Managing Total Quality or Method Tools & Techniques

Managing Total QualityorMethod Tools & Techniques 1. TQ through QC 2. TQ through 5-S 3. TQ through QMS 4. TQ through Bench marking

5. TQ through Cast of Quality 6. International Awards 7. Statistical tools pare to Analysis 8. Quality Function Development (QFD) 9. Failure Mode Effect Analysis (FMEA) 10. Taguchi Quality Fenny 11. Quality by Design 12. Environment Management System 13. IT (Role of Computer in Quality Function)

Five-S 5-S is nothing but a way Managing the work place. An art of house keeping Everyone prefers a clean environment even the animal like DOG. Karl Marx and VI Lenin has talked about class struggle between the capitalist and the laborers. In India we were witnessing a caste struggle from the ancient times.

And which has lead to the hierarchy of works at any given place. We have developer an attitude that- This is my work This is not my work This is somebody else work • In a organization ‘A’ is the manager job ‘B’ is the supervisor job ‘C’ is the peon job ‘D’ is the sweepers job

Cloistered desk Unsystematic approach to work Frequent emergencies Wasteful expenditure in time energy rework Accident Interruption 5-S is a useful tool to have a better organism alular life 5-S change in attitude and behavioral pattern to words. Work in the organization. Result is

What is 5-S 5-S derived from first letter of word SEIRI (Sorting) SEITION (Systematic arrangement) SEISO (Clearing) SEIKETSU (Standardize) SHITSUKE (Sell discipline)

SEIRI (Short) Items • The Golden rule for SEIRI (Sorting) is to remove any thing that will not be used with next 30 days. • Applicable for documents file, disk, racks supplies dies tools machines etc. Unwanted Wanted

SEITION (Systematic arrangement) Means preparing correcting or placing systematically the wanted items. To that they are easily accessible and helps in minimizing. Searching times and finding missing items by visual control. SEISO (Clearing)- means cleanup the working environment.- including of all wanted items identified through.- placed in an orderly manner by applying seiton.

SEIKETSU (Standardize)- implies standardizing the implementation of sciri seiton and seiso.Extending it to all individuals and practice it continuously. Day in day out • SHITSUKE (Self discipline) Means self discipline making implementation of above 4S as a habit on a daily bases. 5-S imbibed in one’s thanking & working

Implementing of 5-S • Preparatory stage • Development stage • Implementation stage

Preparatory stage • Explanation of benefit to employee minimize the resistance to change. • Continuously training of all employee through film and photo graph of top notch companies. • Facilitating employee in the identifications of gap between the bench market company and their own section.

Development Stage • Have a budget • Implementation known to everyone by announcing date. • Create organizational structure of a steering committee for 5-S implementation. • Dividing by entire organization into group or subgroup under the control of steering committee. • Take photo graphs of the existing status of location all over the organization. • Creating display board to be placed at different location • Getting printed red toy. • Developing activity chart for the Implementation of 1S & 2S for every group along with time frame & responsibilities.

Implementation Stage • The actual implementation consist of following stage.

STEP-1SEIRI (SORT) • Short all the items and categories them into two • Wanted (in next 30 days) • Unwanted Put a red tag on all unwonted items Wanted in the future Further sort the unwonted items Having no values or uses throw away

1S – Sorting out 1 • Rag tag campaign will assist the top Management to find out the actuate supplies work in progress and unwanted items on which other quality management tools can be applied and the wastage is minimized. 2 3

STEP-IISEITON (Systematic Arrangement) • Proper and orderly placing of all the wanted items • This help in minimizing the search time & Effort and enhancing visual countries. • All items are properly coded with name designated place maximum/ minimum quantities. • Also help in scheduling the production process. • No over production which ultimately result in loses for the company.

STEP –IISEITON (Systematic Arrangement) F.W. Taylor, the father of Scientific Management raised the output of loading & unloading of pig iron from 12.5 tones per day to 48 tones a day by adopting the formulas of right person at the right place through right equipment in the right manner.

By implementation of 1S & 2S. Company can • Reduce work in progress • Effective utilizations of work space • Change over time in shops • Productivity enhancement • Cost saving

2-S

3S means clearing the work place and convert into a Leedey place • Clearing of all desk drainer rocks machines tools floor • All other items of the work place identified and arranged through the implementation of 1S & 2S. • Clean work place first impression to visitor • It set perception for the organization • Working is simple • Malfunctioning is easily identified and preventive measures are taken. STEP –IISEISO (Scribe)

Normally breakdown due to loose nut & bolts in adequate oil and gearing or through rusting on account of unwonted deposit of dust or oils.

In Wipro no sweeper is suppose to do the dusting the table tops. It is the job of every employee to ensure a clean & tidy work table. Every day a survey done to identify the most tidy and most untidy employee and their names are put for the day on the notice board.

Step – 4SIEKETSU (Standardize) • This step talks about keeping it the way which has been arrived at after implementing 1S, 2S, and 3S. • This looks forward for making sorting ordering checking & clearing as a habit and thus maintaining spotless work place day in day out. • Systems in procedures rules must be assured of continustty.

Step- 5SHITSUKE (Self discipline) The last step of implementation stage talk about self discipline This actually is the evaluating stop to ensure maintenance of standard through out the organization. Employee develop a habit of making 4S as apart of their daily work life.

Quality Circles The four pillars of the quality circle are – • Active participation • In – view • Creativity • Willingness

Quality circle take up behavioral problems • Two types of problems are generally taken – • Problems concerning functional aspect. • Problems concerning behavioural aspects.

Karou Ishikawa, the father of Quality Control (Also called Quality code) defines it as “a small group to perform voluntary quality control activities within the same workshop

Concept of Q.C. • Quality Circle is a small group of employees (8-10) working at one place, who come from voluntarily and discuss their work related problems once in a week (say) for one hour, meet as a group and utilise their inherent ability to think for themselves for identifying constraints being faced by them and pooling their wisdom for final solutions that would their work life in general and contribute towards better results for the organization.

Benchmarking • Introduction – Benchmarking is a systematic method b which organizations can measure themselves against the best industry practices. The essence of benchmarking ideas and adapting them to gain competitive advantages. It is a tool for continuous improvement.

It is a popular tool used b both manufacturing and service organization for example-(i) Xerox AT & TMotorola , Ford, Toyotais a common elements of quality standard. • Example- National record PT Usha – 11.39 see Olympic & world records – 10.54 see 10.49 see We can see ample room for improvement for India women.

Toyota Kirloskar Motor • 436 acre unit Biladi near Bangalore Manufacture 50,000 Qualis/ anum. Sachio Yamasaki MD of TKM follow us benchmark of 10,00,000 vehicles a year for this decade. • The Massachusetts Institute of Technology & JD power & Associates published a survey in 1991. car plants in Japan USA and Europe showing European . 16.8 in Japan had significant opportunity for 36.2 in Europe improvement

Benchmarking Concept What are others performance levels. How did they get there What is our performance level? How do we do it? Creative adaptative Break through performance

Benchmarking measures performance against that of best in class organization, determines how the best in class achieve those performance level and uses the information as the basses for adaptive creativity and break through performance. • Therefore once again we can repeat as “Benchmarking is the search for best practices that will lead to superior performance” • Benchmarking helps a company learn its strength and weakness as--------- and those of other. Industrial leaders – and incorporates the best practices into its own operations.

Benchmarking was imitated by Xerox an eventual winner of the Malcolm Baldrige National Quality are and Xerox initially studied their direct competitors and discovered that. • Their unit manufacturing cost equaled the Japanese selling price in the U.S. • The number of production supplier was nine times that of the best companies. • Assemble line rejects were 10 times higher

Product lead times were twice as long and Defect per hundred machine were seven times higher. There result helped their to understand the amount of change that would be requested and to set realistic target to guide their planning efforts.

Benchmarking process • Determine which function to benchmark • Identify key performance indicators to measure • Identify the best in class companies • Measure the performance of the best in class. Companies and company the result to your own performance. • Define and take actions to meet or exceed the best performance.

Define which function to benchmark- • This have a impact on business performance and key dimensions of competitiveness. • Functions may include processing purchasing production planning and production distribution in which improvement is requared. 2. Identify key performance indicates to measure – • Dined link to customer need & expectation. • Indicator are quality performance delivery

3. Identify the best in class companies- • A university financial office might benchmark a bank’s loan operation for example – Selecting companies requires knowledge of which firm are superior performer in the keys are us. Such information can be obtained from publisher reports and articles. Industry experts trade magazines professional association former employees or customer supplies. 4. Measures the performance of the best in class company and compare the result to your own performance • This information can be found in published resources. • Sili visit • In depth interview.

5. Define and take action to meet or exceed the best performance- - by changing organizational system - Shooting at moving target - Process will continuously improvement - Attempt shown be make to exceed the performance of the best

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Managing Total Quality or Method Tools & Techniques