Tool #19 Short Form

1. Tool #19 Short Form “Kaizen Documentation Foundations For Data Driven Process Variation, Waste Reduction, Lean, Six Sigma” • Topics 1. ISO/QS introduced and overviewed 2. ISO requirements, focus, foundations 3. Lean, six sigma, ISO relationships 4. Time, method, work, facility, flow 5. Characteristics assessed, variation reduction 6. Tool applications……..

2. ISO, international standards organization Focused on global marketplace, and at home QS, domestic customer/supplier, automotive How we do business, future, contract issues Consistent standards, level playing field ISO/QS Introduced And Overviewed 80% of ISO overlaps into QS standards • Automotive Industry Alliance Group (AIAG) • Key part of understanding, satisfying customers ISO is about Baldridge, broad framework, TQM • Baldridge is through Commerce Department • American “push” for quality

3. Baldridge basis, ISO, QS, relationships Leadership, how we do business Information and analysis Strategic quality planning Human resource development Management of process quality, operations Customer focus and satisfaction ISO/QS Introduced And Overviewed Standards do not measure quality……. • Organization identifies, defines, standards • Manages production per customer demands • Specifies, certifies quality, compliance • Organization certifies, contractually, customer

4. Quality Management Systems (QMS) International Standards Organization (ISO) Synchronous Tools, New Product Development Information Analysis, Communication Systems Enhanced Problem Solving, Decision Making Documentation Tools, Lean Project Team Professional Outcomes, Growth, Knowledge Technological Infrastructure Data Tools, Six Sigma Service, Tools Manufacturing, Non- Manufacturing Applied Research, Project Structure Internal, External, E-commerce Relationships Cultural Change And Continuous Improvement Industrial Technologists’ Toolkit For Technical Management ISO/QS Introduced And Overviewed

5. ISO/QS Introduced And Overviewed Registrar selected similar to any supplier • Registrar, body such as Underwriters Lab • Reviews documentation system, quality manual • Do pre-assessment, preparatory work internal • Must understand business, be customer focused • Objective, willing, to work your calendar Process design, documentation routinely updated • Describes what we do, who is responsible • Describes how all is done, records, practices Time to be registered generally 6-12 months ++ • Organization size, processes, preparedness • Startup costs, $15-25K, total easily twice this

6. Basic systems grew out of the 9000 framework 9000 was a five part series, basic guidebook 9001 was service, 9002 detailed production , and 9003 focused on inspection and testing 9001, 9002, 9003 was audited by third party ISO Requirements, Focus, Foundations Assessment, internal, external audit, certification • Internal is to comply, may not certify, correct • External certification, desired, third party More recent ISO developments are QS 9000 • 20 elements describe standard, areas to comply • Totality of elements provide quality system • Documented quality manual, increasingly online

7. 20 elements identified (cont.) Control of inspection, measuring, test equipment Inspection, test status Control, non-conforming product Corrective, preventive action Handle, storage, packaging, delivery preservation Control of quality records Internal quality audits Training Servicing Statistical techniques ISO Requirements, Focus, Foundations 20 elements identified • Management responsibility • Quality system • Contract review • Design control • Document, data control • Purchasing • Control of customer supplied product • Product identification, traceability • Process control • Inspection, testing

8. TS 16949 simplifies the previous 20 ISO elements: Quality management system: relationships, sequences for all functions Management responsibility: demonstrable indications of top management commitment Resource management: assuring that resources are available to fulfill commitments Product realization: understanding quality objectives in product Measurement, analysis and improvement: data-based measures are used to improve ISO Requirements, Focus, Foundations Four levels of quality documentation……. • First level, quality manual, policies and objectives • Second level is Process descriptions, flowcharts • Third level, work instructions, step by step SOPs • Fourth, lowest level, charting form and records

9. Environmental 14000 standard environmental performance: General requirements: requires system compliant, 14000 Environmental policy: top management led environmental policy and commitment Planning: procedures assure environmental actions Implementation and operation: environmental management procedures, clearly documented Management review: management’s scheduled evaluations of systems, for improvement ISO Requirements, Focus, Foundations • ISO/QS 9000, increasingly becoming base • Key management system, umbrella, all quality systems • Systems built on data, documentation as base to improve • Duplicative systems, sub systems can be eliminated • Many quality methods will come, go, brief buzz words • ISO/QS systems have lasting value, mature base for total management, here to stay enabling all quality methods

10. Lean, Six Sigma, ISO Relationships Ongoing Improvement OPCP Becomes Processing Report Summary OPCP Represents Best, Correct Processes Characteristics Assessed Processes, Facilities Modified Teaching, Learning SOP’s, Flow Charts Change Oriented OPCP Based On Other Detailed Documentation Improvement Requires Process Knowledge Broad Team Cooperation, Communication OPCP procedural applications, functions, key ISO document based on strong team work, data derived in production, flow charts, SOP’s, facility and process layouts, and others.

11. Lean, Six Sigma, ISO Relationships

12. Lean, Six Sigma, ISO Relationships Ongoing Process Control Plan (OPCP 1)………. • Process description: diagrams, flow charts, relationships • Tools for manufacturing: equipment explanation • Process parameters: issues, limitations on process • Product characteristics: dimension, attribute, descriptor • Class: a specific customer code, characteristic criticality • Specification: technical indicator of characteristic Who provides information, how communicated? Who maintains, what is the OPCP system?

13. Lean, Six Sigma, ISO Relationships Ongoing Process Control Plan (OPCP 2)……….. • Evaluation method: how, what assessed, measurement? • Sample size, frequency of inspection: data gathered? • Analysis method: statistical tools used, applied? • Reaction program: corrective actions, steps taken How is format modified for various environments? What does OPCP look like in non-manufacturing? What categories do not fit, others needed?

14. Lean, Six Sigma, ISO Relationships Standard Operating Procedure Analysis (SOGA) • Process symbol: line drawn through symbols describes • Step: sequence in process • Operation procedure: description of process step • Time: amount of time allocated to step • Other: important related information to clarify

15. Time, Method, Work, Facility, Flow

16. Time, Method, Work, Facility, Flow

17. Time, Method, Work, Facility, Flow

18. Planer Time, Method, Work, Facility, Flow Rollers Rollers Bathroom Chop Saw Materials And Storage Pneumatic Marking Sander Table Prep/Sand Table Packaging And Band Storage Area Saw Disc Sander Painting/ Router Finishing Lounge/General Offices Tool Rack Feet 1 5 10 Facility Layout Example.

19. Time, Method, Work, Facility, Flow

20. Time, Method, Work, Facility, Flow • Understand, use, study process documention • Customer demands, knowledge, significant • Characteristics, essential process knowledge • Waste surfaces as we analyze variation • Change, maintain, protect process information • Operators, supervisors, key knowledge base • Grow teams, share knowledge, opportunities • Understanding, knowledge, growth = control • Team driven, point of production • Data, documentation, sampling reliable? • Production capacity must be understood • Capacity points to balance, waste • Must identify and understand best, correct, methods and procedures

21. Characteristics Assessed, Variation Reduction • Data is base for team problem solving, from start • Prevention, not detection, built in early communications • Knowledge based to modify, adjust, correct, clearly show • Discipline, uniformity decreases nonconformance, scrap • Fewer samples, inspection costs, waste reduced over time • Measure of capability, ability to perform as stated • Enables data based decisions, problem solving Characteristics And Standards Identification, Evaluation Standard Deviation, SPC Data Collected Documentation, Process Control By Operators Using SOP Brainstorming For Corrective Action Ongoing Improvement In Teams Basic Relationships In Data, SPC, Teams, Documentation, Improvement, Basis For Launch

22. Characteristics Assessed, Variation Reduction Start With Attribute Start Short Run, Pre-Control Where Is Inspection? What Type Chart? Purpose Of The Chart? Inspection As Part Of SOP? Characteristic? Why? How? Sample Size? Information On The Chart? Chart Relation To Documentation? Sample Freq, Consistency? Charting? New Characteristic? Judge Defects And Defectives? Data Recorded Accurately? Forms, Done Properly? Points Plotted, Analyzed? In Control Over Time? Charts Compared Over Time? Review Of Characteristics? Discipline To Follow Up? Information Provided Teams? Improvement, Shifts In Charts Relationship To Variable Charts? Training In Place? Broad Charting Relationships For Data, Analysis, Improvement Systems

23. Characteristics Assessed, Variation Reduction • Capability analysisapplied to startup, launch • SPC charting, problem solving, key measure for teams • Transfer from other programs, products, processes • On-going method, evaluating, improving from start • Represents performance of process itself, baseline • Procedures covered in data-based tools, summarized here • Calculate mean, ranges, estimated standard deviation • Provide upper and lower spec limits, calculate Cp, Cpk • Cp, Cpk, actual data collected, relative to 1, normal curve • Cp, upper and lower spec limits, tolerance width…… • Cp, divided by process capability, six sigma • Cpk, process centering, total spread relative to center • Cpk relationship in mean, specification, process data

24. Characteristics Assessed, Variation Reduction Eventually Phase Out, Begin With Short Run, Over Time, It Is Assumed Move To Different Characteristic Evaluation, That Process Will Come Characteristic, Product Teams Learning, Growing And Remain Under Control Attributes Judgement Specifications Defects P Charts Defined Calls Checklists Or Desireable Collected, Nonconformities Characteristics Checksheets Features Charted, Data For Tracking Dimensions, Variables Discrete Defectives X Bar And R Tolerances Defined Data Characteristic Evaluation, Charting Evolution, Process Improvement And Phase Out System.

25. Characteristics Assessed, Variation Reduction • Evaluating quality characteristics is disciplined, systematic: • Characteristics eventually under control, review ongoing • Lose $, tracking unecessarily, as SPC shows, shift efforts • Customers involved, SPC attribute, variable data key • Detailed internal, external evaluation, benchmarking • Enhances communication, decision-making • Disciplined systems demonstrate process stability: • Process control demonstrates maturity, capacity • SPC, Cpk, effective links to capacity plans, layouts • Customers require assurances of ability, capability • Potential customers can be even more skeptical • Effective communication, decision-making……… • Must have demonstrable data, documentation

26. Tool Applications……. • Toolkit applications are a key part of the courseware • Located in separate folder of the CD • Provides the template for team portfolio • Each application s part of team project, portfolio • Designed to be done by all, each team member • First read long form, then short review, applications • Total contribution in application form is compiled • Portfolio is gradually evolved around applications • Tool 19 applications are: • OPCP, introduced, continuously built, not just at start • SOGA also introduced, built gradually, evolved • Documentation System Design, Communication, DSDC • ISOQSAOPP, designed to help set a plan for team • GOTA, vacabulary, glossary of terms • All follow through, do and post, independently

27. Tool Applications……. • Ongoing Process Control Plan (OPCP) • Continuously built over entire course • Gradually evolved based on team, project growth • Becomes key part of team project, portfolio • Key ISO technical document for improvement • Partial form shown below, gradually addressed……..

28. Tool Applications……. Standard Operating Procedure Analysis (SOGA) • Process symbol: eliminate unused symbols, each step • Step: sequence in process • Operation procedure: description of process step • Time: amount of time allocated to step • Other: important related information to clarify • Built over time like OPCP • Main part of team project, portfolio

29. Tool Applications……. • Glossary Of Terms, Applications (GOTA) • Continuously added to over entire course, by all • Helps enhance vocabulary, get all on same page • Terms are in toolkit, various parts, not just this course • A sampling of the form (partial) is shown……..

30. Tool Applications……. • ISO/QS Audit, Objective Prioritization Plan (ISOQSAOPP) • Preliminary plan, setup of assessments, work for team • Familiarize with ISO, auditing, all on same page, terms • Strategic planning, team level, change and improvement • Project 50% done when “problem” nailed down • “hot spots” focus, project objectives, gradually PPDPOA • Gantt from SDA form or template, for time, sequence • Partial form is shown……..

31. Tool Applications……. • Documentation System Design, Communication (DSDC) • Initial design, plan for how the team will work • Given that all work is about communications……. • Documentation is blackboard is critical • Must consider initially how this will happen, DSDC • DSDC provides opportunity to reflect on, discuss