TQM, 5S, KAIZEN, JIT, KANBAN, POKA YOKE

PRESENTATION ON

DEPARTMENT OF MECHANICAL ENGINEERING AMRUTVAHINI COLLEGE OF ENGINEERING, SANGAMNER 2011-2012

TOTAL QUALITY MANAGEMENT (TQM)

Total : Made up of whole Quality : Degree of excellence Management : Act of handling, controlling, directing, staffing an organisation. Maximum user satisfaction at minimum cost TQM is both a philosophy and a set of guiding principles that represent the foundation of a continuously improving organisation. Quality is determined by the combined efforts of various departments such as design, process planning, engineering, purchase, production and inspection. The golden rule of TQM Do unto others as you would have do unto you.

TOTAL QUALITY MANAGEMENT (TQM)

TOTAL QUALITY MANAGEMENT (TQM)

ELEMENTS OR PILLARS OF TQM
1) 2) 3) 4) 5)

Top Managements commitment to quality Customer focus of the organisation Employee improvement and empowerment Training of employees Process focus and improvement

6)
7) 8)

9)
10) 11)

12)

Continuous improvement Measurement of performance Benchmarking Teams Inventory Management Communication Quality Costs

TOTAL QUALITY MANAGEMENT (TQM)

TOTAL QUALITY MANAGEMENT (TQM)

QUALITY ELEMENTS
1) 2) Definition Priorities Product oriented Second to service and cost

Prior To TQM

With TQM
Customer focused First to service and cost

3) 4) 5) 6) 7) 8)

Decisions Emphasis Errors Responsibility Problem Solving Procurement based on

Short term Detection Operation Quality control Managers Price

Long term Prevention System Every one Teams Life cycle cost, partnership

9)

Managers role

Plan, assign, control and enforce

Delegate, coach, facilitate and mentor

TOTAL QUALITY MANAGEMENT (TQM)

5-S
5 S is a technique that results in a well-organized workplace complete with visual controls and order. Developer- Iwao Kobayashi

Sort (SEIRI) : Clear unnecessary items from work area.

Straighten/Set in order (SEITON) : Organize work area in an orderly manner.

Shine (SEISO) : Clean work area. Standardize (SEIKESTU) : Maintain work area cleanliness. Sustain (SHITSUKE) : Maintain self-discipline in work area.

5-S

Theres no second chance to make the first impression

5-S

TOYOTA ASSEMBLING PLANT

5-S
OBJECTIVE

Increase the Storing places.

Create and preserve standards. Reduce unproductive times.

Readjust the location.

Reduce the document search time with 20%.

5-S

SORT (SEIRI)

SWEEP (SEISO)

5-S

STRAIGHTEN (SEITON): TOYOTA ENGINE ASSEMBLY LINE

5-S

SCHEDULE (SEIKESTU)

SUSTAIN (SHITSUKE)

5-S

5-S
BENEFITS OF IMPLEMENTATION

It reduced the idle time & fatigue to workers. Reduction of wastage of material Improvement in quality & Productivity Punctuality, commitment & discipline Improved effectiveness of employees Reduction in Non- Value-Added Activities Following cost gets decreasedRecord keeping & administrative cost Deterioration cost Handling cost

KAIZEN

KAI : Change ; ZEN : Better Changes for better or Continous Improvement Masaaki Imai developer of Kaizen Kaizen is a Japanese word for the phylosophy, that defines managements role in continously encouraging & implementing small improvement involving everyone. Kaizen makes the process more efficient , effective and adaptable. Kaizen focuses on simplication of complex process by breaking them down into their sub-process and then improving them

KAIZEN

MANUFACTURING OBJECTIVES

KAIZEN
Key Elements of Kaizen foundation of Kaizen
Team

Quality Effort Involvement of all employees Willingness to Change Communication

Work Personal Discipline Improved Morale Quality Circles Suggestions For Improvement

KAIZEN

JOB FUNCTIONS AS PERCIEVED BY JAPANESE MANAGERS

KAIZEN
KAIZEN IMPROVEMENT FOCUSES ON

Value added & non-value added work activities. Muda: wastes

1. 2. 3. 4. 5. 6. 7.

Over Production Delay Transportation Inventory Defective Parts Wasted Motion Processing

Principles of Material Handling

Documentation of standard operating procedures 5-S frame work Better Communication through visual displays- posters, bulletins. Just In Time Principles Poka Yoke : to prevent or detect errors Team Effort on Problem solving, conflict reduction & communication.

KAIZEN
KAIZEN : SMALL SUGGESTIONS
Work

Improvement Environment Improvement Process Improvement Machine capability Improvement Quality Improvement Customer Service Improvement

An example of a Kaizen type improvement would be the change in color of a welding booth from black to white to improve operators visibility

KAIZEN

JUST IN TIME (JIT)

JIT is manufacturing philosophy that produces necessary units, with the required quality, in the necessary quantities, at the last safe moment. Eliminates waste of time, labour and storage space. Its a pull system of production: actual orders provide a signal when to manufacture. Non-value-adding activities are removed for the purposes of : Reducing Cost Improving Quality Improving Performance Improving Delivery Adding Flexibility Increase innovativeness

JUST IN TIME (JIT)

JUST IN TIME (JIT)

Advantages of JIT Limitations of JIT

Reduction in storage space Less working capital Less likelihood of stock perishing Avoids the build up of unsold finished product

Little room for mistakes Production is very reliant on suppliers No spared finished product to meet the expected demand

KANBAN
KAN :

Card ; BAN : Signal Japanese term for "visual record Coined by : Taiichi Ohno Kanban card is A message that signals depletion of product , parts or inventory that when received will trigger replenishment of that product, part or inventory.
The Bernstein

identifies as a highly efficient and effective factory production system.

No.

of kanbans =

KANBAN

scanning bar codes and transmitting electronic orders.

POURS is an innovative Web-based solution that streamlines the process, training and support associated with inventory management.

POKA- YOKE

POKA mistake ; YOKERU Proofing Developer: Shigeo Shingo (1960)- The industrial engineers at Toyota.
Techniques that help operators avoid mistakes in their work caused by choosing the wrong part, leaving out a part, installing a part backwards, etc

It provides instant feedback and prevention of quality problems It is a tool that is

Mistake-proofing systems Does not rely on operators catching mistakes Inexpensive Point of Origin inspection Quick feedback 100% of the time

This tool can be applied to any process, be it in manufacturing or the service industry.

POKA- YOKE
Causes Of Defects
1. 2. 3.

Steps in applying Poka- Yoke

1.

4.
5.

Poor procedures or standards. Machines. Non-conforming material. Worn tooling. Human Mistakes. Except for human mistakes these conditions can be predicted and corrective action can be implemented to eliminate the cause of defects.

2.

3.

Identify the operation or process - based on a Pareto Analysis. Analyze the 5-whys and understand the ways a process can fail. Decide the right Poka-yoke approach, such as using a, Shut out Type: Preventing an error being made, or an AttentionType: Highlighting that an error has been made.

POKA- YOKE
ERROR TYPES
i.

Processing Error: Process operation missed or not performed per the SOP. Setup Error: Using the wrong tooling or setting machine adjustments incorrectly.

ii.

iii.

Missing Part: Not all parts included in the assembly, welding, or other processes.
Improper part/item: Wrong part used in the process. Operations Error: Carrying out an operation incorrectly; having the incorrect version of the specification. Measurement Error: Errors in machine adjustment, test measurement or dimensions of a part coming in from a supplier.

iv.

v.

vi.

POKA- YOKE
EXAMPLES OF POKA- YOKE

3.5 inch diskettes cannot be inserted unless diskette is oriented correctly.

Circuit breakers prevent electrical overloads and the fires that result. When the load becomes too great, the circuit is broken

The sink is fitted with light sensors. These sensors ensure that the water is turned off in the sink.

THANK YOU