1. Short Form Tool 19 ITTTM Tool #19 Short Form “Kaizen Documentation Foundations For Data Driven Process Variation, Waste Reduction, Lean, Six Sigma” Topics 1. ISO/QS introduced and overviewed 2. ISO requirements, focus, foundations 3. Lean, six sigma, ISO relationships 4. Time, method, work, facility, flow 5. Characteristics assessed, variation reduction 6. Tool applications……..

2. Short Form Tool 19 ITTTM ISO/QS Introduced And Overviewed ISO, international standards organization Focused on global marketplace, and at home QS, domestic customer/supplier, automotive How we do business, future, contract issues Consistent standards, level playing field 80% of ISO overlaps into QS standards Automotive Industry Alliance Group (AIAG) Key part of understanding, satisfying customers ISO is about Baldridge, broad framework, TQM Baldridge is through Commerce Department American “push” for quality

3. Short Form Tool 19 ITTTM Baldridge basis, ISO, QS, relationships Leadership, how we do business Information and analysis Strategic quality planning Human resource development Management of process quality, operations Customer focus and satisfaction ISO/QS Introduced And Overviewed Standards do not measure quality……. Organization identifies, defines, standards Manages production per customer demands Specifies, certifies quality, compliance Organization certifies, contractually, customer

4. Short Form Tool 19 ITTTM Documentation Tools, Lean Data Tools, Six Sigma Service, Tools Manufacturing, Non- Manufacturing Synchronous Tools, New Product Development Project Team Cultural Change And Continuous Improvement Information Analysis, Communication Systems Applied Research, Project Structure Enhanced Problem Solving, Decision Making Internal, External, E- commerce Relationships Quality Management Systems (QMS) International Standards Organization (ISO) Professional Outcomes, Growth, Knowledge Technological Infrastructure Industrial Technologists’ Toolkit For Technical Management ISO/QS Introduced And Overviewed

5. Short Form Tool 19 ITTTM Registrar selected similar to any supplier Registrar, body such as Underwriters Lab Reviews documentation system, quality manual Do pre-assessment, preparatory work internal Must understand business, be customer focused Objective, willing, to work your calendar ISO/QS Introduced And Overviewed Process design, documentation routinely updated Describes what we do, who is responsible Describes how all is done, records, practices Time to be registered generally 6-12 months ++ Organization size, processes, preparedness Startup costs, $15-25K, total easily twice this

6. Short Form Tool 19 ITTTM ISO Requirements, Focus, Foundations Basic systems grew out of the 9000 framework 9000 was a five part series, basic guidebook 9001 was service, 9002 detailed production, and 9003 focused on inspection and testing 9001, 9002, 9003 was audited by third party More recent ISO developments are QS 9000 20 elements describe standard, areas to comply Totality of elements provide quality system Documented quality manual, increasingly online Assessment, internal, external audit, certification Internal is to comply, may not certify, correct External certification, desired, third party

7. Short Form Tool 19 ITTTM 20 elements identified (cont.) Control of inspection, measuring, test equipment Inspection, test status Control, non-conforming product Corrective, preventive action Handle, storage, packaging, delivery preservation Control of quality records Internal quality audits Training Servicing Statistical techniques ISO Requirements, Focus, Foundations 20 elements identified Management responsibility Quality system Contract review Design control Document, data control Purchasing Control of customer supplied product Product identification, traceability Process control Inspection, testing

8. Short Form Tool 19 ITTTM TS 16949 simplifies the previous 20 ISO elements: Quality management system: relationships, sequences for all functions Management responsibility: demonstrable indications of top management commitment Resource management: assuring that resources are available to fulfill commitments Product realization: understanding quality objectives in product Measurement, analysis and improvement: data-based measures are used to improve ISO Requirements, Focus, Foundations Four levels of quality documentation……. First level, quality manual, policies and objectives Second level is Process descriptions, flowcharts Third level, work instructions, step by step SOPs Fourth, lowest level, charting form and records

9. Short Form Tool 19 ITTTM Environmental 14000 standard environmental performance: General requirements: requires system compliant, 14000 Environmental policy: top management led environmental policy and commitment Planning: procedures assure environmental actions Implementation and operation: environmental management procedures, clearly documented Management review: management’s scheduled evaluations of systems, for improvement ISO Requirements, Focus, Foundations ISO/QS 9000, increasingly becoming base Key management system, umbrella, all quality systems Systems built on data, documentation as base to improve Duplicative systems, sub systems can be eliminated Many quality methods will come, go, brief buzz words ISO/QS systems have lasting value, mature base for total management, here to stay enabling all quality methods

10. Short Form Tool 19 ITTTM OPCP Represents Best, Correct Processes Improvement Requires Process Knowledge OPCP Based On Other Detailed Documentation OPCP Becomes Processing Report Summary Ongoing Improvement Characteristics Assessed Broad Team Cooperation, Communication Teaching, Learning Change Oriented OPCP procedural applications, functions, key ISO document based on strong team work, data derived in production, flow charts, SOP’s, facility and process layouts, and others. Lean, Six Sigma, ISO Relationships SOP’s, Flow Charts Processes, Facilities Modified

11. Short Form Tool 19 ITTTM Lean, Six Sigma, ISO Relationships

12. Short Form Tool 19 ITTTM Part Name:Process Location:OPCP Form Of Supplier:Revision: Other Pertinent General Information: Process Description Tools For Manufacturing Process Parameters Product Characteristics Class Product/Process Specification Ongoing Process Control Plan (OPCP 1)………. Process description: diagrams, flow charts, relationships Tools for manufacturing: equipment explanation Process parameters: issues, limitations on process Product characteristics: dimension, attribute, descriptor Class: a specific customer code, characteristic criticality Specification: technical indicator of characteristic Who provides information, how communicated? Who maintains, what is the OPCP system? Lean, Six Sigma, ISO Relationships

13. Short Form Tool 19 ITTTM Part Name:Process Location:OPCP Form Of Supplier:Revision: Other Pertinent General Information: Evaluation Method Sample Size, Freq. of Inspection Analysis Method Reaction Program Ongoing Process Control Plan (OPCP 2)……….. Evaluation method: how, what assessed, measurement? Sample size, frequency of inspection: data gathered? Analysis method: statistical tools used, applied? Reaction program: corrective actions, steps taken How is format modified for various environments? What does OPCP look like in non-manufacturing? What categories do not fit, others needed? Lean, Six Sigma, ISO Relationships

14. Short Form Tool 19 ITTTM Operation:Location: Operator (s) Team Members:Part/Service: Other Pertinent Information:# Of Pieces Shift: General Operation InformationPotential Waste Reductions/Analysis Process SymbolStepOperation ProcedureTimeOther Standard Operating Procedure Analysis (SOGA) Process symbol: line drawn through symbols describes Step: sequence in process Operation procedure: description of process step Time: amount of time allocated to step Other: important related information to clarify Lean, Six Sigma, ISO Relationships

15. Short Form Tool 19 ITTTM Time, Method, Work, Facility, Flow

16. Short Form Tool 19 ITTTM Time, Method, Work, Facility, Flow

17. Short Form Tool 19 ITTTM Time, Method, Work, Facility, Flow

18. Short Form Tool 19 ITTTM Materials And Storage Marking Table Band Saw Packaging And Storage Area Painting/ Finishing Tool Rack Pneumatic Sander Disc Sander Router Prep/Sand Table Chop Saw Rollers Bathroom Lounge/General Offices 5101 Feet Facility Layout Example. Planer Time, Method, Work, Facility, Flow

19. Short Form Tool 19 ITTTM Time, Method, Work, Facility, Flow

20. Short Form Tool 19 ITTTM Understand, use, study process documention Customer demands, knowledge, significant Characteristics, essential process knowledge Waste surfaces as we analyze variation Change, maintain, protect process information Operators, supervisors, key knowledge base Grow teams, share knowledge, opportunities Understanding, knowledge, growth = control Team driven, point of production Data, documentation, sampling reliable? Production capacity must be understood Capacity points to balance, waste Must identify and understand best, correct, methods and procedures Time, Method, Work, Facility, Flow

21. Short Form Tool 19 ITTTM Characteristics And Standards Identification, Evaluation Standard Deviation, SPC Data Collected Documentation, Process Control By Operators Using SOP Brainstorming For Corrective Action Ongoing Improvement In Teams Basic Relationships In Data, SPC, Teams, Documentation, Improvement, Basis For Launch Data is base for team problem solving, from start Prevention, not detection, built in early communications Knowledge based to modify, adjust, correct, clearly show Discipline, uniformity decreases nonconformance, scrap Fewer samples, inspection costs, waste reduced over time Measure of capability, ability to perform as stated Enables data based decisions, problem solving Characteristics Assessed, Variation Reduction

22. Short Form Tool 19 ITTTM Purpose Of The Chart? Chart Relation To Documentation? Sample Size? Characteristic? Why? How? Where Is Inspection? Broad Charting Relationships For Data, Analysis, Improvement Systems Charting? New Characteristic? Sample Freq, Consistency? Information On The Chart? Judge Defects And Defectives? Data Recorded Accurately? Forms, Done Properly? Points Plotted, Analyzed? Charts Compared Over Time? Discipline To Follow Up? In Control Over Time? Review Of Characteristics? Information Provided Teams? Improvement, Shifts In Charts Relationship To Variable Charts? Training In Place? What Type Chart? Start Short Run, Pre-Control Start With Attribute Inspection As Part Of SOP? Characteristics Assessed, Variation Reduction

23. Short Form Tool 19 ITTTM Capability analysis applied to startup, launch SPC charting, problem solving, key measure for teams Transfer from other programs, products, processes On-going method, evaluating, improving from start Represents performance of process itself, baseline Procedures covered in data-based tools, summarized here Calculate mean, ranges, estimated standard deviation Provide upper and lower spec limits, calculate Cp, Cpk Cp, Cpk, actual data collected, relative to 1, normal curve Cp, upper and lower spec limits, tolerance width…… Cp, divided by process capability, six sigma Cpk, process centering, total spread relative to center Cpk relationship in mean, specification, process data Characteristics Assessed, Variation Reduction

24. Short Form Tool 19 ITTTM Attributes Defined Variables Defined Characteristic Evaluation, Charting Evolution, Process Improvement And Phase Out System. Checklists Or Checksheets For Tracking Nonconformities Desireable Features Characteristics Defectives Defects Judgement Calls Discrete Data Specifications Dimensions, Tolerances Collected, Charted, Data P Charts X Bar And R Begin With Short Run, Characteristic Evaluation, Teams Learning, Growing Eventually Phase Out, Move To Different Characteristic, Product Over Time, It Is Assumed That Process Will Come And Remain Under Control Characteristics Assessed, Variation Reduction

25. Short Form Tool 19 ITTTM Evaluating quality characteristics is disciplined, systematic: Characteristics eventually under control, review ongoing Lose $, tracking unecessarily, as SPC shows, shift efforts Customers involved, SPC attribute, variable data key Detailed internal, external evaluation, benchmarking Enhances communication, decision-making Characteristics Assessed, Variation Reduction Disciplined systems demonstrate process stability: Process control demonstrates maturity, capacity SPC, Cpk, effective links to capacity plans, layouts Customers require assurances of ability, capability Potential customers can be even more skeptical Effective communication, decision-making……… Must have demonstrable data, documentation

26. Short Form Tool 19 ITTTM Tool Applications……. Tool 19 applications are: OPCP, introduced, continuously built, not just at start SOGA also introduced, built gradually, evolved Documentation System Design, Communication, DSDC ISOQSAOPP, designed to help set a plan for team GOTA, vacabulary, glossary of terms All follow through, do and post, independently Toolkit applications are a key part of the courseware Located in separate folder of the CD Provides the template for team portfolio Each application s part of team project, portfolio Designed to be done by all, each team member First read long form, then short review, applications Total contribution in application form is compiled Portfolio is gradually evolved around applications

27. Short Form Tool 19 ITTTM Tool Applications……. Part Name:Process Location:OPCP Form Of Supplier:Revision: Other Pertinent General Information: Process Description. Provide a written description of process in text format and a process flow chart depicting the same: Tools For Manufacture/Production. Describe equipment required to produce the product, consistent with the flow chart above: Process Parameters. Describe unique elements involved in processing the product which require additional explanation: Product Characteristics. Describe all characteristics of the product, primarily as attributes or variables which are critical: Class. Describe any codes or other unique identifiers per the specific industry or organization to help further distinguish the product: Product/Process Specification. Provide specific measurable definitions for each product characteristic identified above: Evaluation Method. Describe how specifications of characteristics are evaluated, what the measurement systems are: Sample Size, Frequency of Inspection. Describe the sample, how it is derived, including devices used to inspect in a step by step manner: Analysis Methods. Describe the methods and systems used to analyze the sampled data, such as statistical, experimental, and so on: Reaction Program. Describe steps to be taken when product or process is found to be functioning inappropriately: Ongoing Process Control Plan (OPCP) Continuously built over entire course Gradually evolved based on team, project growth Becomes key part of team project, portfolio Key ISO technical document for improvement Partial form shown below, gradually addressed……..

28. Short Form Tool 19 ITTTM Operation:Location: Operator (s) Team Members:Part/Service: Other Pertinent Information:# Of Pieces Shift: General Operation InformationPotential Waste Reductions/Analysis Process SymbolStepOperation ProcedureTimeOther Standard Operating Procedure Analysis (SOGA) Process symbol: eliminate unused symbols, each step Step: sequence in process Operation procedure: description of process step Time: amount of time allocated to step Other: important related information to clarify Built over time like OPCP Main part of team project, portfolio Tool Applications…….

29. Short Form Tool 19 ITTTM Tool Applications……. Glossary Of Terms, Applications (GOTA) Continuously added to over entire course, by all Helps enhance vocabulary, get all on same page Terms are in toolkit, various parts, not just this course A sampling of the form (partial) is shown…….. Provide A Definition For Each Term Identified, Explain How Your Team Will Apply The Concepts, Principles To Your Project: Ongoing Process Control Plan: Corrective Action System: QFD: Pareto Analysis: Statistical Process Control: Variable Measurement, Charting: Attribute Measurement, Charting: Capability: Mean, Range: Gage Repeatability & Reproducibility: Normal Curve:

30. Short Form Tool 19 ITTTM Tool Applications……. ISO/QS Audit, Objective Prioritization Plan (ISOQSAOPP) Preliminary plan, setup of assessments, work for team Familiarize with ISO, auditing, all on same page, terms Strategic planning, team level, change and improvement Project 50% done when “problem” nailed down “hot spots” focus, project objectives, gradually PPDPOA Gantt from SDA form or template, for time, sequence Partial form is shown…….. Organization Under Discussion:Current Operation:Location: General Description Of Operations/Production Functions/Systems Being Assessed As An Internal Audit: ISO/QS Element (TS 16949 2002—Others)Technical Function DescriptionAudit Preliminary InformationActions, Recommendations For Change (list each element separately for analysis/audit)(describe technical function being audited)(How does function compare to standard)(explain anticipated necessary actions, changes) Planning Statement Or Issue, Particularly As Associated With The Service Environment:Criticality Level: HML (H = 5; M = 3; L = 1) Fac = Facility issues; Cost = Cost issues; Time = Time issues; Pers = Personnel issues Objectives Prioritized, 5 Being Highest:Criticality HML FacCostTimePers 5, 4, 3, 2, 1 Problem Background:Resources? (Budget/Other Concerns)? Task/Deliverable/Objective:Who Will Do?How Measured?

31. Short Form Tool 19 ITTTM Tool Applications……. Documentation System Design, Communication (DSDC) Initial design, plan for how the team will work Given that all work is about communications……. Documentation is blackboard is critical Must consider initially how this will happen, DSDC DSDC provides opportunity to reflect on, discuss ResearcherCommunication Method, Internal And External Customers: Toolkit/Blackboard Design Element, How Does It Work? How To Improve Professional Relationships, Communication? 1. Identify How The Systems’ Design You Are Advocating Can Assist IN Tieing Together PPDPOA, TPMSS, FACR, TRIRPA And Other Elements Of Team Problem Solving And Improvement: Explain ISO/QS Characteristics And Other Necessary Entities To Be Possessed By Documentation And Communication Systems, Categorically, Particularly Focused On Service Functions: Using The Template At The End Of The Applications Complete A Cause And Effect Diagram Indicating Issues And Opportunities For Systemic Documentation Relationships/Improvements, Particularly Focused On Service Functions: Identify And Explain Why Your Organization Is Well Suited To The Documentation And Communication System Being Developed, Particularly Focused On Service Functions: