1. Process Approach & Improvement
Lecture 8
Process Approach & Improvement
Total Quality Management
Haroon Bakari

2. Subburaj’s 6S Model for Process Improvement
The Author Subburaj, as headed ETDC, Chennai, declared the year 1993 as a TQM year for the organisation.
As part of this journey, developed and practiced 6S model for process improvement. As
Study
Streamline
Simplify
Standardize
Synergize
Strengthen

3. Subburaj’s 6S Model for Process Improvement
Study
The current performance level triggers improvement, and is important to study the process and document the measured performance level.
Streamline
Meant for process movement with least resistance in the organisation
It is important here to first document the current sequence of events and then eliminate unnecessary or non-value adding processes.
Simplify
It involves the identification of essential processes and simplifying procedure for carrying out the task without increasing the cost and compromising on quality.

4. Subburaj’s 6S Model for Process Improvement
Standardize
Standardization essentially permits performing the process in the same way by every employee at all times, i.e. documented procedure.
Synergize
A process is synergized with at least two other processes- customer and supplier processes and is important to check the effect of revision to other processes.
This may call for modification in other processes also.
Strengthen
A number of activities are required in this phase
Educating & convincing the process owners, their customer & suppliers
Periodic counseling and assuring that the new process will perform better than the older one
Monitoring the results and confirming that process transition has occurred, employees are confident and that the process is practiced as documented.

5. Supply Chain Management (SCM)
A supply chain is series of links and shared processes that exist between the external suppliers and external customers.
It is the customer supplier chain, where the customer can be a supplier to another customer
Hence the total chain can have a number of customer supplier relationships.

6. Supply Chain Management (SCM)
Supply chain management is a task of optimizing all activities throughout the supply chain, so that the products and services are supplied;
In right quantity
In right quality
To right customer
At right time
At the optimal cost

7. Supply Chain Management (SCM)
SCM involves following activities
Demand planning
Involves the accurate forecasts of demand of products & services to improve customer service while decreasing cost by reducing demand uncertainty.
Manufacturing planning and scheduling
Planning process that optimally schedules manufacturing orders with production capacity by combining Material Requirement Planning (MRP) and Capacity Requirements Planning (CRP) to create optimized and constrained production plan
Supply planning
To meet customer demand based on available inventory and transportation resources. Also include Distribution Requirements planning (DRP), determining the needs to replenish the inventory
Transportation planning
To optimally schedule, load, and deliver shipments to customers while considering delivery date, mode of transportation, carrier, etc.

8. Just-In-Time (JIT) Manufacturing
JIT emphasizes the time requirement for manufacturing
Production should be made on demand and material should also arrive just in time, before the manufacturing starts
Thus, no need to stock the material and products.
Although it is difficult to foresee the demand, so as to deliver the product just in time as ordered, because customer cannot wait for actual work.
Toyota in Japan has been the pioneer in Just-In-Time manufacturing.

9. Just-In-Time (JIT) Manufacturing
It is defined as “a philosophy that focused attention on eliminating waste by purchasing or manufacturing just enough of the right items Just-in-Time”.
A synonym for zero inventory or zero inventory program.
It is a break through in TQM environment
Requires a perfect work culture with zero defects and excellent suppliers, machinery and infrastructure
Based on two principles
Production and supply of required number of parts when needed
JI DOKA (self-actualization) means utilizing the full potential of workforce.

10. Just-In-Time (JIT) Manufacturing
Objectives
Development of optimal process and competitive
Streamlining of operations and eliminating unwanted processes
Reducing the levels of wasted materials, time and efforts
Increasing efficiency of production process.

11. Lean Manufacturing
It is an umbrella concept enables JIT manufacturing.
Lean manufacturing is a whole systems approach that creates a culture in which everyone in the organisation continuously improves process and production.
It is an application of more efficient methods that greatly minimize delays, reduce costs and improve quality.

12. Lean Manufacturing
International Motor Vehicle Program (IMVP) researcher John Krafcik, USA commented that the Toyota system was lean because of the following reason:
“Half the human effort in the factory, half the manufacturing space, half the investment in tools, half the engineering hours to develop a new product in half the time. Also, it requires keeping far less than half the needed inventory on site, results in fewer defects, and produces a greater and ever growing variety of products”.

13. Thanks & Good bye