Lesson 03 Continuous Process Improvement PDF

LESSON 03: CONTINUOUS PROCESS IMPROVEMENT SAIF ULLAH KHAN IMS – UNIVERSITY OF PESHAWAR This Photo by Unknown author is licensed under CC BY-SA-NC  Processing People Input O...

LESSON 03: CONTINUOUS PROCESS IMPROVEMENT SAIF ULLAH KHAN IMS – UNIVERSITY OF PESHAWAR This Photo by Unknown author is licensed under CC BY-SA-NC  Processing People Input Output Equipment Material Product Method Outcome Impact Money Services Environment Data Etc Data Procedures Material Feedback Loop PROCESS SETS OF RELATED TASKS OR ACTIVITIES BY WHICH WORK IS ACCOMPLISHED. GENERAL STRATEGIES FOR IMPROVEMENT 1. Viewing all work as a process, whether it is associated with production or business activities. 2. Making all processes effective, efficient and adaptable. 3. Anticipating changing customer needs. 4. Controlling in – process performance. 5. Maintaining constructive dissatisfaction with the present level of performance. 6. Eliminating waste and rework wherever it occurs. 7. Investigating activities that do not add value to the product and eliminating them. 8. Eliminating non – conformance in all phases of everyone’s work, even if the increment is small. 9. Use benchmarking to improve competitive advantage. 10. Innovate to achieve breakthroughs. 11. Incorporating lessons learned into future activities. 12. Using technical tools such as SPC, QFD, Experimental Design and so forth. This Photo by Unknown author is licensed under CC BY-SA. WHAT TO IMPROVE?  Reduce Resource  Reduce Errors  Meet or exceed the expectations of the downstream customers  Make the process safer  Make the process more satisfying for the person doing it. JURAN’S TRILOGY  To attain quality, you must begin by establishing the vision, policies and goals of the organization.  Converting these goals into results is done through three managerial processes called the JURAN TRILOGY. (aka the three universal processes for managing for quality) JURAN’S TRILOGY 1. Quality Planning 2. Quality Control 3. Quality Improvement JURAN’S TRILOGY: QUALITY PLANNING  The structured process for designing products and services that meet new breakthrough goals and -ensure that customer needs are met. 1. Establish the project 2. Identify the customers 3. Discover the customer needs 4. Develop the product 5. Develop the process 6. Develop the controls and transfer to operations This Photo by Unknown author is licensed under CC BY-SA JURAN’S TRILOGY: QUALITY CONTROL  A universal managerial process for conducting operations so as to provide stability—to prevent adverse change and to “maintain the status quo”.  Quality control can also be described as ―a process for meeting the established goals by evaluating and comparing actual performance and planned performance and acting on the difference. JURAN’S TRILOGY: QUALITY CONTROL (PROCESS)  Choose control subject  Establish Measurement  Establish Standards of Performance  Measure Actual Performance  Compare to Standards (interpret the difference)  Act on the difference JURAN’S TRILOGY: QUALITY IMPROVEMENT  The process for creating breakthrough levels of performance by eliminating wastes and defects to reduce the cost of poor quality. 1. Prove the need for improvement 2. Identify the improvement projects 3. Establish project improvement teams (Provide the project teams with resources, training, and motivation to: 1. diagnose the causes 2. stimulate the remedies 3. establish controls to hold the gains This Photo by Unknown author is licensed under CC BY-SA FIVE TYPES OF PROBLEMS This Photo by Unknown author is licensed under CC BY-SA STRATEGIES FOR IMPROVEMENT  Repair  Refinement  Renovation  Reinvention This Photo by Unknown author is licensed under CC BY PDSA CYCLE KAIZEN Japanese term Kai- meaning continuous zen- meaning improvement The Kaizen philosophy assumes that our way of life—be it our working life, our social life, or our home life deserves to be constantly improved. Small scale continuous improvements Incremental steps- addresses single problem First used by DoD Rapid Improvement Event Rapid intense effort lasting 3-5 days Known as Kaizen Events, Kaizen Blitz Kaizen bursts 5-15 minutes in length KAIZEN 1. Value and non-value-added work activities 2. Muda – seven classes of waste: Over Production, Delay, Transportation, Processing, Inventory, Wasted Motion and Defective Parts. 3. Principles of motion study 4. Principles of materials handling and use of one-piece flow 5. Documentation of standard operating procedures 6. Visual displays for communicating to factory personnel 7. JIT- to produce right quantities at right time and with right resources 8. Poka-yoke to prevent or detect errors 9. Team dynamics 10. The 5S’s (on the next slide) This Photo by Unknown author is licensed under CC BY-SA THE 5S METHOD 1. Seiko - Sort ( Proper arrangement ) 2. Seiton - Set ( Systematic or Orderliness ) 3. Seiso - Shine ( Sweep or clean-up ) 4. Seiketso - Standard ( Personal cleanliness ) 5. Shatsuke - Sustain ( Self-discipline ) 6 SIGMA