Allied Quality Concept..Presented by Rahim Khoja

(April 2015)

FIVE ‘S’

• S : SEORI ( SORT ) - To organize or reorganize and throw away unwanted things from your work place.

• S : SEITON ( SET in ORDER) –To fix place for every thing and every things keep in it place.

• S : SEISO ( SHINE or CLEANING) – To Clean and make shine your work place.

• S : SEIKETSU ( Standardize) – To standardize the way of storage all thinks in your work place.

• S : SHITSUKE ( SUSTAIN) – To make sustain by discipline.

Sustain

Set

Sort

KAIZEN

• KAI meaning Change and ZEN meaning GOOD (for better)

• KAI +ZEN meaning to make good change for continual improvement

• Type

• Individual oriented kaizen and Group oriented kaizen, e.g. quality circle

• Gemba Kaizen , e.g. change in work place or in items.

• Kaizen Blitz for breakthrough improvements

Combination of Muri (strain) , Mura (inconsistency), Muda ( Waste) with MEN , Material , Machine , Method will give opportunities for Kaizen.

Muri , Mura,Muda

Men,Material, Machine, Method

Kaizen

TPM

• TPM stand for Total Productive Maintenance

• It is a system of maintaining and improving productivity by plant and equipment with a modest investment in maintenance that add business value to organization.

• The eight pillars of TPM focused on proactive and preventative techniques for improving equipment reliability

• They are ‘Autonomous Maintenance, Planned Maintenance, Quality Maintenance, Focused Improvement, Early Equipment Management, Training and Education, Safety Health Environment, TPM in Administration’.

• Overall Equipment Effectiveness of plant equipment measured by multiply of factors Performance, Availability and Quality.

• Performance Downtime, Delay ; Availability- Breakdown, Changeovers; Quality Reject, Repair, Reprocess.

MASTER

MASTER

WCM

• WCM stand for WORLD CLASS MANUFACTURING

• It is in-depth analysis of Japanese manufacturing methodology and assists the participants to acquire a better understanding of -

• TQC (Total Quality Control),

• TQM (Total Quality Management),

• TPM (Total Productive Maintenance),

• JIT (Just In Time),

• TIE (Total Industrial Engineering) practices and

• KAIZEN (continuous improvement).

TPM

TQM

Kaizen

SIX SIGMA

• It is statistical measure of variation indicated by standard deviation – Six sigma.

• The performance of process are measured at 3 sigma , 4 sigma and etc.

• At 6 sigma , performance level means defects in process is not more than 3.4 part per million

• Six Sigma is management tools to achieve defect less system to reduces cost and waste resultant in satisfaction of customer.

• It realized “FIRST TIME RIGHT QUALITY PRODUCTS” should be manufactured.

2 3 4 5 6 7 8 9 1210 16151413111

LSL USL

6 Sigma curve

3 Sigma curve

3 Sigma Vs 6 Sigma

Poka Yoke

• It refers to techniques that make error proofing by mistakes. It can be thought as an extension of Failure Mode Effective Analysis.

• For developing and implementing cost-effective error or mistakes proofing devices help on innovative problem-solving techniques , e.g. interlocks

Y

POKA

E

SMED

• SMED means Single Minute Exchange of Die, was developed in the automotive sector. Originally used in press shop to improve tool (die) setup time. It is technique used for radically reducing “changeovers” of any kind.

• SMED is structured methodology. In 1950 at Toyo Mazda presses, Dr. Shingo examined die change operation. A missing mounting bolt was replaced removing a long bolt from other press and machined to size.

• The idea of “internal setup” and “external setup” clicked to be completed in less than 10 minutes i.e. single digit , 1 to 9 minutes, called SMED tool.

Process 1

Stop

Process 2

Stop

Start

Process 3 …

LEAN Manufacturing

“If it does not add value, it is waste”. This concept revealed by Henry Ford, and later it was adopted by TOYATO.

An eight non-value-adding wastes can removed from process.

Over production, Waiting, Un necessary transport, Over processing, Excess inventory, Unnecessary movement, Defects, Unused employee creativity

ImprovementWaste

QMS

QMS stands for Quality Management System

ISO 9001 :2008 standards explained by SCOPE, NORMATIVE REFERENCE, TERMS AND DEFINITIONS, QUALITY MANAGEMENT SYSTEM, MANAGEMENT RESPONSIBILITY, RESOURCE MANAGEMENT, RODUCT REALISATION, MEASUREMENT ANALYSIS AND IMPROVEMENT.

Auditing tools strengthen system through FIRST PARTY AUDIT, SECOND PARTY AUDIT, THIRD PARTY AUDIT, SYSTEM AUDIT, PROCESS AUDIT, PRODUCT AUDIT.

Plan

DoCheck

Act

Continual

improvement

Thank You..e-mail : rahimkhoja82@outlook.com