continuous process improvement
TRANSCRIPT
Continuous Process ImprovementTOTAL QUALITY MANAGEMENT PRESENTED BY: GROUP 7
INTRODUCTION
TQM - means gradual and continuous improvement of the process within the organization.
TQM consist of finding:
- New Opportunities for improvements of Processes
In this chapter we will learn the following concepts, techniques and tools that are used for continuous process of improvement
JURAN’S TRILOGY
KAIZEN
KAIZEN BLIZZ
5’S PRACTICE
THREE MU’S
THE 7 DEADLY WASTE
BUSINESS PROCESS REENGINEERING
JURAN’S TRILOGY Juran brings out the financial results are achieved in an organization through three managerial processes namely:
Quality Planning
Quality Control
Quality Improvement
KAIZEN
Continuous improvement is achieved through the current way of manufacturing and eliminating waste
Is a Japanese strategy for continuous improvement
It is succeeded it is a good management practice
It calls for never ending improvements
that is why the word continual may be more appropriate rather than continuous improvement
TWO ACTIVITIES OF KAIZEN MAINTENANCE
maintaining current technological
managerial
operating standards
IMPROVEMENT
revising the current standards
Kaizen is different from innovation.
Innovation aims at dramatic improvement of the existing processes
Kaizen aims at small incremental improvement in the existing processes
KAIZEN ACTIVITIES
1. Finding new ways or improving the ways in which the task are currently carried out
2. Improving working environment
3. Improving processes
4. Improving capability of machinery through periodic as well as preventive maintenance
5. Improvement usage of tools and fixtures
6. Improvement of human resources through training and job rotation
7. Improving plant layout
Top management have to take keen interest in the following activities towards kaizen:
1. Maximizing efficiency and productivity of employees as well as the plant
2. Improving the quality of the process plant and thereby the product
3. Minimizing inventory levels and Work In Progress (WIP)
4. Improvement ergonomics to facilitate the human resources to maximize their output with more comfort
5. Call for suggestions from workers
6. Enabling team work
7. Improving systems in the organization
3 Basic Principles of kaizen
I. Work place effectiveness
II. Elimination of waste, strain and discrepancy
III. Standardization
continued.. Work place effectiveness• Japanese have developed the 5S tools for addressing the work place effectiveness
Eliminating waste, strain and discrepancy•kaizen is achieved through application of 5S tools for workplace effectiveness and elimination of three MU’s :
Muda – Waste
Muri – Strain
Mura – Discrepancy
The following are to be reduced and finally eliminated :
Human resources
Production volumes
Inventory ( materials)
Time
Working space
Machinery
Facilities
Tools and jigs
Thinking
Continued.. Standardization• kaizen stresses standardization of processes, materials machinery, etc, with the following objectives:
1. Represent the best, easiest and safest way to carry out a job in the form of operating procedures and work instructions
2. Represent the best way to preserve know-how and expertize and standardize the procedures for the same
3. Evolve effective means to measure performance and standardize the same
4. Standardize all the procedures that are used in the organization for the maintenance and improvement of process
5. Standardize the training programs
6. Standardize the audit for diagnosing problems
7. Standardize the procedures for preventing occurrence of errors and minimizing variability
PCDA ( plan – do – check – Act )and 7 Quality Tools
Kaizen advocates usage of seven quality tools for the problem solving
It also calls for using PCDA cycle for improvement of processes.
It encourages forming cross- functional teams for improvement.
Goal of Kaizen Kaizen is implemented not for the profit but for the quality.
The success of kaizen should be measurable through its impact on the customer satisfaction
Kaizen will be successful only when it is process oriented
It is important to recognize that any organization will have problems and hence the employees should be encouraged to admit when there is a problem
A suggestion system is an integral part of kaizen. The management should encourage the employees to give suggestions and their involvement in improvement process
Kaizen should be prioritized based on the impact on the customers. Thus, kaizen is a customer driven strategy for improvement
Kaizen is a problem- solving tool based on cross- functional team and collaborative approach
Continued…
Kaizen is basically for improving the processes in the organization
Collaboration between the cross- functional team, the process owners (those who carry out the job regularly) and the management is essential for success of kaizen
Quality Circles can become part of kaizen since it is a group oriented suggestion system
Kaizen implementation
The organizations embrace kaizen in 2 ways as given below:I. Gradual improvement of processes II. Kaizen blitz
KAIZEN BLITZ
Is a quick improvement methodology
To unleash employee creativity and dramatically improve operation overnight
Usually completed in a single week
The solution are implemented quickly
Whether it is a kaizen blitz in the traditional sense, it involves the following:
•Whether it is a kaizen blitz in the traditional sense, it involves the following:
Application of 5S for improving workplace effectiveness
Reduction and finally elimination of three MU’s
Standardization of effectiveness methodologies for carrying out the work
A typical improvement process using kaizen
Revise standardized methodologies
Remove 3 MU’s
Identify problems and wastes
Study process flowchart
Select process for improvement
start
5S PRACTICES Kaizen is a carefully evolved strategy by Japanese for improved competitiveness of business. It is more than just a tactical weapon. It is also a collection of tools
5s practice are :I. SortII. StraightenIII. ScrubIV. SystematizeV. Standardize
Seiri ( sort)•Separate out all unnecessary things and eliminate them
The objective of seiri is to sort and throw away unnecessary items.
Separate:◦ tools◦ machinery products ◦ Inspection◦ work in progress◦ Documentation
Seiri means “separating the things which are necessary for the job from those that are not and keeping the number of the necessary ones as low as possible and at convenient locations”The executive can classify the items into 3 category:
◦ Low usage◦ Medium usage◦ High usage
Seiton - Straighten
Arrange the essential things in order, so that they can be easily accessed
- for easy and fast access when needed, everything has a place and it is in place
The following could be adopted for enabling neatness In the organization:
1.PLAN TO ARRANGE NEATLY – the management should plan to arrange everything at the appropriate manner.
Some problems in retrieving things are :• Not knowing the correct name of the things• Not sure where the things are kept• Storage site at a far off place• Storage sites scattered all around
◦ Repeated visits to far off places for taking and putting back◦ Hard to locate things since the box contains many other things◦ Storage location are not label◦ Things are not there, but not clear whether the stock is exhausted or somebody is having it◦ No distinguish between good parts and defective parts, all look same◦ Too wide to carry◦ Too heavy to carry◦ No trolleys to carry huge things ◦ Improper design of path ways with lot of obstruction
2. Decide where the things should be stored
the following procedures should be adhered to:
everything should have a name
A place for everything and everything in its place
Quick identification and retrieval mechanism
- frequent-use items be retrievable easily
Safe storage/transfer
- heavy things on the bottom
- heavy things to be carried on trolleys
- benches and ladders to be used wherever required
Height consideration for the storage of items depending on the frequency of their use
3. Be consistent in following the rules
Seiso – Scrub Keep machinery and working environments clean
the objective of seiso tool is to clean and inspect the respective work places thoroughly, so that there is no dust on the floor, machinery and equipment. Keep machinery and work environment clean
Seiketsu - Systematize
◦ Make cleaning and checking as a routine practicethe objective of this tool is to maintain high standards of
work place organization by keeping everything clean and orderly at all times. Develop routine practices for cleaning and checking
Shitsuke – standardize ◦ Standardize the previous step
the objective of the last 5S tool is to make the previous four steps part of the daily routine and to observe self-discipline through continuous practice. Follow procedures and standardize continuously to improve processes and reestablish standards
5S Certification National Productivity and Competitiveness Council (NPCC) of Mauritius offers 5S certification (April 2002)
It is aimed at developing and assisting the productivity culture across Mauritius.
THE PROCESS
1.A team of 5 auditors will audit the Gemba ( work place ) proposed for certification. Three audits, spread over the period of one year will be conducted
2.The audited organization should keep the following relevant information◦ General background of the organization◦ Sections or department where 5S is applied◦ Photographs of the section or department where 5S is applied◦ Tangible and intangible benefits gained◦ Documented proof ; support structure for 5S
4. following three random audits and on the basis of the audit report, eligibility of the 5S certification will be considered
5. a certificate will be awarded by NPCC and kaizen institute ( Africa, Asia and pacific) to any organization, which has successfully implemented 5S practices
The Seven Deadly Wastes1.OVERPRODUCTION WASTE – this occurs due to failure of production planning when money is blocked in the unsold products
2.WASTE DUE TO WAITING - WIP is a direct measure of the quality of the organization.
3.TRANSPORTATION - unnecessary transportation is a waste
4.PROCESSING WASTE - the machinery should be kept in smooth working condition by periodic and preventive maintenance to eliminate processing waste
5.INVENTORY WASTE - supply chain management should be such that there are no excess materials
6.WASTE OF MOTION - as Watts Humphrey says, the purpose of driving is to reach the destination on time and not to spin the wheel.
7.PRODUCT DEFECTS - the defective parts or supplies cause loss of money
Business Process Reengineering (BPR)
What is BPR?◦ Is undertaken essentially to result in a quantum jump in performance of
processes.◦ It is synonymous with innovation because it is more than just automating
or applying Information Technology to the existing process or operation◦ The fundamental rethinking and radical redesign of business process to
achieve dramatic improvement in critical, contemporary measures, such as cost, quality, services and speed.
Fundamental Rethinking – dramatic improvements can take place through elimination of redundant operations, unnecessary operation and operations, which cost, but not value to the products and services
Radical Redesign – dramatic improvement cannot be achieved only through fundamental rethinking. It calls for redesign of new processes
How to carry out reengineering?◦ 5 phases of reengineering cycle
◦ Planning◦ Process study◦ Study of the best practices◦ Redesign◦ implementation
◦ Information Technology ◦ BPR AND TQM