Presentation on theme: "Continuous Process Improvement"— Presentation transcript:
1 Continuous Process Improvement Achieve PerfectionWork as Process to make it Effective, Efficient, and AdaptableChanging Customer NeedsControl in process-Reduce Scrap, Time, Idle of ResourcesEliminate Non Conformance in All PhasesBench MarkingInnovationStatistical Tools, QFD,FMEA. Taguchi Loss Function
2 Types of Problems Compliance Unstructured Efficiency Process Design Product Design
3 Shewhart’s PDSA CYCLE in 1930 PLANDOSTUDYACTACTPLANSTUDYDO
4 Continuous Process Improvement Cycle Phase 1 Identify theopportunityPhase 2 Analyze the ProcessPhase 7Plan for theFutureACTPLANPhase 3 Develop the Optimal SolutionPhase 6 Standardizethe SolutionSTUDYDOPhase 4 ImplementationPhase 5 Study the Results
6 The Deming Cycle or PDCA Cycle PLANPlan a change to the process. Predict the effect this change will have and plan how the effects will be measuredACTDOAdopt the change as a permanent modification to the process, or abandon it.Implement the change on a small scale and measure the effectsCHECKStudy the results to learn what effect the change had, if any.
7 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.
8 Juran's TrilogyJuran'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 effective manner possible
9 Juran's Trilogy Quality Planning Identify the Customers Determine the customer’ needsDevelop a processProve process capability
10 Juran's Trilogy Quality Control Choose control Subjects (What to Control)Choose Units of measurementsEstablish MeasurementEstablish Standards of performanceMeasure actual performanceInterpret the differenceTake action on the difference
11 Juran's Trilogy Quality Improvement Prove need for improvement Identify specific projects for ImprovementsOrganize to guide & DiagnosisTo find causesProvide RemediesProve remedies for effective in operating conditionsControl the gains
17 Japanese Mgt Functions and Kaizen TOP MgtInnovationMiddle MgtKAIZENSupervisorsMaintenanceWorkers
18 Japanese Vs Western Approach KAIZENINNOVATIONJAPANStrongWeakWEST
19 Kaizen Implementation Discard Conventional ideasThink in Positive MannerDo not make excuses but question Current PracticeCorrect Mistakes at onceProblem Solving & Find Root CausesTeam Work To achieve MAXIMUMMeeting of Kaizen group once in Month
20 TOTAL MANUFACTURING CHAIN SCIENCETECHNOLOGYDESIGNPRODUCTIONMARKETINNOVATIONKAIZEN
21 Comparison of INNOVATION & KAIZEN CreavitivityAdaptabilityIndividualismTeam WorkTechnologyPeople- orientedInformation- ClosedInformation-OpenSeeks New TechnologyBuilds on Existing TechnologyLimited FeedbackComprehensive Feedback
22 3-MU’s Checklist of Kaizen Activities Muda (Waste)Muri (Strain)Mura (Discrepancy)Man PowerTechniqueMethodTimeMaterialsInventoryWay of Thinking
23 In an Organization, Kaizen activities will be carried out by asking the Questions-Who, Where, When, Why, and HowEg-Who does it?What to do?Where to do it?When to do it?Why to do it?How to do it?
25 HOUSE KEEPING_5-S MODEL ThrowEvery WhereNeverThrow3 rd Class Work Place1st Class Work Place?AlwaysCleanNeverClean
26 5 S 5 S FOUNDATION FOR PRODUCTIVITY IMPROVEMENT Better Tomorrow for EveryoneUltimate GoalEffective Use ResourcesEfficiency ImprovementEconomic OperationIntermediateGoalJITTQCTPMTQMApproach& Method5 SFoundation5 S FOUNDATION FOR PRODUCTIVITY IMPROVEMENT
30 SEI-TON = ORGANIZINGOnce Cleaned and then arrange them in orderly manner.People should cultivate the habit of return the tools to the place from where it was taken.Easily accessibleReduces time and confusionsImproves Efficiency
34 SEI-KE-TSU=Personal Cleanliness Good Working Condition and Personal HygieneClean Person is conscious of his Work PlaceGood Sanitary Condition
35 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