short form tool 19 itttm tool #19 short form “kaizen documentation foundations for data driven...

Short Form Tool 19

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Tool #19 Short Form“Kaizen Documentation Foundations For

Data Driven Process Variation, Waste Reduction, Lean, Six Sigma”

Topics

1. ISO/QS introduced and overviewed2. ISO requirements, focus, foundations3. Lean, six sigma, ISO relationships4. Time, method, work, facility, flow 5. Characteristics assessed, variation reduction6. Tool applications……..

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ISO/QS Introduced And OverviewedISO, 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 field80% 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

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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

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Documentation Tools, Lean

Data Tools, Six Sigma

Service, Tools Manufacturing, Non- Manufacturing

Synchronous Tools, New Product Development

Project Team

Cultural Change And Continuous Improvement

Information Analysis,Communication Systems

Applied Research, Project Structure

Enhanced Problem Solving, Decision Making

Internal, External, E-commerce Relationships

Quality Management Systems (QMS)International Standards Organization (ISO)

Professional Outcomes, Growth, Knowledge

Technological Infrastructure

Industrial Technologists’ Toolkit For Technical Management


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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

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ISO Requirements, Focus, Foundations

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

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

Assessment, internal, external audit, certification• Internal is to comply, may not certify, correct• External certification, desired, third party

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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


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

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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, FoundationsFour 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

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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/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

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OPCP RepresentsBest, Correct

Processes

ImprovementRequires Process

Knowledge

OPCP Based OnOther DetailedDocumentation

OPCP BecomesProcessing

Report Summary

Ongoing Improvement

Characteristics Assessed

Broad Team

Cooperation,Communication

Teaching, Learning

Change Oriented

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.

Lean, Six Sigma, ISO Relationships

SOP’s, Flow Charts

Processes, FacilitiesModified

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Best Practices

Establishes Benchmarks

Support Documentation

Procedural Summary

SOP As A Standard, Quality System Base.

Customer Demands Facilitated By Teams For Cooperative Improvement And Controlled Change


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Part Name: Process Location: OPCP Form Of

Supplier: Revision:

Other Pertinent General Information:

Process Description

Tools ForManufacturing

ProcessParameters

Product Characteristics

Class Product/Process Specification

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?


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Supplier: Revision:


EvaluationMethod

Sample Size,Freq. of Inspection

AnalysisMethod

Reaction Program

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?


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Operation: Location:

Operator (s)

Team Members: Part/Service:

Other Pertinent Information: # Of Pieces

Shift:

General Operation Information Potential Waste Reductions/Analysis

Process Symbol Step Operation Procedure Time Other

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


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Study The Job Or Work Area To Be Analyzed

Use SOP's, Flow Charts, Layouts

Involve Operator In Positive Ways, Self Conducted

Involve Supervisor

Best Case-- Supervisor Conducts

Some Operators May Work In Non Normal Ways

Use Stop Watch Or Electronic Method, Device

Record Data On Form For Further Analysis

Use Continual Or Element Analysis

Determine, Compare, With Standards

Improvement Through Time Study And Methods Analysis

Time Study, Work Methods, Approach.

Time, Method, Work, Facility, Flow

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Storage

TransportationDelay

StorageInspection

Operation

Flow Chart Example.

Cut to size by supplier

Drill hole

Inspection

Delay for assembly

Screws Gather components for assembly

Secure cover

Insert pegs and marbles

Attach felt pads

Marbles/pegs

Felt pads

Labels Attach label to block

Inspect assembly

Packaging

Fold label and staple

Labels/stapler

Inspection

Store

Distribution

Delay

Inspection

Apply finish

Dust removal

Sand entire body

Sand sides

Drill holes

Saw divisions

Drill pilot hole

Drill peg holes

Cut to length

Raw stock


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Use The Shortest Path Between Points

Consider The Safe Work Methods First

Avoid Dead Head Trips

Use Sequential Logic And Steps, Order

Use Machines Compatible With People

Combine Easy And Difficult Steps, Tasks

Avoid Fatiguing And Hazardous Steps, Tasks

Analyze Each Step Against The Big Picture

The Workplace Should Be Accessible

Eliminate, Simplify, Combine Tasks

Consider Curved Work Patterns Versus Straight

Maintain Body Balance, Start, Stop Motions

Use Consistent Locations For Tools, Materials

Build Planning Into Steps, Use Opportunities

Detail All Activities, Step By Step

Do Not Use Hands As Fixtures

Work Methods Analysis Pointers.


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Materials And Storage

Marking Table

Band Saw

Packaging And Storage Area

Painting/ Finishing

Tool Rack

Pneumatic Sander

Disc Sander

Router

Prep/Sand Table

Chop Saw

Rollers RollersBathroom

Lounge/General Offices

5 101Feet

Facility Layout Example.

Planer


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Process 1

Process 2 Process 3

Process 4

Intermittent Or Job-lot Production.

Process 1

Process 2 Process 3

Process 4

Continuous Production.


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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


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CharacteristicsAnd StandardsIdentification,

Evaluation

Standard Deviation, SPC DataCollected

Documentation,Process Control

By OperatorsUsing SOP

Brainstorming For

Corrective Action

OngoingImprovement

In Teams

Basic Relationships In Data, SPC, Teams, Documentation, Improvement, Basis For Launch

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 Assessed, Variation Reduction

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Purpose OfThe Chart?

Chart Relation To Documentation?

Sample Size?Characteristic? Why? How?

Where Is Inspection?

Broad Charting Relationships For Data, Analysis, Improvement Systems

Charting? New Characteristic?

Sample Freq,Consistency?

InformationOn The Chart?

Judge Defects And Defectives?

Data Recorded Accurately?

Forms, Done Properly?

Points Plotted, Analyzed?

Charts Compared Over Time?

Discipline To Follow Up?

In Control Over Time?

Review OfCharacteristics?

Information Provided Teams?

Improvement,Shifts In Charts

Relationship ToVariable Charts?

Training In Place?

What Type Chart?

Start Short Run, Pre-Control

Start With Attribute

Inspection As Part Of SOP?


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Capability analysis applied 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


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Attributes Defined

Variables Defined

Characteristic Evaluation, Charting Evolution, Process Improvement And Phase Out System.

Checklists Or Checksheets For Tracking

NonconformitiesDesireable Features

Characteristics

Defectives

Defects Judgement Calls

Discrete Data

Specifications

Dimensions, Tolerances

Collected, Charted, Data

P Charts

X Bar And R

Begin With Short Run, Characteristic Evaluation, Teams Learning, Growing

Eventually Phase Out, Move To Different Characteristic, Product

Over Time, It Is Assumed That Process Will Come And Remain Under Control


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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

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Tool 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

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

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Supplier: Revision:


Process Description. Provide a written description of process in text format and a process flow chart depicting the same:

Tools For Manufacture/Production. Describe equipment required to produce the product, consistent with the flow chart above:

Process Parameters. Describe unique elements involved in processing the product which require additional explanation:

Product Characteristics. Describe all characteristics of the product, primarily as attributes or variables which are critical:

Class. Describe any codes or other unique identifiers per the specific industry or organization to help further distinguish the product:

Product/Process Specification. Provide specific measurable definitions for each product characteristic identified above:

Evaluation Method. Describe how specifications of characteristics are evaluated, what the measurement systems are:

Sample Size, Frequency of Inspection. Describe the sample, how it is derived, including devices used to inspect in a step by step manner:

Analysis Methods. Describe the methods and systems used to analyze the sampled data, such as statistical, experimental, and so on:

Reaction Program. Describe steps to be taken when product or process is found to be functioning inappropriately:

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……..

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Operation: Location:

Operator (s)

Team Members: Part/Service:

Other Pertinent Information: # Of Pieces

Shift:

General Operation Information Potential Waste Reductions/Analysis

Process Symbol Step Operation Procedure Time Other

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


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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……..

Provide A Definition For Each Term Identified, Explain How Your Team Will Apply The Concepts, Principles To Your Project:

Ongoing Process Control Plan:

Corrective Action System:

QFD:

Pareto Analysis:

Statistical Process Control:

Variable Measurement, Charting:

Attribute Measurement, Charting:

Capability:

Mean, Range:

Gage Repeatability & Reproducibility:

Normal Curve:

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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……..

Organization Under Discussion: Current Operation: Location:

General Description Of Operations/Production Functions/Systems Being Assessed As An Internal Audit:

ISO/QS Element (TS 16949 2002—Others) Technical Function Description Audit Preliminary Information Actions, Recommendations For Change

(list each element separately for analysis/audit)

(describe technical function being audited) (How does function compare to standard) (explain anticipated necessary actions, changes)

Planning Statement Or Issue, Particularly As Associated With The Service Environment: Criticality Level: HML (H = 5; M = 3; L = 1)

Fac = Facility issues; Cost = Cost issues; Time = Time issues; Pers = Personnel issues

Objectives Prioritized, 5 Being Highest: Criticality HML

Fac Cost Time Pers

5, 4, 3, 2, 1

Problem Background: Resources? (Budget/Other Concerns)?

Task/Deliverable/Objective: Who Will Do? How Measured?

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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

Researcher Communication Method, Internal And External Customers:

Toolkit/Blackboard Design Element, How Does It Work?

How To Improve Professional Relationships, Communication?

1. 1. 1. 1.

Identify How The Systems’ Design You Are Advocating Can Assist IN Tieing Together PPDPOA, TPMSS, FACR, TRIRPA And Other Elements Of Team Problem Solving And Improvement:

Explain ISO/QS Characteristics And Other Necessary Entities To Be Possessed By Documentation And Communication Systems, Categorically, Particularly Focused On Service Functions:

Using The Template At The End Of The Applications Complete A Cause And Effect Diagram Indicating Issues And Opportunities For Systemic Documentation Relationships/Improvements, Particularly Focused On Service Functions:

Identify And Explain Why Your Organization Is Well Suited To The Documentation And Communication System Being Developed, Particularly Focused On Service Functions:

short form tool 19 itttm tool #19 short form “kaizen documentation foundations for data driven...

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