054 JIT and Quality Management System

INTEGRATION OF JIT INTEGRATION OF JIT INTO QUALITY CONTROL INTO QUALITY CONTROL SYSTEMSYSTEM

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JIT & Quality Management JIT & Quality Management SystemsSystems

The existing quality management The existing quality management systems -ISO 9000 should include systems -ISO 9000 should include JIT.JIT.

It is practical to integrate ISO 9000 It is practical to integrate ISO 9000 (20 clauses) with the 7 JIT concepts.(20 clauses) with the 7 JIT concepts.


Successful firms are using 7 concepts Successful firms are using 7 concepts of JIT with ISO 9000 quality of JIT with ISO 9000 quality management systems in order to management systems in order to improve their productivity.improve their productivity.

To have high quality product and high To have high quality product and high productivity is a challenging task for productivity is a challenging task for project management team. project management team.


All large construction companies have already All large construction companies have already established quality management systems within established quality management systems within their organisation to meet ISO 9000 their organisation to meet ISO 9000 requirements.requirements.

Some companies are implementing the concepts Some companies are implementing the concepts of JIT and ISO 9000 separately.of JIT and ISO 9000 separately.

There are similarities between JIT and ISO There are similarities between JIT and ISO 9000. 9000.

The management team should always consider The management team should always consider incorporating them for a better outcome. incorporating them for a better outcome.


Both ISO 9000 and JIT objectives are: Both ISO 9000 and JIT objectives are: 1) high productivity 1) high productivity 2) perfect product each time and every 2) perfect product each time and every

time.time. ISO has no any clause related to project ISO has no any clause related to project

time.time. It is a tool for productivity improvement. It is a tool for productivity improvement.


Quality and productivity are inter-Quality and productivity are inter-related.related.

High quality product will eliminate High quality product will eliminate repeat work and increases repeat work and increases productivity.productivity.

The generic requirements of ISO The generic requirements of ISO clauses with JIT can be shown as: clauses with JIT can be shown as:

JIT Concepts

1-Waste elimination2-Kaban System

3-Smooth workflow4-Total Quality Control

5-Employee involvement6-Supplier relationship

7-Continuous improvement

Solution

High productivity

ISO 9000-R equirements

4.1 Management responsibility4.2 Quality system4.3 Contract review4.4 Design control

4.5 Document and data control4.6 Purchasing

4.7 supply chain4.8 Product identification/availability/track record/green

issues/price/etc4.9 Process control

4.10 Inspection/testing4.11 Control of inspection, measuring, test requirement

4.12 Inspection and test status4.13 Control of non-conforming products

4.14 Preventive action and corrective action4.15 Handling of materials, good storage policy, preservation and

delivery policy4.16 Quality control and record keeping

4.17 Internal quality audit4.18 Training4.19 Servicing

4.20 Statistical techniques

INTEGRATING JIT INTOQUALITY MANAGEMENT

SYSTEM

ISO 4.1 Managementresponsibility

ISO 4.2 Quality system

ISO 4.3 Control review

ISO 4.4 Design control

ISO 4.5 Document and datacontrol

ISO 4.6 Purchasing

ISO 4.7 Supply chain

ISO 4.8Product

identification/availability/ track record/green

issues/ISO 4.9 Process control

ISO 4.10 Inspection and testing

ISO 4.11 Test requirement,measuring, control,.

ISO 4.12 Inspection and testcontrol

ISO 4.13 Control of nonconforming products

ISO 4.14 Preventive action andcorrective action

ISO 4.15 Handling of materialsand good storage

policy,ISO 4.16 Quality control/record

keepingISO 4.17 Internal quality audit

ISO 4.18 Training

ISO 4.19 Servicing

ISO 4.20 Statistical techniques

JITWaste

elimination

JITKa bansystem

JITSmooth

workflow

JITTotal

qualitycontrol

JITEmployee

involvement

JITSuppler

relationship

JITContinuous

improvement

INTEGRATING JIT INTO QUALITY MANAGEMENT SYSTEM

JIT & Quality Management JIT & Quality Management Systems-waste reductionSystems-waste reduction

OverproductionOverproduction Long waiting timesLong waiting times Poor transportation schedulesPoor transportation schedules Processing failuresProcessing failures High inventoriesHigh inventories Excessive movement of materials on siteExcessive movement of materials on site Poor workmanshipPoor workmanship Defective productsDefective products


JIT requires a system to control the level JIT requires a system to control the level waste on sitewaste on site

Project management team can achieve Project management team can achieve waste reduction if they involve:waste reduction if they involve:

1.1. Human elementsHuman elements2.2. Documentation and data control toolDocumentation and data control tool3.3. Quality assessment techniquesQuality assessment techniques


1.1. Planning proceduresPlanning procedures2.2. CommunicationsCommunications3.3. Verification proceduresVerification procedures4.4. Identification proceduresIdentification procedures5.5. Reviews of designReviews of design6.6. Continuous improvementContinuous improvement

ISO 9000 -Clause 4.1 Management ISO 9000 -Clause 4.1 Management responsibilityresponsibility

Quality policy statement should Quality policy statement should incorporate JIT.incorporate JIT.

Waste control be stated clearly in the Waste control be stated clearly in the policy.policy.

A good technique should be adopted to A good technique should be adopted to measure waste on site.measure waste on site.

Waste due to poor workmanship most not Waste due to poor workmanship most not exceed 2% of the total cost.exceed 2% of the total cost.

ISO 9000Clause

4.1Managementresponsibility

Resources4.1.2.2

Qualitypolicy4.1.1

Managementreviews

4.1.3

Waste eliminationGood techniquesto measure waste

IncorporateJIT

Poor workmanshipwaste must beless than 2% of

total cost

Define role ofindividuals in relation

to wastemanagement and

control

Labour

Material

MachineryClause 4.1 Management responsibilityClause 4.1 Management responsibility

Clause 4.1 Management Clause 4.1 Management responsibilityresponsibility

There should be regular training for There should be regular training for workforce reminding them of waste workforce reminding them of waste policy.policy.

A qualified person should be A qualified person should be responsible for waste control.responsible for waste control.

New products and machinery requires New products and machinery requires new system, polices and processes.new system, polices and processes.

This will demand new roles for the This will demand new roles for the individual.individual.

ISO 9000-Clause 4.2 Quality ISO 9000-Clause 4.2 Quality systemsystem

sub-clause 4.2.3sub-clause 4.2.3 JIT requires tight waste management JIT requires tight waste management

control.control. Waste elimination is required at all Waste elimination is required at all

stages and requires several stages such stages and requires several stages such as:as:

A quality plan to control and define A quality plan to control and define waste.waste.

Identifying relevant tools for waste Identifying relevant tools for waste reduction.reduction.

ISO 9000-Clause 4.2 Quality ISO 9000-Clause 4.2 Quality systemsystem

Identifying relevant tools for quantifying Identifying relevant tools for quantifying the level of waste.the level of waste.

Site management involvement from Site management involvement from design stages.design stages.

Proper waste standards and Proper waste standards and requirements.requirements.

Knowledge based system to identify and Knowledge based system to identify and prepare report for waste reduction.prepare report for waste reduction.

ISO 9000-Clause 4.3ISO 9000-Clause 4.3Contract review Contract review

Sub-clause 4.3.2 ReviewSub-clause 4.3.2 Review The project duration and resources are identified The project duration and resources are identified

in the project.in the project. The reduction of buffer stock will increase the The reduction of buffer stock will increase the

shortage of materials.shortage of materials. Double handling will increase material waste on Double handling will increase material waste on

site.site. Any change in material specification will result in Any change in material specification will result in

contractual change.contractual change. The master plan will suffer, completion time The master plan will suffer, completion time

might change.might change.

ISO 9000-Clause 4.4ISO 9000-Clause 4.4ISO 9000

Clause4.4

Design control

4.4.6design review

4.4.3Organisationaland technical

interfaces

4.4.8Design

validation

4.4.4Design input

4.4.5Designoutput

sub-clauses

4.4.7Design

verification

4.4.9Design changes

4.4.2Design and

developmentplanning

ISO 9000-Clause 4.4ISO 9000-Clause 4.4 Design is the main factor for resource planning.Design is the main factor for resource planning. Change of design after work commencing will Change of design after work commencing will

cause delay, create waste, change resource cause delay, create waste, change resource allocation, the master schedules are derived allocation, the master schedules are derived from final design.from final design.

Design variation must be kept to a minimum.Design variation must be kept to a minimum. Have a system to control design.Have a system to control design. Statutory requirement, client expectations, Statutory requirement, client expectations,

project quality plan, should all be included into project quality plan, should all be included into design control system. design control system.

ISO 9000-ClausesISO 9000-Clauses Clause 4.5 Data and document with sub-Clause 4.5 Data and document with sub-

clause 4.5.1clause 4.5.1 Clause 4.6 Purchasing sub-clauses are: Clause 4.6 Purchasing sub-clauses are: 1.1. 4.6.2 evaluation of sub-contractors4.6.2 evaluation of sub-contractors2.2. 4.6.3 purchasing data4.6.3 purchasing data3.3. 4.4.4 verification of purchasing data4.4.4 verification of purchasing data4.4. 4.4.4.1 supplier verification at sub-contractors 4.4.4.1 supplier verification at sub-contractors

head officehead office5.5. 4.4.4.2 customers verification of the sub-4.4.4.2 customers verification of the sub-

contracted productcontracted product

ISO 9000-ClausesISO 9000-Clauses Suppliers and sub-contractors make major Suppliers and sub-contractors make major

contribution in waste reduction.contribution in waste reduction. Their product, their workmanship, the Their product, their workmanship, the

method of delivery can influence the level method of delivery can influence the level of waste.of waste.

Purchasing data and verification of Purchasing data and verification of products are tools to establish the products are tools to establish the suppliers and sub-contractor's ability to suppliers and sub-contractor's ability to eliminate wastage.eliminate wastage.

ISO 9000-ClausesISO 9000-Clauses

Clause 4.7 Control of customer-supplied Clause 4.7 Control of customer-supplied productproduct

Clause 4.8 Product identification-Clause 4.8 Product identification-availabilityavailability

Clause 4.9 Process control-waste can be Clause 4.9 Process control-waste can be identified and reduced or completely identified and reduced or completely eliminated through process control. By eliminated through process control. By considering items such as:considering items such as:


Process flow-is a method of considering Process flow-is a method of considering the flow of production from start to end.the flow of production from start to end.

It is about workmanship control, It is about workmanship control, machinery control, transporting on site, machinery control, transporting on site, handling of materials, layout.handling of materials, layout.

A procedural study by an expert in this A procedural study by an expert in this field and the method of human field and the method of human communication all will reduce waste.communication all will reduce waste.


Clause 4.9 Inspection and testing and Clause 4.9 Inspection and testing and the sub-clauses are:the sub-clauses are:

1.1. 4.10.2 Receiving inspection and testing4.10.2 Receiving inspection and testing2.2. 4.10.3 In progress inspection and testing4.10.3 In progress inspection and testing3.3. 4.10.4 Final inspection and testing4.10.4 Final inspection and testing The accuracy of test equipment and The accuracy of test equipment and

materials test, will provide the means of materials test, will provide the means of measuring and controlling waste.measuring and controlling waste.

ISO 9000-ClausesISO 9000-Clauses These test would provide information to These test would provide information to

check the client’s required standards and check the client’s required standards and the contractors standards.the contractors standards.

Clause 4.11 Control of inspection, Clause 4.11 Control of inspection, measuring and test equipmentmeasuring and test equipment

The is a general sub-clause of 4.11.1The is a general sub-clause of 4.11.1 Clause 4.13 Control of nonconforming Clause 4.13 Control of nonconforming

product with a sub-clause 4.13.1 Review product with a sub-clause 4.13.1 Review and disposition of nonconforming product.and disposition of nonconforming product.


Clause 4.14 Corrective and preventive Clause 4.14 Corrective and preventive action and sub-clauses are;action and sub-clauses are;

1.1. 4.14.1 Corrective action,4.14.1 Corrective action,2.2. 4.14.2 Preventive action4.14.2 Preventive action Clause 4.15 Handling, storage, Clause 4.15 Handling, storage,

packaging, preservation and deliverypackaging, preservation and delivery Clause 18 TrainingClause 18 Training Clause 4.19 Servicing Clause 4.19 Servicing

Managementresponsibility

Clause 4.1

sub-clause 4.1.2.1

Responsibility andauthority

sub-clause 4.1.3Management review

sub-clause 4.1.2.2Resources

Section-CDemand for Resources

Forecasting

Section-BDemand for Resources

(Forecasting)

Projectedresourcedemand

Sub-section

Section-ADemand for Resources

(Forecasting)

054 JIT and Quality Management System

Engineering

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