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TQM Models

WORLD CLASS

THROUGH CONTINUOUS

IMPROVEMENTS

TOTAL EMPLOYEE INVOLVEMENT

(TEI)

LEADERSHIP, TEAMWORK, CONSENSUS,EMPOWERMENT.

TOTAL QUALITY

CONTROL (TQC)

SYSTEMS, SPC,

PDCA, PROBLEMSOLVING TOOLS

JUST IN TIME /

WASTE

ELIMINATION

PROBLEM

EXPOSURE

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TQM Models continued

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PILLARS OF TQM

ORGANISATION

WORKING

VISIONMISSION

CORE

COMPETENCY

STRATEGIES

GOALS /

OBJECTIVES

7 QC / SPC

BM

6 Sigma

ISO 9000

ISO 14000

QS 9000

5S

KAIZEN

JIT

TPM

SGAS

QCS

CFTS

CONCURRENT WORKING

TOOLS &

TECHNIQUESSYSTEM WCMS PEOPLE

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TQM vs Problem

Inventory Levels

Manufacturing Problems*

* Unreliable Supply, Rework/Reject, Untrained Staff.

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JIT exposes the problems and Controls

Waste in material, capacity and labour.

Inventory Level

Waste Removed..

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Responding to Market Demand

Requires a change in the way .

we think about manufacturing

The consumers act of buying activates the process of manufacturing.

FROM

TO

PUSH

MAKE

MAKE

BUY

BUYPULL

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JUST-IN-TIME( JIT )

A structural approach followed by an organization, focusing on

improving:

Timeliness.

Flexibility. Productivity.

Quality.

By utilizing various methods of work

simplification andwaste reduction.

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JIT Continued.

JIT means to manufacture and deliver:

Finished Goods just in time to be sold.

Arrange/ Manufacture Sub- assemblies just in time forassembling into finished goods.

Arrange/ Manufacture parts and components just in time to betransformed into subassemblies.

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Seven Wastes in Operational

Environment

Overproduction.

Waiting for something ( Instruction, material, equipment readiness).

Material Transport.

Inventory

Inspection, Rework and Scrap.

Equipment Downtime

Set- up Time for Machine/ Facility.

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Five Wastes in Office Environment

Lack Of Planning

Absence of System for Working.

Cumbersome procedures.

Information Storage and Retrieval

Inconclusive style of Working.

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The Seven Elements that addresses Elimination of Waste are:

Focused Factory

Group Technology

Quality at Source

J I T Production

Uniform plant loading

KANBAN Production Control System

Minimized Set-up Times

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Quality at Source :

Right first time.

Do not accept reject

Do not produce reject

Do not deliver reject

Self inspection

Stop line & use of Pokayoke

ANDON for trouble indication

Team problem solving

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JIT Methods

Good Housekeeping.

Visual Control. Total Productive maintenance. ( TPM )

Pokayoke .i.e. Mistake Proofing

Andon/ Jidoka.

Cellular Layout.

Modern Material handling and transportation.

Lot Size reduction.

Operation with Minimum Stock. Self Certified Vendors.

Demand Pull and Kanban.

Multiskilled and Flexible workforce.

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JIT People

Do not accept reject.

Do not produce reject.

Do not send reject.

Can stop the Line.

Team Member and Flexible.

Understand products and processes.

Measure Selfs output .i.e. Quantity and Quality.