the authority to stop the production line. Operators must never accept or pass on a known defect. The ratio of Inspectors to operators in a lean factory is very low. The title Inspector is reserved for highly-trained specialists using specialized equipment.
Jidoka – Autonomation – means giving machines the ability to detect when a defect is created and stop immediately. As a result only one defective product is made and the source of the problem can be investigated. Jidoka frees the operator from watching the machine, now one operator can monitor many machines (reducing cost). By giving machines the ability to perform simple repetitive tasks, then human can focus on problem-solving and improvement.
Poke Yoke translated from Japanese means mistake-proofing: Modify the production system so that abnormalities cannot occur, as opposed to detecting abnormalities which have already occurred. Mistake Proofing eliminates the possibility for a defect from occurring. If mistakes aren’t made in the first place, then we don’t have to spend extra time and money fixing them.
Example: A cast part must have a hole drilled in it in order to be used in assembly. The original jig required that the operator carefully orient the part on the drill press table in order to ensure a proper fit during the assembly process. Taking advantage of the “L” shaped slot on the part, a piece of angle iron has been attached to the drill press table which matches the slot in the part, allowing the part to be loaded only with the correct orientation.
Continuous Improvement in product quality is accomplished through application of root cause analysis and statistical process monitoring. Workers are educated in the use and application on the seven quality tools. Often small teams of employees (called Quality Circles) are assigned responsibility for analyzing the root cause of defects.
Defects, rework, and scrap add cost and represent waste that must be eliminated. Lean factories apply a Total Quality Approach to detecting and eliminating the sources of defects. As a result lean factories simultaneously reduce cost and improve quality.
Traditionally manufacturing relied on Inspection to detect defects before reaching the customer. Although this approach may result in high quality for the customer, it does nothing to eliminate the source of the defect and the associated costs. In a lean factory equipment is designed to detect abnormalities and stop automatically whenever defects occur. Operators in a lean factory are trained to stop the production line whenever they note anything suspicious. These practices prevent defective items from continuing into the production process and preventing the waste that would result from producing a series of defective items. Another advantage of these practices, it immediately signals the detection of abnormality so that the root cause can be quickly determined and eliminated
Stop the Line Authority – In a lean factory every operator is an Inspector, responsible for the quality of their own work. Operators are trained in evaluating quality and are given the authority to stop the production line. Operators must never accept or pass on a known defect. The ratio of Inspectors to operators in a lean factory is very low. The title Inspector is reserved for highly-trained specialists using specialized equipment.
Jidoka – Autonomation – means giving machines the ability to detect when a defect is created and stop immediately. As a result only one defective product is made and the source of the problem can be investigated. Jidoka frees the operator from watching the machine, now one operator can monitor many machines (reducing cost). By giving machines the ability to perform simple repetitive tasks, then human can focus on problem-solving and improvement.
Poke Yoke translated from Japanese means mistake-proofing: Modify the production system so that abnormalities cannot occur, as opposed to detecting abnormalities which have already occurred. Mistake Proofing eliminates the possibility for a defect from occurring. If mistakes aren’t made in the first place, then we don’t have to spend extra time and money fixing them.
Example: A cast part must have a hole drilled in it in order to be used in assembly. The original jig required that the operator carefully orient the part on the drill press table in order to ensure a proper fit during the assembly process. Taking advantage of the “L” shaped slot on the part, a piece of angle iron has been attached to the drill press table which matches the slot in the part, allowing the part to be loaded only with the correct orientation.
Continuous Improvement in product quality is accomplished through application of root cause analysis and statistical process monitoring. Workers are educated in the use and application on the seven quality tools. Often small teams of employees (called Quality Circles) are assigned responsibility for analyzing the root cause of defects.
Defects, rework, and scrap add cost and represent waste that must be eliminated. Lean factories apply a Total Quality Approach to detecting and eliminating the sources of defects. As a result lean factories simultaneously reduce cost and improve quality.
Traditionally manufacturing relied on Inspection to detect defects before reaching the customer. Although this approach may result in high quality for the customer, it does nothing to eliminate the source of the defect and the associated costs. In a lean factory equipment is designed to detect abnormalities and stop automatically whenever defects occur. Operators in a lean factory are trained to stop the production line whenever they note anything suspicious. These practices prevent defective items from continuing into the production process and preventing the waste that would result from producing a series of defective items. Another advantage of these practices, it immediately signals the detection of abnormality so that the root cause can be quickly determined and eliminated
Stop the Line Authority – In a lean factory every operator is an Inspector, responsible for the quality of their own work. Operators are trained in evaluating quality and are given the authority to stop the production line. Operators must never accept or pass on a known defect. The ratio of Inspectors to operators in a lean factory is very low. The title Inspector is reserved for highly-trained specialists using specialized equipment.
Jidoka – Autonomation – means giving machines the ability to detect when a defect is created and stop immediately. As a result only one defective product is made and the source of the problem can be investigated. Jidoka frees the operator from watching the machine, now one operator can monitor many machines (reducing cost). By giving machines the ability to perform simple repetitive tasks, then human can focus on problem-solving and improvement.
Poke Yoke translated from Japanese means mistake-proofing: Modify the production system so that abnormalities cannot occur, as opposed to detecting abnormalities which have already occurred. Mistake Proofing eliminates the possibility for a defect from occurring. If mistakes aren’t made in the first place, then we don’t have to spend extra time and money fixing them.
Example: A cast part must have a hole drilled in it in order to be used in assembly. The original jig required that the operator carefully orient the part on the drill press table in order to ensure a proper fit during the assembly process. Taking advantage of the “L” shaped slot on the part, a piece of angle iron has been attached to the drill press table which matches the slot in the part, allowing the part to be loaded only with the correct orientation.
Continuous Improvement in product quality is accomplished through application of root cause analysis and statistical process monitoring. Workers are educated in the use and application on the seven quality tools. Often small teams of employees (called Quality Circles) are assigned responsibility for analyzing the root cause of defects.
As processes are dynamic over time , new wastes appear. The continuous improvement cycle repeats indefinitely in order to address the changing face of waste.