A

PAPER ON

PRESENTED BY
1.KARBHARI PRAMOD P.
(Third year Mech. Eng.)

ON
DEPARTMENT OF MECHANICAL ,

NANASAHEB MAHADIK COLLEGE OF ENGG. , PETH

 Contents
 TQM

 Gurus of TQM

 Kaizen

 Six Sigma

 5’S Housekeeping

 Kanban

 Conclusion

 References
 INTRODUCTION TO TQM

 Total Quality Management is an approach to improving the effectiveness and flexibility of

the business as a whole .
 Total Quality Management is the dynamic concept.

Total - Made up of the whole

Quality - Degree of Excellence a Product or Service provides.

Management - Art of handling, controlling, directing etc.

 GURUS OF TQM

SHEWHART - 1) Control chart theory, 2) PDCA Cycle

DEMING - 1)Statistical Process Control

JURAN - 1) Concepts of SHEWHART, 2) Return on Investment ( ROI )

FEIGANBAUM - 1) Total Quality Control, 2) Management involvement

- 3)Employee involvement , 4) Company wide quality control

ISHIKAWA - 1) Cause and Effect Diagram, 2)Quality Circle concept

CROSBY - 1) “Quality is Free” , 2)Conformance to requirements

TAGUCHI - 1) Loss Function concept , 2)Design of Experiments

 KAIZEN

KAIZEN is Japanese word KAI and ZEN. KAI means change and ZEN means better.
KAIZEN means change for better.

Kaizen involves removal of 3MUs at different check points, which helps in reducing waste
and losses.

Japanese MUs are :-

1. Muda – means waste.

2. Muri – means strain.

3. Mura – means discrepancy.

Principle for successful implementation of kaizen :-

1. Team work

2. Poor-man approach

3. Creative thinking

4. Intelligent tools and techniques

5. Employee training

6. Encourage employees
 Example of Kaizen

 Toyota sought ways to increase the loading capacity of transporter trucks by modification
of their deck design.
 A double-deck transporter conventionally just carried three Land Cruiser Prado models on
the upper deck.
 In an improvement action, the hollow square pipes for the lower-deck side frame member
were replaced with band plates to gain space so that a truck could always carry four Prado
models at a time, resulting in an average of 3.7 vehicles per trip.
 Six Sigma
Six sigma is a quality improvement programme with goal to reduce the number
of defects to as low as 3.4 parts per million.

Six Sigma stands for Six Standard Deviations (Sigma is the Greek letter used to
represent standard deviation in statistics)from mean. Six Sigma methodology provides the
techniques and tools to improve the capability and reduce the defects in any process.

Implementation of 6 σ :-

1. Focus on the customers

2. Focus on process

3. Proactive management

4. Smash the barriers

Statistical background:-
EXAMPLE:-

One of the most recognized example Of Six Sigma is “THE MUMBAICHA DEBEWALA”
 5-S : HOUSEKEEPING

 5S is a methodology which helps us to better organise our workplace in order to improve

safety and productivity.

 5-S Means everything in its place.

 5S comes from Japanese but is typically translated to English as:

1. Seiri - Sorting

2. Seiton - Set or Straighten

3. Seiso - Shine

4. Seiketsu - Standardise

5. Shitsuke - Sustain/Discipline
 Meaning of 5S

IMPLEMENTING 5S
Sort out of process area
– get rid of unused NEEDED HOW TO STORE?
ref.nr
eliminate
once a year
materials & tools. Use stow away
published (date)

once 2-6 months

of Red Tags once a month
once a week
move to storage analysis target

made by
once a day store in work cell
every hour
ready (date)

1.
Sort
Everyone plays a part to
make sure the changes stick.
Keeping to the new rules 5. ID locations for tools and
and standards through 2.
Sustain materials used in the process.
regular audits. Awards can Straighten
Set min / max limits
be given for best practice at 5S
each audit.

4. 3.
Standardize Shine

Use of new standard Regular cleaning and

as basis for inspection of the
inspections and process by the process
audits. operators
 IMPLEMENTING 5-S

1. Top Management resolve and training.

2. Establishing priorities and targets.

3. Major cleaning.

4. Establishing improvement plans in each priority area.

5. Verifying results.

6. Standardizing.
 KANBAN

Kanban stands for Kan - card, Ban- signal. The essence of the Kanban
concept is that a supplier, the warehouse or manufacturing should only deliver components as
and when they are needed, so that there is no excess Inventory.

A B C
Component Production Finished Pick, Pack
Storage Line Goods Storage & Ship

Move Production Pack

Kanban Kanban List

KANBAN

MATERIAL FLOW
 HISTORY OF KANBAN

 The original idea for kanban came from supermarkets. The customer essentially
selects what he or she wants, when necessary in the quantity desired.

 Kanban is a tool to achieve Just-In-Time production, that is, to supply the right parts,
at the right time, in the right amount.
 CONCLUSION

 Total Quality Management is continuously Improving process.

 TQM become basic necessity of Business for quality as well as economical

growth.

 For better improvement in production KAIZEN is more suitable.

 For zero % defect SIX SIGMA is more suitable.

 For comfortable working environment follow the 5’S HOUSEKEEPING.

 To reduce wastage of material KANBAN system is useful.

 REFERANCES

 Industrial Engineering And Production Management By - Martand Telsang,

 Industrial Engineering And Management By - O.P. Khanna,

 Management By - Anil Bhat & Arya Kumar.

 Statistical Quality Control By- M. Mahajan.

 Modern Productivity/Operation Management By - Elwood S. Buffa & Rakesh K. Sarin.

 A Technical Paper On TQM By - A .John Martin.

 A Technical Paper By - ABB Basic Quality Tools Series

 www. wikipedia.com
Any Questions ?