QUALITY MANAGEMENT SYSTEM MOHAMMAD FIRDAUS BIN RAMLAN PB13073 MOHAMAD HAFIZ BIN RAMLI PB13066 NORAIN BINTI AB RAHMAN PB13008 NUR ‘AMIRAH BINTI MOHD MUSTAFA PB13010 NAIMAH BINTI DUN PA NURUZZAKIYAH BINTI MOHD ISHANUDDIN PA13009

SHIGEO SHINGO Born : 1909 in Saga, Japan Died : 1990 in Japan Nationality : Japanese Other names : Shingō dai-sensei Education : Saga Technical High School / Yamanashi Technical College Occupation : Management trainer and consultant, in Industrial engineering & Business management Known for : Single Minute Exchange of Die (SMED), P-Course

1945 and 1946 : - As Manufacturing Section Chief. - Shingo worked for several manufacturers. - Began a long association with the Japanese Management Association (JMA) – 1954 : - Had many assignments, delivered several important papers and crystallized his ideas on process and plant layout. - He also applied Statistical Process Control : - Began another long association, with Toyota. - He first started work on setups by doubling the output of an engine bed planer at Mitsubishi’s shipyard.

1959 : - Dr. Shingo left JMA to start his own consulting company. Early 1960 : - As an outgrowth of work with Matsushita, he developed his concepts of “Mistake-Proofing” : - Shingo traveled in Europe and North America on many lectures, visits and assignments. - He began to see Toyota’s efforts as an integrated system and began to assist several U.S. and European firms in implementation. * Dr. Shigeo Shingo has written 14 major books and hundreds of important papers on manufacturing. The Shingo Prize is awarded for excellence in manufacturing as a tribute to Dr. Shingo and his lifelong work. He died in 1990.

Just in Time A philosophy of manufacturing based on planned elimination of all waste and continuous improvement of productivity. It encompasses the successful execution of all manufacturing activities required to produce a final product, from design engineering to delivery and including all stages of conversion from raw material onward. The primary elements include having only the required inventory when needed; to improve quality to zero defects; to reduce lead time by reducing setup times, queue lengths and lot sizes; to incrementally revise the operations themselves; and to accomplish these things at minimum cost.“

Single Minute Exchange of Dies Dr. Shigeo’s approach to developing the SMED concept was to isolate and identify the Setup time as two entities: internal setup time and external setup time. According to him, A simple approach to achieving a quick setup and changeover of the dies can be done in the following steps:  Separating internal and external setup as it is existing  Converting internal to external setup  Streamlining all aspects of the setup operation

Zero Quality Control Dr. Shigeo Shingo’s Zero Quality Control (ZQC) techniques make use of the following engineering principles:  100 percent inspections done at the source instead of sampling inspections  Immediate feedback from successive quality checks and self checks  Poka-yoke designed manufacturing devices The Zero Quality Control concepts are based on a theoretically ideal scenario. However, by using these principles and concepts, quality improvements can be made. Dr. Shigeo’s basic idea was to implement mistake-proofing devices in the assembly line to eliminate the possibility of defective operations. In addition, his emphasis on targeting the root cause of defect (source defect) whenever a defect occurs, virtually eliminates the need for statistical process control.

The advantages of approach for quality management  Advantages for concept Just In Time:  Workers with various skills used efficiently.  Production scheduling and consistent working hours in line with demand.  Improving relationship between suppliers  Reduced setup time.  Reduction is waste, rejects, and rework by detecting errors at the source.

 Advantages for concept Single Minute Exchange of Dies (SMED).  reduce the amount of cash tied up in stock.  increase our flexibility to produce a variety of products.  the amount of handling and handling equipment required can be reduced  Advantages for Zero Quality Control It combines steps that helps one to either detect or prevent an error before it becomes a mistake

Example of application of Concept Just in Time (JIT) DELL - leveraged JIT principles to make its manufacturing process a success. - leverage their suppliers to achieve the JIT goal. - Dell is able to provide exceptionally short lead times to their customers, by forcing their suppliers to carry inventory instead of carrying it themselves and then demanding (and receiving) short lead times on components so that products can be simply assembled by Dell quickly and then shipped to the customer.

Important Factors to DELL Success Dependable suppliers with the ability to meet Dell’s demanding lead time requirements. A seamless system that allows Dell to transmit its component requirements so that they will arrive at Dell in time to fulfill its lead times. A willingness of suppliers to keep inventory on hand allowing Dell to be free of this responsibility.

Harley Davidson Harley Davidson’s use of JIT is mostly characterized by its transformation in the late World War 2 era from an inefficient manufacturer that solved all of its problems with extra inventory to a nimble manufacturer able to meet demand and provide short lead times.

Results of Harley Davidson’s JIT Implementation Inventory levels decreased 75 per cent. Increased productivity. Harley Davidson’s success with the implementation of JIT had a lot to do with the fact that when JIT was put into practice, process problems could no longer be hidden by costly inventory that helped to meet ship dates. The inefficiencies in the processes were quickly identified and solved.

Single Minute Exchange of Dies (SMED) Single Minute Exchange of Dies is changing process tooling in 9 minutes or less. „ The process was developed by Shigeo Shingo at Mazda, Mitsubishi and Toyota in the 1950’s and 1960’s. „ Separate internal and external activities. „ Convert internal activities to external activities.

Internal set -up activities. Elements in the changeover which can only be done when the machine is stopped. „ External set- up activities. Elements that can be performed when the machine is running.

Why SMED? „ Reduced inventories. „ Improved productivity. „ Higher quality levels. „ Increased safety. „ Improved flexibility. „ Reduction in throughput time. „ Improve operator capabilities. „ Lower manufacturing costs.

REFERENCES Bright Hub PM. (2012). Examples of Successful JIT Systems - Toyota, Dell, and Harley Davidson. Retrieved from of-successful-jit-systems/ LEAN.PRODUCTION.com. (2013). SMED – Single-Minute Exchange of Dies. Retrieved from Quick Changeover Quick Changeover Single Minute Exchange of Dies Single Minute Exchang. (n.d.). Retrieved from Quality Gurus. (n.d.). Shigeo Shingo. Retrieved from