Process Management

Waste Elimination

Zero Waste
· Waste of Over production
· Waste of Correction
· Waste of Information movement
· Waste of Inventory
· Waste of Waiting
· Waste Motion
· Lack of Employee

Work Environment:

Inspiring and Challenging Work place
Lean manufacturing and Productivity
Measuring Productivity
Lean Productivity
Improving Productivity

Just in Time and Waste free Supply Chain:

Zero interruptions
F Design Flow Process
Ø F Redesign/relay out for flow
Ø L Reduce lot sizes
Ø O Link operations
Ø W Balance workstation capacity
Ø M Preventative maintenance
Ø S Reduce Setup Times
o Q Total quality control
Ø C worker compliance
Ø I Automatic inspection
Ø M quality measures
Ø M fail-safe methods
Ø W Worker participation

S Stabilize Schedule
Ø S Level Schedule
Ø W establish freeze windows
Ø UC Underutilize Capacity
o K Kanban Pull System
Ø D Demand pull
Ø B Backflush
Ø L Reduce lot sizes
o V Work with vendors
Ø L Reduce lead time
Ø D Frequent deliveries
Ø U Project usage requirements
Ø Q Quality Expectations
o I Further reduce inventory in other area
Ø S Stores
Ø T Transit
Ø C Implement Carroussel to reduce motion waste
Ø C Implement Conveyor belts to reduce motion waste

P Improve Product Design
Ø P Standard Production Configuration
Ø P Standardize and reduce the number of parts
Ø P Process design with product design
Ø Q Quality Expectations

Some Aspects of TPM

1. Kaizen or Continuous Improvement Activities : This deals with elimination of all losses in the production and support sections. Small but continuous changes for the better is the essential theme of Kaizen.
2. Autonomous Maintenance: Autonomous maintenance activities include all activities carried out by the production department which has a maintenance function like cleaning, checking, lubricating etc. to establish the condition of the equipment as it performance self-motivated teams.
3. Education and Training : Education and Training programs are intended to evaluate, analyze and improve the skill level of all employees.
4. Planned Maintenance: Planned Maintenance system is designed to create systems for achieving increased mean time between failure of equipment (MTBF), reduced mean time to repair(MTTR) and sizeable cuts in maintenance costs.
5. Quality Maintenance: The objective of Quality Maintenance program is to initiate and achieve zero defects, zero customer complaints and zero reprocessing.
6. MP (Maintenance Prevention) Design and Flow Control: These are activities developed to ensure maintenance free equipment and reduction in the life cycle cost (LCC) of equipment.
7. Safety & Hygiene: Safety & Hygiene programs establish zero accidents, zero pollution and a perfect hygienic environment.
8. Office TPM: Administrative and support sections of the production systems are geared upto cater to the demands of the production system without generating wastes or losses. Office productivity improvement is the goal of Office TPM activities.
9. Major Losses to be addressed

· Shutdown Losses
· Production Losses
· Equipment failure Losses
· Process failure Losses
· Normal Production Losses
· Abnormal Production Losses
· Quality Defect Losses
· Reprocessing Losses
· Management Losses
· Motion Losses
· Line Organization Losses
· Downtime from breakdown and changeover times
· Speed losses (when equipment fails to operate at its optimum speed)
· Idling and minor stoppages due to the abnormal operation of sensors, blockage of work on chutes, etc.
· Process defects due to scrap and quality defects to be repaired
· Reduced yield in the period from machine start-up to stable production.

Lean Sigma

Zero Defects: Six Sigma Performance

What is six sigma?
Six sigma as a system management
Six sigma in your organization.
Note to Manager. How you can help lead Six sigma?
Quality is conformance to requirements
Defect prevention is preferable to quality inspection and correction
Zero Defects is the quality standard
BS EN ISO 9000
Quality is measured in monetary terms – the Price of Nonconformance (PONC)

Customer Delight

Internal & External Customer Driven: Zero Customer Complaints
The importance of customer Satisfaction
Creating Satisfaction customers
Understanding customer Needs
Gathering customer information
Customer Relationship Information
Measuring customer Satisfaction