Beruflich Dokumente
Kultur Dokumente
Index
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Meaning of Quality Best practices in manufacturing Industries Lean Manufacturing 5S Six Sigma Kaizen
Meaning Of Quality
1. 2.
Quality can be defined as the degree of excellence of any thing. According to American society for Quality:-totality of features and characteristics that satisfy needs Ex:-
Meaning of Quality
Producers Perspective
Consumers Perspective
Quality Management
Basic Practises:
exploitation of mineral resources (coal, oil, gas)
processing highly specialized capital goods production such as turbines process-oriented production such as chemicals discrete consumables such as cars.
processes
acceptability) into the system so as to put it close to the possible source of any problems
Identify & Correct problem processes Develop (and nurture) highly reliable product sources and suppliers As quality improves reduce quality inspections!!!
Check sheets: used to gather information on problem under investigation where and how much Pareto Diagram the so called 80-20 chart used to identify the vital few that cause the most problems helps to focus the improvement studies Histogram shows stratification in production
Continued
Flow Charts describes, visually, the process
under study. Allows teams to focus on problem areas and structural issues Cause-and-effect diagrams also called fishbone diagrams relates relationships between various factors influencing the problem under study. Control Chart charts of SPC to that assess status of the problem under study.
LEAN MANUFACTURING
Lean Manufacturing
"Lean," is a production practice that considers the expenditure of
resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination. Lean manufacturing is derived from Toyota Production System (TPS) Hence known as Toyotism. Termed as Lean in 1990. It has been applied in many sectors such as Engineering, Call center, manufacturing, services etc.
Types Of Lean
There are two types of Lean: Just in Time(JIT) or Flow Aut0mation" (smart automation)
Over processing
Motion Transportation
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7. 8.
Get everyone Involved Get Company Authorization Final Responsibilities Rests with President Make yourself Understood and Aware of. Do It All The Way. The President should Inspect The GEMBA personally Do nt Stop Halfway while implementing 5S 5S is Halfway towards other Improvement
Basics
A new way of doing business
Wise application of statistical tools within a
structured methodology Repeated application of strategy to individual projects Projects selected that will have a substantial impact on the bottom line
reviewing, updating and re-tuning the existing process. Six Sigma improves the process performance, decreases variation and maintains consistent quality of the process output. This leads to defect reduction and improvement in profits, employee morale, product quality and finally customer satisfaction. Six Sigma Strives for perfection. It allows for only 3.4 defects per million opportunities for each product or service transaction. Six Sigma relies heavily on statistical techniques to reduce defects and measure quality.
Six Sigma
Practical: Emphasis on financial result. Start with the voice of the customer.
Japan has been credited with the evolvement of Quality Systems like TQM, Kanban, Kaizen, etc. Pioneered in the U.S. by Bill Smith at Motorola in 1986; Early adopters include Bank of America, Caterpillar, Honeywell International (previously known as Allied Signal), Raytheon, Merrill Lynch and General Electric. Six Sigma was originally centered around manufacturing improvements. The reason for this was knowledge of the statistical tools in the manufacturing functions and the ease with which we can quantify the benefits.
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deviation from the normal or average. The higher the sigma level the better the quality level. Levels of Sigma Performance
1. As a Metric
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The term Sigma is often used as a scale for levels of "goodness" or quality. Equates to 3.4 defects per one million opportunities . Six Sigma started as a defect reduction effort in manufacturing and was then applied to other business processes for the same purpose.
2. As a Methodology
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Understanding and managing customer requirements Aligning key business processes to achieve those requirements Utilizing rigorous data analysis to minimize variation in those processes Driving rapid and sustainable improvement to business processes
called DMAIC which is a continuous process as the diagram shows until the highest level in the Six Sigma is achieved, i.e., 3.4 defects per million.
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What Is Six Sigma?
99.99966%
3.4 29
General Electric
In 1995 GE mandated each employee to work towards achieving 6 sigma The average process at GE was 3 sigma in 1995 In 1997 the average reached 3.5 sigma GEs goal was to reach 6 sigma by 2001 Investments in 6 sigma training and projects reached 45M US$ in 1998, profits increased by 1.2B US$
MOTOROLA
At Motorola we use statistical methods daily throughout all of our disciplines to synthesize an abundance of data to derive concrete actions. How has the use of statistical methods within Motorola Six Sigma initiative, across disciplines, contributed to our growth? Over the past decade we have reduced in-process defects by over 300 fold, which has resulted in cumulative manufacturing cost savings of over 11 billion Robert W. Galvin dollars*.
Nutan Mumbai Tiffin Box Suppliers Charity Trust Gangaram Talekar, a tiffin carrier contractor . The New York Times reported in 2007 that the 125 year old dabbawala industry continues to grow at a rate of 510% per year. In its July 11, 2008 issue, The Economist news magazine reported that dabbawallas are a model of Six Sigma management, holding a delivery accuracy rate of 99.9999%.
Barriers to implementation
Barrier #1: Engineers and managers are not interested in mathematical statistics
Barrier #2: Statisticians have problems communicating with managers and engineers Barrier #3: Non-statisticians experience statistical anxiety which has to be minimized before learning can take place Barrier # 4: Statistical methods need to be matched to management style and organizational culture
Reality
Six Sigma through the correct application of
statistical tools can reap a company enormous rewards that will have a positive effect for years or Six Sigma can be a dismal failure if not used correctly ISRU, CAMT and Sauer Danfoss will ensure the former occurs
Strong leadership (Jack Welch, Larry Bossidy and Bob Galvin personally involved) Initial focus on operations Aggressive project selection (potential savings in cost of poor quality > $50,000/year) Training the right people
KAIZEN- Background
Masaaki Imai is
'good'
What is KAIZAN?
So basically kaizen is small incremental changes made for
Consider the process and the results! The need to look at the entire process of the job at hand and to evaluate the job as to the best way to get the job done. Kaizen must be approached in such a way that no one is blamed and that the best process is put into place.
5S is a method for organizing a workplace, especially a shared workplace (like a shop floor or an office space), and keeping it organized.
To take the concept of Kaizen performance to its ultimate level of simplicity, it offered the following "5S" steps
Sorting
Simplifying Sweeping Standardizing
keeping only essential item eliminates extra motion. keep the workplace clean standardized work practices
Sustaining
FEATURES OF KAIZEN
Widely applicable Can be used in both manufacturing and non-
manufacturing environments
quick results, Measurable results, Establish the baseline, and measure the change!!!
A Learning Experience Every member of a Kaizen Team will
Team based & cross functional Team members can be from various functions of the business. Top management participation is encouraged.
STEPS INVOLVED:
BENEFITS OF KAIZAN
Kaizen Reduces Waste-
like inventory waste, time waste, workers motion Kaizen Improves space utilization, product quality Results in higher employee moral and job satisfaction, and lower turn-over.
Toyota is well-known as one of the leaders in using Kaizen. In 1999 at one U.S. plant, 7,000 Toyota employees submitted over 75,000 suggestions, of which 99% were implemented.
procedure to implement
Too much suggestion