short form tool 19 itttm tool #19 short form “kaizen documentation foundations for data driven...
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Short Form Tool 19
ITTTM
Tool #19 Short Form“Kaizen Documentation Foundations For
Data Driven Process Variation, Waste Reduction, Lean, Six Sigma”
Topics
1. ISO/QS introduced and overviewed2. ISO requirements, focus, foundations3. Lean, six sigma, ISO relationships4. Time, method, work, facility, flow 5. Characteristics assessed, variation reduction6. Tool applications……..
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ISO/QS Introduced And OverviewedISO, international standards organization• Focused on global marketplace, and at home• QS, domestic customer/supplier, automotive• How we do business, future, contract issues• Consistent standards, level playing field80% of ISO overlaps into QS standards• Automotive Industry Alliance Group (AIAG) • Key part of understanding, satisfying customers
ISO is about Baldridge, broad framework, TQM• Baldridge is through Commerce Department• American “push” for quality
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Baldridge basis, ISO, QS, relationships• Leadership, how we do business• Information and analysis• Strategic quality planning• Human resource development• Management of process quality, operations• Customer focus and satisfaction
ISO/QS Introduced And Overviewed
Standards do not measure quality…….• Organization identifies, defines, standards• Manages production per customer demands• Specifies, certifies quality, compliance• Organization certifies, contractually, customer
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Documentation Tools, Lean
Data Tools, Six Sigma
Service, Tools Manufacturing, Non- Manufacturing
Synchronous Tools, New Product Development
Project Team
Cultural Change And Continuous Improvement
Information Analysis,Communication Systems
Applied Research, Project Structure
Enhanced Problem Solving, Decision Making
Internal, External, E-commerce Relationships
Quality Management Systems (QMS)International Standards Organization (ISO)
Professional Outcomes, Growth, Knowledge
Technological Infrastructure
Industrial Technologists’ Toolkit For Technical Management
ISO/QS Introduced And Overviewed
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Registrar selected similar to any supplier• Registrar, body such as Underwriters Lab• Reviews documentation system, quality manual• Do pre-assessment, preparatory work internal• Must understand business, be customer focused• Objective, willing, to work your calendar
ISO/QS Introduced And Overviewed
Process design, documentation routinely updated• Describes what we do, who is responsible• Describes how all is done, records, practices Time to be registered generally 6-12 months ++• Organization size, processes, preparedness• Startup costs, $15-25K, total easily twice this
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ISO Requirements, Focus, Foundations
Basic systems grew out of the 9000 framework• 9000 was a five part series, basic guidebook• 9001 was service, 9002 detailed production , and
9003 focused on inspection and testing• 9001, 9002, 9003 was audited by third party
More recent ISO developments are QS 9000• 20 elements describe standard, areas to comply• Totality of elements provide quality system• Documented quality manual, increasingly online
Assessment, internal, external audit, certification• Internal is to comply, may not certify, correct• External certification, desired, third party
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20 elements identified (cont.)• Control of inspection, measuring, test equipment• Inspection, test status• Control, non-conforming product• Corrective, preventive action• Handle, storage, packaging, delivery preservation• Control of quality records• Internal quality audits• Training• Servicing• Statistical techniques
ISO Requirements, Focus, Foundations
20 elements identified• Management responsibility• Quality system• Contract review• Design control• Document, data control• Purchasing• Control of customer supplied product• Product identification, traceability• Process control• Inspection, testing
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TS 16949 simplifies the previous 20 ISO elements:• Quality management system: relationships, sequences
for all functions• Management responsibility: demonstrable indications
of top management commitment• Resource management: assuring that resources are
available to fulfill commitments• Product realization: understanding quality objectives
in product• Measurement, analysis and improvement: data-based
measures are used to improve
ISO Requirements, Focus, FoundationsFour levels of quality documentation…….• First level, quality manual, policies and objectives• Second level is Process descriptions, flowcharts• Third level, work instructions, step by step SOPs• Fourth, lowest level, charting form and records
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Environmental 14000 standard environmental performance:• General requirements: requires system compliant, 14000• Environmental policy: top management led
environmental policy and commitment• Planning: procedures assure environmental actions• Implementation and operation: environmental
management procedures, clearly documented• Management review: management’s scheduled
evaluations of systems, for improvement
ISO Requirements, Focus, Foundations
ISO/QS 9000, increasingly becoming base• Key management system, umbrella, all quality systems• Systems built on data, documentation as base to improve• Duplicative systems, sub systems can be eliminated• Many quality methods will come, go, brief buzz words• ISO/QS systems have lasting value, mature base for total
management, here to stay enabling all quality methods
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OPCP RepresentsBest, Correct
Processes
ImprovementRequires Process
Knowledge
OPCP Based OnOther DetailedDocumentation
OPCP BecomesProcessing
Report Summary
Ongoing Improvement
Characteristics Assessed
Broad Team
Cooperation,Communication
Teaching, Learning
Change Oriented
OPCP procedural applications, functions, key ISO document based on strong team work, data derived in production, flow charts,SOP’s, facility and process layouts, and others.
Lean, Six Sigma, ISO Relationships
SOP’s, Flow Charts
Processes, FacilitiesModified
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Best Practices
Establishes Benchmarks
Support Documentation
Procedural Summary
SOP As A Standard, Quality System Base.
Customer Demands Facilitated By Teams For Cooperative Improvement And Controlled Change
Lean, Six Sigma, ISO Relationships
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Part Name: Process Location: OPCP Form Of
Supplier: Revision:
Other Pertinent General Information:
Process Description
Tools ForManufacturing
ProcessParameters
Product Characteristics
Class Product/Process Specification
Ongoing Process Control Plan (OPCP 1)……….• Process description: diagrams, flow charts, relationships• Tools for manufacturing: equipment explanation• Process parameters: issues, limitations on process • Product characteristics: dimension, attribute, descriptor• Class: a specific customer code, characteristic criticality• Specification: technical indicator of characteristic
Who provides information, how communicated?Who maintains, what is the OPCP system?
Lean, Six Sigma, ISO Relationships
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Part Name: Process Location: OPCP Form Of
Supplier: Revision:
Other Pertinent General Information:
EvaluationMethod
Sample Size,Freq. of Inspection
AnalysisMethod
Reaction Program
Ongoing Process Control Plan (OPCP 2)………..• Evaluation method: how, what assessed, measurement? • Sample size, frequency of inspection: data gathered?• Analysis method: statistical tools used, applied?• Reaction program: corrective actions, steps taken
How is format modified for various environments?What does OPCP look like in non-manufacturing?What categories do not fit, others needed?
Lean, Six Sigma, ISO Relationships
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Operation: Location:
Operator (s)
Team Members: Part/Service:
Other Pertinent Information: # Of Pieces
Shift:
General Operation Information Potential Waste Reductions/Analysis
Process Symbol Step Operation Procedure Time Other
Standard Operating Procedure Analysis (SOGA)• Process symbol: line drawn through symbols describes • Step: sequence in process• Operation procedure: description of process step• Time: amount of time allocated to step• Other: important related information to clarify
Lean, Six Sigma, ISO Relationships
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Study The Job Or Work Area To Be Analyzed
Use SOP's, Flow Charts, Layouts
Involve Operator In Positive Ways, Self Conducted
Involve Supervisor
Best Case-- Supervisor Conducts
Some Operators May Work In Non Normal Ways
Use Stop Watch Or Electronic Method, Device
Record Data On Form For Further Analysis
Use Continual Or Element Analysis
Determine, Compare, With Standards
Improvement Through Time Study And Methods Analysis
Time Study, Work Methods, Approach.
Time, Method, Work, Facility, Flow
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Storage
TransportationDelay
StorageInspection
Operation
Flow Chart Example.
Cut to size by supplier
Drill hole
Inspection
Delay for assembly
Screws Gather components for assembly
Secure cover
Insert pegs and marbles
Attach felt pads
Marbles/pegs
Felt pads
Labels Attach label to block
Inspect assembly
Packaging
Fold label and staple
Labels/stapler
Inspection
Store
Distribution
Delay
Inspection
Apply finish
Dust removal
Sand entire body
Sand sides
Drill holes
Saw divisions
Drill pilot hole
Drill peg holes
Cut to length
Raw stock
Time, Method, Work, Facility, Flow
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Use The Shortest Path Between Points
Consider The Safe Work Methods First
Avoid Dead Head Trips
Use Sequential Logic And Steps, Order
Use Machines Compatible With People
Combine Easy And Difficult Steps, Tasks
Avoid Fatiguing And Hazardous Steps, Tasks
Analyze Each Step Against The Big Picture
The Workplace Should Be Accessible
Eliminate, Simplify, Combine Tasks
Consider Curved Work Patterns Versus Straight
Maintain Body Balance, Start, Stop Motions
Use Consistent Locations For Tools, Materials
Build Planning Into Steps, Use Opportunities
Detail All Activities, Step By Step
Do Not Use Hands As Fixtures
Work Methods Analysis Pointers.
Time, Method, Work, Facility, Flow
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Materials And Storage
Marking Table
Band Saw
Packaging And Storage Area
Painting/ Finishing
Tool Rack
Pneumatic Sander
Disc Sander
Router
Prep/Sand Table
Chop Saw
Rollers RollersBathroom
Lounge/General Offices
5 101Feet
Facility Layout Example.
Planer
Time, Method, Work, Facility, Flow
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Process 1
Process 2 Process 3
Process 4
Intermittent Or Job-lot Production.
Process 1
Process 2 Process 3
Process 4
Continuous Production.
Time, Method, Work, Facility, Flow
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Understand, use, study process documention •Customer demands, knowledge, significant •Characteristics, essential process knowledge •Waste surfaces as we analyze variation•Change, maintain, protect process information•Operators, supervisors, key knowledge base•Grow teams, share knowledge, opportunities
Understanding, knowledge, growth = control• Team driven, point of production• Data, documentation, sampling reliable?• Production capacity must be understood• Capacity points to balance, waste• Must identify and understand best, correct,
methods and procedures
Time, Method, Work, Facility, Flow
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CharacteristicsAnd StandardsIdentification,
Evaluation
Standard Deviation, SPC DataCollected
Documentation,Process Control
By OperatorsUsing SOP
Brainstorming For
Corrective Action
OngoingImprovement
In Teams
Basic Relationships In Data, SPC, Teams, Documentation, Improvement, Basis For Launch
Data is base for team problem solving, from start• Prevention, not detection, built in early communications• Knowledge based to modify, adjust, correct, clearly show• Discipline, uniformity decreases nonconformance, scrap• Fewer samples, inspection costs, waste reduced over time• Measure of capability, ability to perform as stated• Enables data based decisions, problem solving
Characteristics Assessed, Variation Reduction
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Purpose OfThe Chart?
Chart Relation To Documentation?
Sample Size?Characteristic? Why? How?
Where Is Inspection?
Broad Charting Relationships For Data, Analysis, Improvement Systems
Charting? New Characteristic?
Sample Freq,Consistency?
InformationOn The Chart?
Judge Defects And Defectives?
Data Recorded Accurately?
Forms, Done Properly?
Points Plotted, Analyzed?
Charts Compared Over Time?
Discipline To Follow Up?
In Control Over Time?
Review OfCharacteristics?
Information Provided Teams?
Improvement,Shifts In Charts
Relationship ToVariable Charts?
Training In Place?
What Type Chart?
Start Short Run, Pre-Control
Start With Attribute
Inspection As Part Of SOP?
Characteristics Assessed, Variation Reduction
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Capability analysis applied to startup, launch• SPC charting, problem solving, key measure for teams• Transfer from other programs, products, processes• On-going method, evaluating, improving from start• Represents performance of process itself, baseline
Procedures covered in data-based tools, summarized here • Calculate mean, ranges, estimated standard deviation • Provide upper and lower spec limits, calculate Cp, Cpk
Cp, Cpk, actual data collected, relative to 1, normal curve• Cp, upper and lower spec limits, tolerance width……• Cp, divided by process capability, six sigma• Cpk, process centering, total spread relative to center• Cpk relationship in mean, specification, process data
Characteristics Assessed, Variation Reduction
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Attributes Defined
Variables Defined
Characteristic Evaluation, Charting Evolution, Process Improvement And Phase Out System.
Checklists Or Checksheets For Tracking
NonconformitiesDesireable Features
Characteristics
Defectives
Defects Judgement Calls
Discrete Data
Specifications
Dimensions, Tolerances
Collected, Charted, Data
P Charts
X Bar And R
Begin With Short Run, Characteristic Evaluation, Teams Learning, Growing
Eventually Phase Out, Move To Different Characteristic, Product
Over Time, It Is Assumed That Process Will Come And Remain Under Control
Characteristics Assessed, Variation Reduction
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Evaluating quality characteristics is disciplined, systematic:• Characteristics eventually under control, review ongoing • Lose $, tracking unecessarily, as SPC shows, shift efforts• Customers involved, SPC attribute, variable data key• Detailed internal, external evaluation, benchmarking• Enhances communication, decision-making
Characteristics Assessed, Variation Reduction
Disciplined systems demonstrate process stability:• Process control demonstrates maturity, capacity • SPC, Cpk, effective links to capacity plans, layouts • Customers require assurances of ability, capability• Potential customers can be even more skeptical• Effective communication, decision-making………• Must have demonstrable data, documentation
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Tool Applications…….
Tool 19 applications are:• OPCP, introduced, continuously built, not just at start• SOGA also introduced, built gradually, evolved• Documentation System Design, Communication, DSDC• ISOQSAOPP, designed to help set a plan for team• GOTA, vacabulary, glossary of terms• All follow through, do and post, independently
Toolkit applications are a key part of the courseware• Located in separate folder of the CD• Provides the template for team portfolio• Each application s part of team project, portfolio• Designed to be done by all, each team member• First read long form, then short review, applications• Total contribution in application form is compiled• Portfolio is gradually evolved around applications
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Tool Applications…….
Part Name: Process Location: OPCP Form Of
Supplier: Revision:
Other Pertinent General Information:
Process Description. Provide a written description of process in text format and a process flow chart depicting the same:
Tools For Manufacture/Production. Describe equipment required to produce the product, consistent with the flow chart above:
Process Parameters. Describe unique elements involved in processing the product which require additional explanation:
Product Characteristics. Describe all characteristics of the product, primarily as attributes or variables which are critical:
Class. Describe any codes or other unique identifiers per the specific industry or organization to help further distinguish the product:
Product/Process Specification. Provide specific measurable definitions for each product characteristic identified above:
Evaluation Method. Describe how specifications of characteristics are evaluated, what the measurement systems are:
Sample Size, Frequency of Inspection. Describe the sample, how it is derived, including devices used to inspect in a step by step manner:
Analysis Methods. Describe the methods and systems used to analyze the sampled data, such as statistical, experimental, and so on:
Reaction Program. Describe steps to be taken when product or process is found to be functioning inappropriately:
Ongoing Process Control Plan (OPCP)• Continuously built over entire course• Gradually evolved based on team, project growth • Becomes key part of team project, portfolio• Key ISO technical document for improvement• Partial form shown below, gradually addressed……..
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Operation: Location:
Operator (s)
Team Members: Part/Service:
Other Pertinent Information: # Of Pieces
Shift:
General Operation Information Potential Waste Reductions/Analysis
Process Symbol Step Operation Procedure Time Other
Standard Operating Procedure Analysis (SOGA)• Process symbol: eliminate unused symbols, each step • Step: sequence in process• Operation procedure: description of process step• Time: amount of time allocated to step• Other: important related information to clarify• Built over time like OPCP• Main part of team project, portfolio
Tool Applications…….
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Tool Applications…….Glossary Of Terms, Applications (GOTA)• Continuously added to over entire course, by all• Helps enhance vocabulary, get all on same page• Terms are in toolkit, various parts, not just this course• A sampling of the form (partial) is shown……..
Provide A Definition For Each Term Identified, Explain How Your Team Will Apply The Concepts, Principles To Your Project:
Ongoing Process Control Plan:
Corrective Action System:
QFD:
Pareto Analysis:
Statistical Process Control:
Variable Measurement, Charting:
Attribute Measurement, Charting:
Capability:
Mean, Range:
Gage Repeatability & Reproducibility:
Normal Curve:
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Tool Applications…….ISO/QS Audit, Objective Prioritization Plan (ISOQSAOPP)• Preliminary plan, setup of assessments, work for team• Familiarize with ISO, auditing, all on same page, terms• Strategic planning, team level, change and improvement• Project 50% done when “problem” nailed down• “hot spots” focus, project objectives, gradually PPDPOA• Gantt from SDA form or template, for time, sequence• Partial form is shown……..
Organization Under Discussion: Current Operation: Location:
General Description Of Operations/Production Functions/Systems Being Assessed As An Internal Audit:
ISO/QS Element (TS 16949 2002—Others) Technical Function Description Audit Preliminary Information Actions, Recommendations For Change
(list each element separately for analysis/audit)
(describe technical function being audited) (How does function compare to standard) (explain anticipated necessary actions, changes)
Planning Statement Or Issue, Particularly As Associated With The Service Environment: Criticality Level: HML (H = 5; M = 3; L = 1)
Fac = Facility issues; Cost = Cost issues; Time = Time issues; Pers = Personnel issues
Objectives Prioritized, 5 Being Highest: Criticality HML
Fac Cost Time Pers
5, 4, 3, 2, 1
Problem Background: Resources? (Budget/Other Concerns)?
Task/Deliverable/Objective: Who Will Do? How Measured?
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Tool Applications…….
Documentation System Design, Communication (DSDC)• Initial design, plan for how the team will work• Given that all work is about communications…….• Documentation is blackboard is critical• Must consider initially how this will happen, DSDC• DSDC provides opportunity to reflect on, discuss
Researcher Communication Method, Internal And External Customers:
Toolkit/Blackboard Design Element, How Does It Work?
How To Improve Professional Relationships, Communication?
1. 1. 1. 1.
Identify How The Systems’ Design You Are Advocating Can Assist IN Tieing Together PPDPOA, TPMSS, FACR, TRIRPA And Other Elements Of Team Problem Solving And Improvement:
Explain ISO/QS Characteristics And Other Necessary Entities To Be Possessed By Documentation And Communication Systems, Categorically, Particularly Focused On Service Functions:
Using The Template At The End Of The Applications Complete A Cause And Effect Diagram Indicating Issues And Opportunities For Systemic Documentation Relationships/Improvements, Particularly Focused On Service Functions:
Identify And Explain Why Your Organization Is Well Suited To The Documentation And Communication System Being Developed, Particularly Focused On Service Functions: