Report By: Engr. Nancy Mercado

PROCESS APPROACH

INTRODUCTION

Every organization should therefore be a well-knit collection of processes so as to practice TQM and be competitive successful.

This concept is also advocated by the IOS9001:2000 standard.

Process approach in the organization is essential to make continuous improvement, get ISO9000 certification as well as practicing TQM. To reduce costs and increase profits.

Product and Service Quality Depend on Processes

Manufacturing and service organization were measuring, confirming and analyzing quality with reference to the final product alone.

Process orientation should be adopted for Total Quality Management (TQM).

Process orientation is the right strategy to be adopted for practicing quality as well as management of organizations so that the producer can be certain about the quality of the products or services even before the final inspection.

Process Orientation Helps in Finding Defects Early

Quality should be built into the product or service right from the early stages. If a defect cannot be corrected early in the process, it cannot be removed at the final stages. Therefore, the defects are to be found early. In the product orientation, the defects are found only at the final stages, whereas in the process orientation, defects could be prevented totally by eliminating the cause of failure in the process.

MODEL FOR PROCESS DEFINITION

Input/s to the processOutput/s of the processThe process or task

Input of the process

The various inputs required for any process are:

Bill of materials Specification or each material Requirements for inspection for

the incoming materials Procedure for receipt of

materials.

Output of the process

The output of process consists of the following:

The products or service to be delivered Documents to be delivered The specifications for all the above Method of measurements for verifying

conformance to the specifications Criteria for acceptance / rejection

Value Addition in the process

Every organization attains profit only through value addition to its processes. Therefore, the primary goal of the organization is value addition. It, in turn, applies to every process in the organization.

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The process may need machinery, infrastructure or techniques for achieving the desired value addition as per the goals and objectives of the process.

The process owners and the other employees attached to the process for carrying out the assigned tasks should be clearly identified and documented, along with their authority and responsibility.

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ETX MODEL

The most popular process model is ETX as shown in figure.

ENTRY

TASK

EXITINPUT OUTPUT

EXT MODEL

EXT stands for Entry, Task and Exit. The value adding process is called Task. The new items in the diagram are Entry and Exit

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Entry – Conditions to be satisfied before the task is undertaken.Exit - Conditions to be fulfilled before the task is considered as completed.

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Training for Process Orientation The most important requirement for

transforming the employee from product orientation to process orientation is training and coaching.

It should also be helped to identify their customers and suppliers and coached as how to conduct themselves in the roles of customers as well as suppliers. NEXTPREVIOUS

Measure Process

Before giving a go ahead for normal production, the process parameters should be studied, statistical analysis made and only then the process should be authorized for normal deployment.

This should repeated at regular intervals.

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Improve Process Continuously In line with the TQM philosophy,

the processes should be improved continuously. Efforts should be put in for continuous process improvement.

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SUBBURAJ’s 6s MODEL FOR PROCESS IMPROVEMENT Since 1991, the author has been

heading ETDC, Chennai which is a testing and calibration service provider, offering services to more than 700 organization in a year.

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Subburaj’s 6s for Process Improvement

Strengthen

Study

ProcessImprovement

Synergize

Streamline

Simplify

Standardize

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6’S MODEL FOR PROCESS IMPROVEMENT Study

Streamline

Simplify

Standardize

Synergize

Strengthen

STUDY

The current performance level of the process triggers improvement. It could be the defects found (both internal and external), cycle time achieved, customer feedback/complaint, employee feedback, customer waiting time, hassles of the employees or customers, etc.

STREAMLINE

The process should offer the least resistance to motion in the organization.

For instance, before embarking on TQM, the CEO of the organization was formally issuing the test and calibration reports under his signature.

SIMPLIFY

One has to formulate a simplified procedure for carrying out the task without increasing the cost and compromising on quality.

STANDARDIZE

permits performing the process in the same way by every employee at all times.

SYNERGIZE

No process is a stand-alone activity in any organization. A process may interact with at least two other processes – customers and supplier processes.

STRENGTHENEducating and convincing the process owners, customers and suppliersPeriodic counseling and assuring that the new process will perform better than the old processMonitoring the result s and confirming that the process transition has occurred

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CUSTOMER SUPPLIER CHAINS Increased Inspection Adds Cost, not Value

Identify Internal Customers and Suppliers

Customer-supplier Chains

Educate

Customer Orientation Includes Internal Customers

Advantage of Customer-Supplier Chains

Increased Inspection Adds Cost, not Value

Customer supplier chains have to be established for building quality into the products and services.

increased expenditure in increased inspections is not worth it. It only adds to the increased cost of the product or service, without adding value.

This can be achieved through establishing customer supplier chains in the organization.

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Identify Internal Customers and Suppliers

“divide and conquer” approach is advocated in customer-supplier chains which is suitable for solving quality problem or for that matter any scientific problem.

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Customer-supplier Chains

Each sub-process has an owner, who actually is responsible for giving an output to internal customers after receiving the right inputs from internal suppliers and adding value.

Some sub-processes would terminate at the internal customer. Some sub-processes would have external suppliers.

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Educate

The employees should also be educated about the customer supplier chain to treat the internal customers and suppliers, as the organization would like to treat the external customers and suppliers.

The management’s task is only to make the customers supplier chain work for the successful implementation of TQM.

Customer Orientation Includes Internal Customers

Customer orientation should be equality applicable to the internal customers in addition to the external customers. The process owners who are customers should not only inspect, but also spend time in educating the internal suppliers for improving the quality of the incoming products.

Advantage of Customer-Supplier Chains

a) It improves communications within the organization.

b) It reduces communication gap.c) It helps in documenting the process flow.d) It helps in defining the specifications not

for the overall input and output, but also for the entire process.

e) It helps in finalizing verification methodology throughout the process with clear accept/reject criteria. NEXT

f) It facilitates immediate feedback from colleagues rather than time lapsed feedback from customers through the channel of hierarchy.g) The management can easily identify problem areas clearly, easily and deal with them specifically, instead of going for global solution across the organization.

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h) It helps in building quality throughout the organization.i) It enables the management to

have absolute control over quality with optimal expenditure.

j) Above all, it helps the management to understand its own organization and operations better, leading to effective planning, management and improvement.

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SUPPLY CHAIN MANAGEMENT

Supply Chain-is the series of links and

shared processes that exist between the suppliers and customers.

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SUPPLY CHAIN MANAGEMENT(SCM)

a task of optimizing all activities throughout the supply chain, so that the products and services are supplied in the right quantity, right quality, to the right customer, at the right time and at the optimal cost.

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SUPPLY CHAIN MANAGEMENT(SCM) Demand Planning

Manufacturing Planning and Scheduling

Supply Planning

Transportation Planning

DEMAND PLANNING

A planning process to predict the demand of products and services based on forecasts.

Forecasting customer demands improves customer service while decreasing costs by reducing demand uncertainty.

MANUFACTURING PLANNING AND SCHEDULING

A planning process that optimally schedules manufacturing orders with production capacity. This is performed by combining Material Requirements Planning (MRP) and Capacity Requirements Planning (CRP) to create optimized and constrained production plans.

SUPPLY PLANNING

Supply planning process that meets customers demand based on available inventory and transportation resources. This includes Distribution Requirements Planning (DRP), which determines the need to replenish inventory at branch warehouse.

TRANSPORTATION PLANNING

A planning process to optimally schedule, load, and deliver shipments to customers while considering constraints, such as delivery date, mode of transportation, carrier, etc.

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JUST-IN-TIME (JIT) MANUFACTURING

The products should be made to order, just in time for immediate delivery to the customers. The materials, which go into the product or service, should also arrive on just time, before manufacturing starts.

OBJECTIVES OF JUST-IN-TIME Development of optimal process and

be competitive Streamlining of operations and

eliminating unwanted processes Continuous improvement Reducing the levels of wasted

materials, time and effort Increasing efficiency of production

process

BENEFITS OF JUST-IN-TIME

Reduction of wastes Reduction of Work-In-Progress(WIP) Establishing proper customer-

supplier relationship Reduction in lead-time Less-inventory of raw materials Improvement in flexibility Lower cost and high productivity

Enhanced customer satisfaction due to lower price owing to elimination of wastes

Improved employee morale owing to a perfect system without waiting

Improved satisfaction of shareholders due to high profit

Reduced space requirements on total elimination of WIP and buffer stock of materials, sub-assemblies and products

Improved productivity and improved quality

LEAN MANUFACTURING

The International Motor Vehicle Program (IMVP) was created at MIT, USA to study the techniques used in automobile production around the world. IMVP researcher John Krafcik commented that the Toyota System was lean.

Major Tenets of Lean Manufacturing

Quick Changeover/ Set-up Reduction

Pull/Kanban System

Workplace Organization 5S System

Value Stream Analysis

Total ProductiveMaintenance (TPM)

Cellular Manufacturing

SUPPORTING STRATEGIES AND CONCEPTS

One Piece Flow

Visual Controls TAKT Time

Team Building Balanced Flow

Quality at the source

Employee Involvement

Stabilized Operations

Standardized Continuous Improvement

Equipment Replacement

TENETS AND CONCEPTS OF LEAN MANUFACTURING

Kanban Systems Cellular Manufacturing One Piece Flow

KANBAN SYSTEMS The Kanban System was developed by Mr.

Taiichi Ohno, Vice President of Toyota, to achieve objectives that included: Reducing costs by eliminating waste/scrap Try to create work sites that can respond to

changes quickly Facilitate the methods of achieving and

assuring quality control Design work sites according to human

dignity, mutual trust and support and allowing workers reach their maximum potential. NEXT

TWO MOST COMMON TYPES OF KANBANS USED:

i. Withdrawal Kanban- Is to pass the authorization for

the movement of parts from one stage to another.ii. Production Kanban

- The main function of the production Kanban is to release an order to the preceding stage to build the lot size indicated on the card.

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KANBAN PROCESS FEATURES

Parts travel from one process to the next process

Parts are received from the preceding process as per details in kanban such as the type and time when required

Kanban must always be attached to the parts

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The quantity produced should match the requirement of the subsequent process

No extra pieces are produced If no Kanban is attached to a product, no

manufacturing should be made In case if defective items are produced, they

should not be transferred to the subsequent process.

It should be ensure that the parts are placed in the container should be defect free

The kanban can be used to respond to changes in demand by increasing or decreasing the number of units to be produced. NEXTPREVIOUS

ADVANTAGES OF KANBAN PROCESS

Simple and understandable process Provides quick and precise information Low costs associated with the transfer

of information Provides quick response to changes Avoids overproduction Minimizes waste Control can be maintained Delegates responsibility to line workers

CELLULAR MANUFACTURING

A cell is configured normally for speed and material handling and can reap substantial benefits in cost saving, time compression and inventory reduction.

Cellular manufacturing and work cells are at the heart of lean manufacturing. Their benefits are many and varied. They increase productivity and quality. Cells simplify material flow, management and accounting systems.

Improvement in efficiency cell build vs. batch build

Resources

Batch Build

Cell Build Improvemnt

Direct Labour

11 hours 10 hours 9%

Floor space

12,000 sq. ft.

3000 sq. ft.

42%

Lead time 12 weeks 2 weeks 83%

Inventory $ 564,000 $ 279,000 51%

Scrap and network

$ 23,040 $ 12,030 48%

SINGLE PIECE FLOW

Cellular manufacturing demands single piece flow methodology. This is also called one-piece flow or continuous flow manufacturing. It is a technique used to manufacture components in a cellular environment.

The goals of one piece however are: to make one part at a time correctly all the time without lengthy queue.

FLOW MANUFACTURING vs. BATCH PRODUCTION

The opposite of one-piece flow is large-lot production. Although, many companies produce goods in large lots or batches, it builds delays into the process. No items can move on to the next process, until all the items in the lot have been processed.

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Single Piece Flow Diagram

ProcessA

ProcessB

ProcessC

10 minutes10 minutes

10 minutes

Lead Time: 30 + minutes for total order 21 + minutes for first pieces

A. Batch and Queue Processing

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ProcessA

ProcessB

ProcessC

12 min, for total order3 min, for first part

B. Continuous Flow Processing

Single Piece Flow Diagram

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Table: Single Piece Flow

Was Is Change Goal

People/Parts Travel (feet)

1690 430 -75% -60%

Increase in Floor Space

(sq. ft.)

1559 2229 43% 30%

Non-Value Added Work (minutes)

433 30 -93% -50%

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ZERO DEFECTS Performance standard should be zero

defect and not Acceptable Quality Level (AQL)

Is it Possible to Achieve Zero Defect? Determination Required Right Mindset Required Do not Accept Work from Others Which

is not up to the Standard Do not Pass on the Work to Others

Saying that will be Good Enough

Do not Put Off Till Later Do not Put the Blame on Others

Perfect System Required Cultural Change Required Never Ending Enthusiasm Required Training Required Management Commitment

Required

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THANK YOU!