continuous improvement. ideas of ci continually seeking ways to improve operations not unique to...
Post on 19-Dec-2015
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Continuous Improvement
Ideas of CI
Continually seeking ways to improve operations
Not unique to quality – also applies to other process improvements
Never-ending process of achieving small wins
CI approaches vary from very structured SPC tools to simple
suggestion systems
Areas for ImprovementMachineryMaterialsLabor utilizationProduction methods
CI MethodsBenchmarksSense of employee ownership Reducing:
Time ScrapInjuriesCustomer problemsSupplier issues , etc.
Reduce or eliminate activities that don’t add value
PDCA Cycle (Deming Wheel):
Conveys the sequential and continual nature of CI
Plan DoCheckAct
Act Plan
Check Do
TQM versus Business Process Design (BPD)
BPD – The fundamental rethinking and radical redesign of business processes to bring about dramatic improvements in
performance. – Michael HammerBPD is revolutionary & CI is
incremental!!BPD is NOT restructuring!Driving forces behind BPD:
CustomersCompetitionChange
TQM versus BPDTQM
Large number of small incremental changes
Start with existing system
Changes made continuously.
Implement in as little as one day.
Change starts at the bottom
Change affects workers in a single functional department.
Primary enabler is statistical quality control techniques.
BPD
Large radical change.
Begins with a clean slate.
Major changes are made infrequently.
A long time frame, several months and perhaps a year or more
Changes begin at the top.
Changes affect workers across functional departments.
Primary enabler is new technology.
BPD Algorithm1. Prioritize processes for radical change.
2. Organize and educate.
3. Document the current processes.
4. Develop a vision for the future processes.
5. Starting with the current process, design the future process.
6. Develop an implementation plan.
7. Implement the plan.
Top Ten BPD Mistakes1. Don’t really make radical changes but say you are.2. Don’t focus on processes.3. Spend a lot of time analyzing the current situation.4. Proceed without strong executive leadership.5. Be timid in redesign.6. Go directly from conceptual design to
implementation.7. Redesign slowly.8. Place some aspects of the business off-limits.9. Adopt a conventional implementation style.10. Ignore the concerns of your people. - Michael Hammer © 1995
So you’re not ready for BPD – Steps for TQM Success
1. Train employees in the methods of SPC and other tools for improving quality and other performance measures
2. Make SPC methods a normal aspect of daily operations
3. Build work teams and employee involvement4. Utilize problem-solving tools within the work
team.5. Develop a sense of operator ownership in the
process.
Continuous Improvement/TQM Tools
For Generating Ideas:BrainstormingEmployee Suggestion Box
To Collect & Organize the Data:Check sheet Pareto charts Flow charts (Process diagrams)
For Identifying Problems:Cause & Effect diagram Scatter diagram Histogram – a distribution showing the frequency of
occurrences of a variableStatistical Process Control
Continuous Improvement Approaches we will consider
Deming Approach – Reduce variability
Kaizen Approach – Just Do It
Shingo Approach – Zero Defects
– Poka Yoke
Goldratt’s Approach – Theory of Constraints
These will each be discussed in detail and then compared/contrasted.