4 Objectives of Productivity and Quality Systems
Ensure Quality of Product Definition
Ensure product quality in the design process
Ensure product quality during the manufacturing and packaging processes
Ensure product quality from the perspective of the customer
Quality from the Perspective of the Customer
Performance
Features
Conformance
Warranty
Productivity and Quality Systems and Methodologies
Lean
TQM
Lean Methodology
Emphasizes the minimization of activities that do not add value to the customer
TQM
Total Quality Management
Management approaches to quality improvement and customer satisfaction
Based on the participation of all members of an organization in improving process, goods, services and the culture in which they work.
QFD - Quality Function Deployment
Quality Function Deployment
A methodology designed to ensure that all the major requirements of the customer are identified and met or exceeded
Uses a structured process called the House of Quality
House of Quality
A structured process that relates customer-defined attributes to the product's technical features needed to support and generate these attributes
Six Steps of the House of Quality
Identify customer requirements
Identify supporting technical design requirements
Compare the customer requirements to the technical design requirements and assign relationship ratings
Assign importance to the customer requirements
Evaluate competitors
Ide
House of Toyota
A lean process
Comprised of Five Parts:
The Roof - Eliminating waste
The Pillars - JIT or rate of customer demand and Jidoka - stopping the production line if a defect occurs
The Base - operational stability; standardization of work and reduction of varia
Continuous Flow Production
Production matches customer demand
Items are processed directly from one step to the next
Optimal is one piece at a time flow
Little inventory is held
Demand pulls product through the system
Easiest to implement when there is a narrow product line with de
Push System
Items are produced or materials are released at a time determined by a schedule planned in advance
Pull System
Items are produced or materials are released as they are needed
Takt Time
the rate of customer demand
The rate of flow between work centers in a fixed routing is controlled by a Kanban system.
Process (functional) Layout
Used by discrete manufacturers
The plant is laid out by departments using similar equipment
A silo-type layout
individual processes are separated physically
batches move through creating WIP inventory
Cellular Layout
Used in a flow production line
Products move through one at a time from station to station with limited WIP inventory. Reduces waste
Process Flexibility
Enables companies to swiftly change the volume and mix of their products
Required for Process Flexibility:
Flexible Machinery
Cross-Trained employees
Quick Changeovers
Total Productive Maintenance (TPM)
Preventive maintenance plus continuing efforts to adapt, modify, and refine equipment to increase flexibility, reduce material handling, and promote continuous flows.
Schedule preventive maintenance
Train/Empower operators to perform maintenance
Operators
Process Improvement
The activities designed to identify and eliminate causes of poor quality, process variation and non-value-added activities
Continuous Improvement
A never-ending effort to expose and eliminate root causes of problems; small-step improvement as opposed to big-step improvement
Improves productivity
Eliminates waste
Involves Teams
Employee Involvement
Using the experience, creative energy, and intelligence of all employees by treating them with respect, keeping them informed, and including them and their ideas in decision-making processes
Employee Empowerment
The practice of giving non-managerial employees the responsibility and power to make decisions regarding their jobs or tasks
Jidoka
Workers are allowed to stop the production line if defects occur
Lean Tools and Techniques
Value Stream Mapping
Heijunka
Five Ss
Hoshin Planning
Value Stream Mapping
process mapping that is a graphical representation plotting the path from raw material to finished good
Heijunka
a form of production leveling to match the rate of end-product sales. The production volume and mix are distributed evenly over time.
Five Ss
Five terms that enable the creation of a clean, well-ordered workplace:
Sort
Simplify
Scrub
Standardize
Sustain
Hoshin Planning
A lean manufacturing version of strategic planning
Supplier partnership
The establishment of a working relationship with a supplier organization whereby two organizations act as one
Benefits
-Greater share of business
-Long term contracts
Total Quality Management
Product Quality - at a minimum all products must be within specification
Quality related costs
Costs related to making defect-free products:
External - Costs of Failure. Cost of correcting problems after goods have been delivered to customer
Internal - Costs of Controlling Quality. Cost of correcting problems while goods are still in production fac
Costs of Failure
Internal Failure costs - the cost of correcting problems while goods are still in the production facility
External Failure - the cost of correcting problems after the goods or services have been delivered to the customer
Costs of Controlling Quality
Prevention Costs - The cost of preventing problems from occurring
Appraisal Costs - The cost of checking and auditing quality.
Flowchart
represents the tasks or elements associated with a process and a visualization of the steps and sequences in the process.
Cause-and-Effect Diagram
Fishbone Diagram
Illustrates the main causes and subcauses leading to an effect
Six main "causes"
Materials
Machine
People
Method
Environment
Measurement
Control Charts
A tool used to track process variation
SPC
Statistical Process Control
Applies statistical techniques to monitor and adjust an operation
Process Capability
A measure of process spread in relation to the upper and lower specification limits
The ability of the process to produce parts that conform to upper and lower engineering specification limits for the product
Check Sheet
Used to summarize a tally count of event occurrences
Histogram
a graph of contiguous vertical bars representing a frequency distribution
Pareto
a graphical tool for ranking causes from most significant to least significant.
A bar chart
Used to determine the largest frequency of items in a data set.
80% of the defects come from 20% of the causes
Scatter Diagram
used to analyze the relationship between two variabilities
The more scatter, the lower the relationship of the variables to each other
Six Sigma
A set of concepts and practices that focus on reducing variation in processes, and therefore reduces defect and improves quality.
Sigma is used to designate the standard deviation
the Higher the sigma value, the less likely the process will result in prod
Causes of Variation
Special Causes
Common Causes
Special Causes of Variation
can be isolated and are assignable to a particular source
variations outside of the natural, historical variations
Common Causes of Variation
Inherent in a process
Occur naturally in processes
correcting common causes involve more long-term process improvement activities
Six Sigma DMAIC
The phases of a Six Sigma project
Define
Measure
Analyze
Improve
Control
Benchmarking
A systematic method by which organizations compare their performance to a best-in-class organization
Select the process to benchmark
Identify an organization that is best-in-class
Study the benchmarked organization
Analyze the data
6 Requirements of Customer
Quality
Flexibility
Service
Short Lead Time
Consistency
Cost Savings
8 Types of Waste
Process
Movement
Methods
Product Defects
Waiting Time
Overproduction
Excess Inventory
Unused people skills
Kanban in Pull System
Kanban (signal) used to trigger replenishment of parts and sub-assemblies needed by workstations.
7 Quality Control Tools
Flowchart
Cause and effect
Control charts
Check sheet
Histogram
Pareto
Scatter Diagram