Date post: | 30-May-2018 |
Category: |
Documents |
Upload: | nafeeskhan |
View: | 224 times |
Download: | 0 times |
of 26
8/14/2019 Tqm 04 Continuous Improvement
1/26
Slide 1 of 29Slide 1 of 29
TOTAL QUALITY MANAGEMENTCONTINUOUS PROCESS
IMPROVEMENT
8/14/2019 Tqm 04 Continuous Improvement
2/26
Slide 2 of 29
Continuous ProcessImprovement
Improvement is made by:
Viewing all work as a process. Making all processes effective. Anticipating changing customer needs. Controlling in-process performance using measures such as
scrap reduction, cycle time, control charts, and so forth.
Maintaining constructive dissatisfaction with the present levelof performance. Eliminating waste and rework wherever it occurs. Investigating activities that do not add value to the product or
service. Eliminating nonconformities in all phases of everyones work. Using benchmarking to improve competitive advantage. Innovating to achieve breakthroughs. Incorporating lessons learned into future activities. Using technical tools such as statistical process control (SPC),
experimental design, benchmarking, quality functiondeployment (QFD), and so forth.
8/14/2019 Tqm 04 Continuous Improvement
3/26
Slide 3 of 29
FIVE BASIC WAYS TO IMPROVE
Reduce resources Reduce errors Meet or exceed expectations of
customer Make the process safer Make the process satisfactory to the
person doing it
8/14/2019 Tqm 04 Continuous Improvement
4/26
Slide 4 of 29
INPUT / OUTPUT PROCESS MODEL
ProcessPeopleMethod
Materials
Procedures
InputMaterials
MoneyInformation
Data etc.
OutputProduct
InformationService.
Outcomes
Conditions
Feedback
8/14/2019 Tqm 04 Continuous Improvement
5/26
Slide 5 of 29
APPROACHES TOWARDSCONTINUOUS
IMPROVEMENTS Jurans Trilogy Shewharts Plan-Do-Study-Act Cycle Kaizen Reengineering
SixSigma
8/14/2019 Tqm 04 Continuous Improvement
6/26
Slide 6 of 29
JURANS TRILOGY Quality Planning.
Determinationof ExternalCustomers
Needs of External
Customers
DevelopmentOf ProductOr Services
Features
DevelopmentOf The
Process
TransferringPlans toOperations.
Quality Control.Quality Control.Determination
Of ItemsSet Goals
MeasurementOf Actual
Performance
ComparisonOf actual with
Goals
Act on thedifferences.
Quality Improvement.Allocate Resources, People to Pursue Quality
Training
8/14/2019 Tqm 04 Continuous Improvement
7/26
Slide 7 of 29
IMPROVEMENT STRATEGIES
R e p
a ir
R e f
i n e
m e n
t
R e n
o v
a t i o n
R e i
n v
e n t
i o n
8/14/2019 Tqm 04 Continuous Improvement
8/26
Slide 8 of 29
IMPROVEMENT STRATEGIES Repair:
Anything broken must be fixed so that itfunctions as designed.
Strategies divided into two levels:
1. Temporary or Short- term measure
2. Permanent measure Refinement:
Activities that continually improve aprocess that is not broken.Refinement improves efficiency and
8/14/2019 Tqm 04 Continuous Improvement
9/26
Slide 9 of 29
IMPROVEMENT STRATEGIES Renovation:
Strategy results in major or breakthroughimprovement.
Innovation & technological advancement arekey factors in this approach.
Reinvention (Re-Engineering):
Reinvention begins by imagining that theprevious condition does not exist; A cleansheet of paper
8/14/2019 Tqm 04 Continuous Improvement
10/26
Slide 10 of 29
TYPES OF PROBLEMS
ComplianceUnstructured
Efficiency
Process Design
Product Design
8/14/2019 Tqm 04 Continuous Improvement
11/26
Slide 11 of 29
PROBLEM SOLVING METHOD1. Identity theopportunities
4. Implement
3. Develop theoptimal Solution
2. Analyze theProcess
6. Standardizethe solution
5. Study Results
7. Plan for The Future act
doStud
y
plan
8/14/2019 Tqm 04 Continuous Improvement
12/26
Slide 12 of 29
Phase 1: Identify the Opportunity Identify the problem Form the team Define the scope
Charter for the team: Authority Objective and scope Direction and Control General (Methods, Resources.)
Phase 2: Analyze the Current Process Development of process diagram Target Performance Measure Identify the root causes
Problem Solving Method
8/14/2019 Tqm 04 Continuous Improvement
13/26
Slide 13 of 29
Phase 3: Develop the Optimal Solution Establishing Potential & Feasible Solution Select of one possible Solution
Phase 4: Implement Changes Implementation Plan & Obtaining approval
Contents of implementation plan report: Why will it be written?
How will it be done? When will it be done? Who will do it? Where will it be done?
Problem Solving Method
8/14/2019 Tqm 04 Continuous Improvement
14/26
Slide 14 of 29
Phase 5: Study the Results
TQM addresses the quality of management as well themanagement of quality.
Phase 6: Standardize the Solution
Phase 7: Plan for the Future
PROBLEM SOLVING METHOD
8/14/2019 Tqm 04 Continuous Improvement
15/26
Slide 15 of 29
KaiZen Kai Change; Zen Better
Kaizen Make it Better (Improvement)
A selection of better means or achange of current method for
achieving an objective.
An accumulation of small changes
8/14/2019 Tqm 04 Continuous Improvement
16/26
Slide 16 of 29
DIFFERENT STYLES OFCHANGES
Small Change (KaiZen) : By individual effort, a better way of proceeding a job
is considered. (idea generation)
Medium Change (Small Group Activities) By group effort, a better way is proposed by following
predetermined steps (or rule)
Big Change (Innovation) :
By investments in new technology or equipment,dramatic alterations are achieved.
8/14/2019 Tqm 04 Continuous Improvement
17/26
Slide 17 of 29
8/14/2019 Tqm 04 Continuous Improvement
18/26
Slide 18 of 29
8/14/2019 Tqm 04 Continuous Improvement
19/26
Slide 19 of 29
8/14/2019 Tqm 04 Continuous Improvement
20/26
Slide 20 of 29
KaiZen : 5S
5S movement is a determination toorganize work place, to keep it neat, toclean, to maintain the discipline to do agood job.
Japanese concept for house keeping Sort ( Seiri ) Straighten ( Seiton ) Shine ( Seiso ) Standardize ( Seiketsu ) Sustain ( Shitsuke )
8/14/2019 Tqm 04 Continuous Improvement
21/26
Slide 21 of 29
KaiZen : 5S Sort (Seiri)
the first S focuses on eliminating unnecessary items from theworkplace.
Tags are placed on all unnecessary item declaring as waste.
Straighten (Seiton) Effective & efficient storage methods Arrange needed items so they are easy to find, use and return, to
streamline production and eliminate time searching for them. Shine ( Seiso )
Clean and care for equipment and areas, and inspect while doingso.
Standardize ( Seiketsu ) Make all work areas similar so procedures are obvious , and
defects stand out.
Sustain ( Shitsuke ) within the context of 5s sustain means making a habit of properly
maintaining correct procedures
8/14/2019 Tqm 04 Continuous Improvement
22/26
Slide 22 of 29
Benefits
Improves on-time delivery Improves quality/reduced defects Increases productivity Reduces lead times Reduces waste in materials, space and time Reduces inventory and storage costs Reduces equipment downtime
Contributes positively towards safety Promotes standardization Promotes work satisfaction
8/14/2019 Tqm 04 Continuous Improvement
23/26
Slide 23 of 29
10 HINTS FOR DOING SUCCESSFULKAIZEN
1. No Excuses: Dont make excuses Dont acceptexcusesExplanations are often still excuses (if youhave time to makeup excuses, you have time to think of improvement ideas).
2. Dont be a concrete head: Throughout traditional
concepts Think how a new method can work, not howit wont.3. Do Kaizen by getting your hands dirty on the shop floor4. Quick & Crude is better than slow and elegant: Dont
seek perfection 50% improvement rate is as long as itis done on the spot.
5. Produce Actual Improvement6. Implement Kaizen Newspaper items as committed: Dont
Put of kaizen until tomorrow.
10 Hi f d i f l
8/14/2019 Tqm 04 Continuous Improvement
24/26
Slide 24 of 29
10 Hints for doing successfulKaiZen
7. Do Kaizen by adopting ideas of workers: Put yourself in theworkers position The idea of 10 people are better thanthe knowledge of one.
8. Do Kaizen without spending lots of money: Many smallimprovements add up to big results Implement quicklywith less risk.
9. Dont overlook even the smallest waste (Muda): Overproduction, delay, transportation, processing, inventory, etc.
10. Document results on target progress report: Document and
report results at regular report outs. Fill in the conditioneven if there has been no change.
8/14/2019 Tqm 04 Continuous Improvement
25/26
Slide 25 of 29
QUESTIONS
8/14/2019 Tqm 04 Continuous Improvement
26/26
Slide 26 of 29
End of Chapter 5