Beruflich Dokumente
Kultur Dokumente
Achieve Perfection
Work as Process to make it Effective, Efficient, and Adaptable
Changing Customer Needs
Control in process-Reduce Scrap, Time, Idle of Resources
Eliminate Non Conformance in All Phases
Bench Marking
Innovation
Statistical Tools, QFD,FMEA. Taguchi Loss Function
1
Types of Problems
• Compliance
• Unstructured
• Efficiency
• Process Design
• Product Design
2
Shewhart’s PDSA CYCLE
in 1930
• PLAN
• DO
• STUDY ACT PLAN
• ACT
STUDY
DO
3
Continuous Process Improvement
Phase 1 Identify the
Cycle
opportunity
PLAN
Plan a change to the process. Predict the
effect this change will have and plan how
the effects will be measured
ACT DO
Adopt the change as a Implement the change on
permanent modification a small scale and measure
to the process, or the effects
abandon it.
CHECK
Study the results to
learn what effect the
6
change had, if any.
Kaoru Ishikawa has expanded Deming's
four steps into six:
Determine goals and targets.
Determine methods of reaching goals.
Engage in education and training.
Implement work.
Check the effects of implementation.
Take appropriate action.
7
Juran's Trilogy
Juran's Trilogy is
possibly the most simple,
complete, and pure
representation of
managing for Quality
ever devised. The trilogy
exemplifies the essence of
Quality. It completely
meets its objective in the
most efficient and 8
effective manner possible
Juran's Trilogy
Quality Planning
Identify the Customers
Determine the customer’ needs
Develop a process
Prove process capability
9
Juran's Trilogy
Quality Control
Choose control Subjects (What to Control)
Choose Units of measurements
Establish Measurement
Establish Standards of performance
Measure actual performance
Interpret the difference
Take action on the difference
10
Juran's Trilogy
Quality Improvement
Prove need for improvement
Identify specific projects for Improvements
Organize to guide & Diagnosis
To find causes
Provide Remedies
Prove remedies for effective in operating conditions
Control the gains
11
JURAN’S QUALITY
TRIOLOGY
Quality
Quality Threshold
Cost Improvement
Planning Of Plan
of
Quality
Time 12
Juran’s Spiral of Progress in
Quality
Customers
Further Product
Development
Marketing Customers
Product
Operation
Development
13
Quality Improvement Strategies
• Repair
• Refinement
• Renovation
• Reinvention
14
KAI Change
ZEN Good
(for the better)
TOP Mgt
Innovation
Middle Mgt
EN
I Z
KA
Supervisors
Maintenance Workers
17
Japanese Vs Western Approach
KAIZEN INNOVATION
JAPAN Strong Weak
WEST Weak Strong
18
Kaizen Implementation
• Discard Conventional ideas
• Think in Positive Manner
• Do not make excuses but question Current
Practice
• Correct Mistakes at once
• Problem Solving & Find Root Causes
• Team Work To achieve MAXIMUM
• Meeting of Kaizen group once in Month
19
TOTAL MANUFACTURING CHAIN
INNOVATION KAIZEN
20
Comparison of INNOVATION &
KAIZEN
INNOVATION KAIZEN
Creavitivity Adaptability
Individualism Team Work
Technology People- oriented
Information- Closed Information-Open
Seeks New Technology Builds on Existing
Technology
Limited Feedback Comprehensive Feedback
21
3-MU’s Checklist of Kaizen
Activities
Muda (Waste) Muri (Strain) Mura (Discrepancy)
Man Power Man Power Man Power
Technique Technique Technique
Method Method Method
Time Time Time
Materials Materials Materials
Inventory Inventory Inventory
Way of Way of ThinkingWay of Thinking
Thinking
22
• In an Organization, Kaizen activities will be
carried out by asking the Questions-Who,
Where, When, Why, and How
• Eg-Who does it?
What to do?
Where to do it?
When to do it?
Why to do it?
How to do it?
23
5S
24
HOUSE KEEPING_5-S MODEL
3 rd Class Work Place
?
Never Always
Clean Clean
25
Ultimate Goal Better Tomorrow for Everyone
J T
Approach T T
I Q
& Method P Q
T C
M M
Foundation 5S
28
29
SEI-TON = ORGANIZING
30
31
SEI-SO= CLEANING
32
33
SEI-KE-TSU=Personal Cleanliness
34
SHI-TSU-KE =Self Discipline
• Not only Job Related but also Personally it is
important.
• Job Discipline is the habit of Skill Development
to do work as per Standards.
• Observe Rules & Policies of the Company
35
36
O U
Y
N K
H A
T
37