Continuous Process Model

Process

Sets of related tasks or activities by which work is accomplished.

Process refers to business and production activities of an organization

Input/output Process Model

1. Input: May be material,money,information data etc

2. Process: is the interaction of some combination of people,materials,eqiupments,method and the environment to produce an outcome such as products or services

3. Output: May be information,data,products or services etc.

4. Feedback: is provided to improve the process

Five ways to Improve a Process

1. Reduce resources

2. Reduce errors

3. Meet or exceed expectations of internal/external customers

4. Make the process safer

5. Make the process more satisfying to the person doing it.

The Juran Trilogy

is an improvement cycle that is meant to reduce the cost of poor quality by planning quality into the products/process

Steps of Juran Trilogy:

1. Planning

2. Control

3. Improvement

Planning

i. Determine external and internal customers.

ii. Identify their needs and translate into requirements.

iii. Develop product/service as per needs of not only customer but other stakeholders too.

iv. Develop processes able to produce product/service.

v. Transfer plans to operations ensuring process validity

Control

i. Determine items to be controlled and their units of measure.

ii. Set goals for controls and determine what sensors are needed.

iii. Measure actual performance.

iv. Compare it with goals.

v. Act on the difference

Improvement

The process for creating breakthrough levels of performance by eliminating wastes and defects to reduce the cost of poor quality

Steps for Quality Improvement:

1. Prove the need for improvement

2. Identify the improvement projects

3. Establish project improvement teams

4. Provide the team with resources

Strengths and Weaknesses of Juran Trilogy

Strengths:

i. Provides a continuous improvement of quality

ii. Allows the use of different tools

iii. Well structured and easy understanding

Weaknesses:

i. Need of Training and Knowledge

ii. Focus on company process instead of labor force

iii. Complex levels

iv. Risk for the company

Improvement Strategies

1. Repair

2. Refinement

3. Renovate

4. Re-invent

Types of problems

1) Compliance

2) Unstructured

3) Efficiency

4) Process design

5) Product design

Compliance

• This problem occurs when the

• Input, processes, output are unacceptable from user view point.

• Identification of this problem is difficult.

Unstructured• This problem occur when the standards of the

organization are not specified.

• The major challenges are:

• To determine the customer needs. Prevent the cause of poor performance

Efficiency

This problem occurs when the performance is unacceptable from the view point of owner or operator.

Process design

This problem involves the development of new of processes and revision of existing processes.

Product design

This problem involves the development of new of processes and revision of existing products.

Plan - Do - Study - Act (PDSA)

PDSA is a four step quality model that focus on achieving continuous improvement.

Steps PDSA cycle

1. Plan

2. Do

3. Check/Study

4. Act

Problem Solving Method

Phases:

1) Identify problems

2) Analyze Process

3) Develop optimal solutions

4) Implement changes

5) Study the results

6) Standardize solution

7) Plan for the future

Phase-1

The objective of this phase is to identify and prioritize the opportunity.

It consist of three parts:

a) Identify the problem

b) Form the team

c) Define the scope

Phase-2

a) Develop Process Flow diagram

b) Define target performance measures

c) Relevant Data collection

d) Fishbone diagram

Phase-3

a) Brainstorm – create new process/combine different process/modify existing process

b) Evaluate Test solutions using control charts –criteria: feasibility, scope, training and effects

Phase-4

a) Prepare implementation plan

b) Obtain approval

c) Implement process improvements

Phase-5

a) Monitor and evaluate the change

b) Check if fine tuning is needed

c) If dissatisfied with results, repeat some phases

Phase-6

a) Positrol (Positive control) – ensures important variables are kept under control

b) Process Certification

c) Operator Certification

Phase-7

a) Regular reviews of progress by QC

b) Knowledge Management System – save learning

c) Repeat Phase 1

Kaizen

Process of continuous improvement in small increments without complex technology or high costs making processes better

The kaizen improvement focus on the use:

1) Value-added and non_value_added work activities.

2) Principles of material handling and use of one piece flow.

3) Documentation of standard operating procedure.

4) Just in time principles to produce only the units in the right quantities, at the right time, and with the right resources.

5) Team dynamics, which include problem solving, communication skills, and no conflict resolution

Reengineering

It is the fundamental rethinking and radical redesign of business process to achieve dramatic improvements in critical measure of performance. it is use in a five phased problem solving approach that ultimately reduced operating costs by 12%.

Six sigma

• Seek to improve the quality of process outputs by identifying and removing the causes of defects.

• Six sigma approaches is a collection of managerial and statistical concept technology that focuses on reducing variation in processes and preventing deficiencies in product.

Statistical aspect

Decrease your process variation (remember variance is the square of your process standard deviation ) in order to increase your process sigma the end result is greater customer satisfaction and lower cost.

Other aspect

• DMAIC (define, measure, analysis, improve, control).

• Six sigma emphasizes the need for management, commitment and involvement.

Criticism on six sigma

• It would be very Difficult and not very cost effective for small business .

• Six sigma present absolutely nothing new to the quality field .

• It is an old appraisal methodology that focus on problem .

Any Question?

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