tqm_continuous process improvement

7/29/2019 TQM_Continuous Process Improvement

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Continuous Process

Improvement

Unit V


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Vision of CPI

The Macro Vision

Macro refers to the executive level

of the institution.

The Micro Vision

Micro refers to all of the managers,

faculty, and staff.


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Systems Principles - Systems Thinking

INPUTS PROCESSES OUTPUTS CUSTOMERS

EXTERNAL

INTERNAL

MEASURES OF PERFORMANCE

TIME; QUANTITY, QUALITY (Accuracy/ Fir for Use); COST; MANNER OF PERFORMANCE

Products

&

Services

Critical ProcessNecessary to

Produce the

Outputs

METHODS

ENVIRONMENT

PERSON

POWER

FACILITIES

&

EQUIPMENT

SUPPLIES

A Contemporary Systems View


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Some important definitions

1. Input: May be material, money, information, data, etc.

2. Output: May be information, products, service, etc.

3. Process: It is the interaction of some combination of

people, materials, equipment, method, measurement and

the environment to produce an outcome such as product,

service or an input to another person.


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Reduce Resources

Reduce Errors

Meet or exceed expectations Make the process safer

Make the process more satisfying to the

person doing it

5 Basic Ways to Define Improvement


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Methods to improve process

1. Jurans Triology (Planning /

Control/Improvement)

2. The PDCA/ PDSA cycle


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PLAN

DOSTUDY

ACT

Continuous Process Improvement Cycle

Phase 1 Identify the

opportunity

Phase 2 Analyze the

Process

Phase 3 Develop the

Optimal Solution

Phase 4

ImplementationPhase 5 Study the

Results

Phase 6 Standardize

the Solution

Phase 7Plan for the

Future


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4 primary Improvement Strategies

Repair

Refinement

Renovation Reinvention

All employee have the freedom to

solve problem

Break through improvements


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5 Types of problems associated

Compliance

Occurs when a structured system having

standardized inputs, processes and output is

performing unacceptably from the users

viewpoint.

Unstructured

It is similar to compliance except that they

are not specified by standards.


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5 Types of problems associated

Efficiency

When the system is performing unacceptably

form the viewpoint of the owner or the operator

Process Design

Poor design of the process of formation of the

components

Product Design

Poor product design


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Kaizen- The Japanese Word

Kaizen is a Japanese word for the philosophy

that defines managements role in

continuously encouraging and implementing

small improvements involving everyone.

It is the process of continuous improvement in

small increments that make the process more

efficient, effective, under control andadaptable.


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Kaizen- The Japanese Word

Improvements are usually accomplished at

little or no expense without sophisticated

techniques or expensive equipment.

It focuses on simplification by breaking down

complex processes into their sub-processes

and then improving them.


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Kaizen Improvement focuses on

Value added and non-valued added workactivities

MUDA, which refers to the seven classification ofwaste: Over production

Delay

Transportation

Processing

Inventory

Wasted motion

Defective parts


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Why are these classified as wastes?

Transportation

Each time a product is moved it stands the risk of being damaged, lost, delayed, etc. as

well as being a cost for no added value. Transportation does not make any

transformation to the product that the consumer is willing to pay for.

Inventory

Inventory, be it in the form of raw materials, work-in-progress (WIP), or finished

goods, represents a capital outlay that has not yet produced an income either by the

producer or for the consumer. Any of these three items not being actively processed to

add value is waste.


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Motion

In contrast to transportation, which refers to damage to products and transaction costs associated with

moving them, motion refers to the damage that the production process inflicts on the entity that creates

the product, either over time (wear and tear for equipment and repetitive stress injuries for workers) or

during discrete events (accidents that damage equipment and/or injure workers).

Waiting/Delay

Whenever goods are not in transport or being processed, they are waiting. In traditional processes, a large

part of an individual product's life is spent waiting to be worked on.

Over-processing

Over-processing occurs any time more work is done on a piece than what is required by the customer.

This also includes using tools that are more precise, complex, or expensive than absolutely required.


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Over-production

Overproduction occurs when more product is produced than is required at that time by your

customers. One common practice that leads to this muda is the production of large batches, as

often consumer needs change over the long times large batches require. Overproduction is

considered the worst muda because it hides and/or generates all the others. Overproduction leads

to excess inventory, which then requires the expenditure of resources on storage space and

preservation, activities that do not benefit the customer.

Defects

Whenever defects occur, extra costs are incurred reworking the part, rescheduling production, etc.

This results in labor costs, more time in the "Work-in-progress". Defects in practice can

sometimes double the cost of one single product. This should not be passed on to the consumer

and should be taken as a loss.


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Principles of motion study and the use of cell

technology

Principles of material handling and the use of

one piece flow

Documentation of standard operating system


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The 5S

Seiko (Proper arrangement)

Seiton (orderliness)

Seiketso (Personal Cleanliness)

Seiso (Clean up)

Shitsuke (Discipline)


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Visual management by means of visual

displays that everyone in the plant can use for

better communications.

Just in Time principles to produce only the

units in the right quantities at the right time

and with the right resources


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POKA YOKE to prevent or detect errors

Poka-yoke is a Japanese term that means"fail-safing" or "mistake-proofing".

A poka-yoke is any mechanism in a leanmanufacturing process that helps an equipmentoperator avoid (yokeru) mistakes (poka).

Its purpose is to eliminate product defectsby preventing, correcting, or drawing attention tohuman errors as they occur.


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Team Dynamics which includes problem

solving, communication skills and conflict

resolution.


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Re-engineering

It is the fundamental rethinking and radical

redesign of business processes to achieve

dramatic improvements in critical measures of

performance.


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Six Sigma

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