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LECTURE NOTE
WORLD-CLASS MANUFACTURERWORLD-CLASS MANUFACTURERWORLD-CLASS MANUFACTURERWORLD-CLASS MANUFACTURER
Mistake-free ● Fast ● Lean ● Flexible ● Environment-friendlyMistake-free ● Fast ● Lean ● Flexible ● Environment-friendlyMistake-free ● Fast ● Lean ● Flexible ● Environment-friendlyMistake-free ● Fast ● Lean ● Flexible ● Environment-friendly
TOTAL QUALITY MANAGEMENTTOTAL QUALITY MANAGEMENTTOTAL QUALITY MANAGEMENTTOTAL QUALITY MANAGEMENT
PRO
DU
CTS
PRO
DU
CTS
Del
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Del
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PRO
DU
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PRO
DU
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PEO
PLE
PEO
PLE
Invo
lved
, Com
mitt
edIn
volv
ed, C
omm
itted
& C
reati
ve&
Cre
ative
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PLE
PEO
PLE
Invo
lved
, Com
mitt
edIn
volv
ed, C
omm
itted
& C
reati
ve&
Cre
ative
PRO
CESS
ESPR
OCE
SSES
Capa
ble
and
Effici
ent
Capa
ble
and
Effici
ent
PRO
CESS
ESPR
OCE
SSES
Capa
ble
and
Effici
ent
Capa
ble
and
Effici
ent
HOUSE OF TQM
TQMTQMTQMTQM
ContinuousContinuousImprovementImprovement
TeamsTeams
ContinuousContinuousImprovementImprovement
TeamsTeams
Innovative Innovative CreativeCreative
CircleCircle
Innovative Innovative CreativeCreative
CircleCircle
AutonomousAutonomousMaintenance Maintenance
& 5S& 5S
AutonomousAutonomousMaintenance Maintenance
& 5S& 5S
LeanLeanManufacturingManufacturing
LeanLeanManufacturingManufacturing
EmployeeEmployeeSuggestionSuggestion
SchemeScheme
EmployeeEmployeeSuggestionSuggestion
SchemeSchemeTraining &Training &EducationEducation
Training &Training &EducationEducation
QualityQualityManagementManagement
SystemSystem
QualityQualityManagementManagement
SystemSystem
EHSEHSManagementManagement
SystemSystem
EHSEHSManagementManagement
SystemSystem
TQM CORE INITIATIVES
TRANSFORMATION
Continuously Steering Towards Excellence
AMS – 5 FOCUS TARGET
1-Improve in Employee Satisfaction Index2-Increase in number of employees suggestions and implementations.3-Improve in employee rewards 4-Improve in the training hours per employee5-Increase in numbers of improvement projects.6-Reduce employees absenteeism & turnover
MORALE
1- Improve profit2- Reduction of: a) Raw material, WIP and FG b) Utilities costs c) Space usage d) Overtime cost e) Maintenance cost f) Labor employed g) Equipment downtime h) New investment
1-Zero accident2-Compliance to DOE & DOSH regulation3- Certify to OHSAS & EMS4-Increase S.H.E awareness5-Good housekeeping & improve 5S index.
1-Reduction of through put time2-Reduce non-value added work3- Increase stock turn4-On-time-delivery to customer5-Reduction of lot size6- Improvement of OEE. 7- Change-over time8- Optimization of logistic
1-Elimination of customers downtime2-Reduction of in-process ppm3-Reduction of customer reject ppm4-Reduction in suppliers in-coming parts ppm5- Certified to International standards.6-Reduce cost of quality
QUALITY COST
DELIVERY
EHS
5FOCUS
TARGETS
DETERMINING THE AMS PRINCIPLE
brainstorming
REFERENCES a) TOYOTA Production System b) MERCEDES Production Systemc) BOSCH Production Systemd) ISUZU KAIZEN Network Systeme) FORD Production System
5FOCUS
TARGETSVALUES
QU
ALIT
Y RI
GH
T 1ST
TIM
E
PULL
SYS
TEM
VISUAL MANAGEMENTTOTAL EMPLOYEE INVOLVEMENT & DEVELOPMENT
LONG TERM BUSINESS THINKING
WAS
TE E
LIM
INAT
ION
FLE
XIBI
LITY
PRO
DU
CTIO
N L
EVEL
LIN
G
STA
ND
ARD
IZAT
ION
BEST QUALITY – LOWEST COST– SHORTEST LEADTIME- BEST ENVIRONMENT & SAFETY – HIGH MORALE
QU
ALIT
Y RI
GH
T 1ST
TIM
E EV
ERY
TIM
E
PULL
SYS
TEM
VISUAL MANAGEMENT
TOTAL EMPLOYEE INVOLVEMENT & DEVELOPMENT
LONG TERM BUSINESS THINKING
PRO
DU
CTIO
N L
EVEL
LIN
G
STA
ND
ARD
ISAT
ION
WAS
TE E
LIM
INAT
ION
FLE
XIBI
LITY
BEST QUALITY – LOWEST COST– SHORTEST LEADTIME- BEST ENVIRONMENT & SAFETY – HIGH MORALE
HOUSE OF AMS
13 INITIATIVES
13 INITIATIVES
KEY PERFORMANCE INDICATORS (KPI)KEY PERFORMANCE INDICATORS (KPI)
5FOCUS
TARGET
5FOCUS
TARGET
HMS STRUCTURE
QU
ALIT
Y RI
GH
T 1ST
TIM
E EV
ERY
TIM
E
PULL
SYS
TEM
VISUAL MANAGEMENT
TOTAL EMPLOYEE INVOLVEMENT & DEVELOPMENT
LONG TERM BUSINESS THINKING
PRO
DU
CTIO
N L
EVEL
LIN
G
STA
ND
ARD
ISA
TIO
N
WA
STE
ELIM
INA
TIO
N
FLE
XIBI
LITY
BEST QUALITY – LOWEST COST– SHORTEST LEADTIME- BEST ENVIRONMENT & SAFETY – HIGH MORALE
P1. Long Term Business ThinkingP1. Long Term Business Thinking Business decisions are guided by long term thinking and being embraced by every employee.
P2. Total Employee Involvement & Development P2. Total Employee Involvement & Development
Committed and engaged employees are involved in their task with sense of ownership and responsibility.
P9. StandardizationP9. Standardization Standardize for consistency, maintain predictability, regular timing and consistent output of processes.
P4. Quality Right 1st Time Every Time P4. Quality Right 1st Time Every Time Deliver right quality to the next customers by avoiding non-conformity through preventive actions all the time.
P3. Visual ManagementP3. Visual Management Make visible status, deviations, and install self explaining control systems and procedures.
P6. Waste EliminationP6. Waste Elimination Continuously improve to eliminate all type of wastes.
P7. FlexibilityP7. FlexibilityFlexible with regards to human resources, processes, logistics & volume variations.
P8. Production LevelingP8. Production Leveling Eliminate unevenness in production scheduling and level out workload of manufacturing and service processes.
P5. Pull SystemP5. Pull System Produce based on actual customer demands and avoid over production throughout the processes.
HMS 9 PRINCIPLES (OVERVIEW)
STRATEGIC MANAGEMENT
PROCESS OWNERSHIP THINKING
5S
VISUAL MANAGEMENT
Strategies that involved business plan, KPI, investment, customer satisfaction, employee satisfaction and product analysis.
To enable all the status of process or system to be visualized and understand without explanation. i.e. Visual Board, Footprint , Obeya, etc.
Activity that make working environmental tidy and systematic .
To develop K-Worker, meaning that workers having knowledge in technical, method, application, human and social responsibilities.
HMS INITIATIVES
QUALITY MANGEMENT
SYSTEM
EMPLOYEE SUGGESTION
SCHEME
SMALL GROUP ACTIVITIES
3 TYPES OF CERTIFICATION :(a) TS16949 (b) ISO14001 (c) ISO 18001
To encourage employee to give and idea or suggestion for improvement.
Employee involvement in continuous improvement program for QCDMS.
Production process with the method of ‘One piece continuous flow’’ without extra raw material or finish good product (zero inventory).
JUST-IN-TIME (JIT)
HMS INITIATIVES
12
VALUE STREAM MAPPING
A method that use to analyse overall production process starts from supplier, production and customers.
AUTONOMASI (JIDOKA) One of the method to use for controlling the product quality (quality control process) by using certain methods (engineering).
SINGLE MINUTE EXCHANGE DIE (SMED)
Quick changeover method using for model change process from old method to new within the shortest time.
AUTONOMOUS MAINTENANCE (AM)
Activity that encourage machine operator to carry out basic maintenance on his/her machines. Objective of AM are zero defect, zero downtime and zero accident.
HMS INITIATIVES
FLEXIBILITY
Flexibility Production System is the system that able to accommodate the variable production planning either it was plan or not. There are two category of flexibility system :
1) Resource flexibility – includes the flexibility of the system to produce new product..
2) Routing flexibility – includes variety of line and system that able to produce high productivity and capicity at any time required..
HMS INITIATIVES