MODULE 7

PTTQM MODULE 8RECENT TRENDSWhat is BenchmarkingA method for identifying and importing best practices in order to improve performanceThe process of learning, adapting, and measuring outstanding practices and processes from any organization to improve performanceWhy BenchmarkIdentify opportunities to improve performanceLearn from others experiencesSet realistic but ambitious targetsUncover strengths in ones own organizationBetter prioritize and allocate resources

Types of Benchmarking: 1Strategic Benchmarking

How public, private, and nonprofit organizations compare with each other. It moves across industries and cities to determine what are the best strategic outcomes.Types of Benchmarking: 2Performance Benchmarking

How public, private, and nonprofit organizations compare themselves with each other in terms of product and service. It focuses on elements of cost, technical quality, service features, speed, reliability, and other performance comparisons.Types of Benchmarking: 3Process Benchmarking

How public, private, and nonprofit organizations compare through the identification of the most effective operating practices from many organizations that perform similar work processes.When not to BenchmarkTarget is not critical to the core business functionsCustomers requirement is not clearKey stakeholders are not involvedInadequate resources to carry throughNo plan for implementing findingsFear of sharing information with other organizationsBenchmarking ProcessPlanningCollectingDataAnalysisImprovingPracticesMaintenance DefinitionMaintenance is a set of organised activities that are carried out in order to keep an item in its best operational condition with minimum cost acquired.

Maintenance ActivitiesActivities of maintenance function could be either repair or replacement activities, which are necessary for an item to reach its acceptable productivity condition and these activities should be carried out with a minimum possible cost. Types of Maintenance Preventive Maintenance (PM)

Corrective Maintenance (CM) or Breakdown Maintenance

Improvement Maintenance (IM)

Predictive Maintenance (PDM)What is Total Productive Maintenance?TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment, and closed-loop measurement of results12TOTAL = All encompassing by maintenance and production individuals working togetherPRODUCTIVE = Production goods and services that meet or exceed customers expectationsMAINTENANCE = Keeping equipment and plant in as good as or better than the original conditions at all timesBreakdown of TPMTPM - HistoryProductive maintenance (PM) originated in the U.S. in late 1940s & early 1950sJapanese companies modified and enhanced it to fit the Japanese industrial environmentThe first use of the term TPM was in 1961 by Nippondenso, a Japanese auto components manufacturerSeiichi Nakajima head of JIPM, one of the earliest proponents, known as the Father of TPM Goals of TPM1. Aims at getting the most effective use of equipment2. Builds a comprehensive PM system3. Brings together people from all departments concerned with equipment4. Requires the support and cooperation of everyone from top managers downPromotes and implements PM activities based on autonomous small group activities.Maintaining Equipment for lifeEncouraging input from all employeesUsing teams for continuous improvement15Three Principles of Prevention

Maintenance of normal conditionsEarly discovery of abnormalitiesPrompt response16TPM 8 PILLARSPILLARS OF TPMKobetsu KaizenPlanned MaintenanceQuality MaintenanceTrainingOffice TPMSafety, health and Environment5sAutonomous Maintenance18TPM - BenefitsImproved equipment eliminates the root cause of defectsDefects are prevented through planned maintenancePreventive maintenance costs are reduced as equipment operators conduct autonomous maintenanceImproved equipment designs ensure that new equipment naturally produces fewer defectsSimplified products designs and a redesigned process produce with few defectsEngineers, technicians and managers are trained in maintenance and quality

Continuous Improvement Process Create a system for constant and continuous improvement

Process ModelDemings PDSA Cycle:Embedded in the Continuing System PlanDoCheck/StudyActAnalyzePlan again

2223What is a Zero Defect Quality System (ZDQ)?A quality concept to manufacture ZERO defects & elimination of waste associated with defects!

ZERO is the goal!

2324The 4 Components of ZDQZDQ functions by combining four elementary components:1. Point of Origin Inspection2. 100 % Audit Checks3. Immediate Feedback4. Poka-Yoke

2425How ZDQ Makes Work EasierMistake-Proof or Poka-yoke the process!

Recognize that it is natural for people to make mistakes.25TEN TYPES OF HUMAN MISTAKESForgetfulnessMisunderstandingWrong identificationLack of experienceWillful (ignoring rules or procedure)Inadvertent or sloppinessSlowlinessLack of standardizationSurprise (unexpected machine operation, etc.)Intentional (sabotage)

27Poka-yokeWhat is Poke-yoke?A method that uses sensor or other devices for catching errors that may pass by operators or assemblers.Poka-yoke effects two key elements of ZDQ:Identifying the defect immediately ( Point of Origin Inspection)Quick Feedback for Corrective Action

How effective the system is depends on where it is used: Point of Origin or Informative Inspection.

2728The Seven Steps to Poka- Yoke Attainment1.) Quality Processes - Design Robust quality processes to achieve zero defects.2.) Utilize a Team Environment- leverage the teams knowledge, experience to enhance the improvement efforts.3.) Elimination of Errors -Utilize a robust problem solving methodology to drive defects towards zero.4.) Eliminate the Root Cause of The Errors-Use the 5 Whys and 2 Hs approach 5.) Do It Right The First Time- Utilizing resources to perform functions correctly the first time. 6.) Eliminate Non-Value Added Decisions- Dont make excuses-just do it !7.) Implement an Incremental Continual Improvement Approach-implement improvement actions immediately and focus on incremental improvements; efforts do not have to result in a 100% improvement immediately.

28These are the sevens rules to a successful Poka-yoke implementation, generally in most text you will see 8 guidelines to poke-yoke attainment; we combined two steps into one.These should be custom fitted to your organization and culture.What is CMM?CMM: Capability Maturity ModelDeveloped by the Software Engineering Institute of the Carnegie Mellon UniversityFramework that describes the key elements of an effective software process.Describes an evolutionary improvement path for software organizations from an ad hoc, immature process to a mature, disciplined one.Provides guidance on how to gain control of processes for developing and maintaining software and how to evolve toward a culture of software engineering and management excellence.What is CMM?Process Maturity ConceptsSoftware Processset of activities, methods, practices, and transformations that people use to develop and maintain software and the associated products (e.g., project plans, design documents, code, test cases, user manuals)Software Process Capabilitydescribes the range of expected results that can be achieved by following a software processmeans of predicting the most likely outcomes to be expected from the next software project the organization undertakesProcess Maturity ConceptsSoftware Process Performanceactual results achieved by following a software processSoftware Process Maturityextent to which a specific process is explicitly defined, managed, measured, controlled and effectiveimplies potential growth in capabilityindicates richness of process and consistency with which it is applied in projects throughout the organizationWhat are the CMM Levels?(The five levels of software process maturity) Maturity level indicates level of process capability:InitialRepeatableDefinedManagedOptimizing

What are the benefits ?Helps forge a shared vision of what software process improvement means for the organizationDefines set of priorities for addressing software problemsSupports measurement of process by providing framework for performing reliable and consistent appraisalsProvides framework for consistency of processes and product