Cindy Novak Quality Expo 092209 Presentation
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Transcript of Cindy Novak Quality Expo 092209 Presentation
CINDY NOVAK, CQIAQUALITY EXPO
SEPTEMBER 22, 2009
ISO 9001:2008 and Lean Six Sigma in Manufacturing for
the Better Good
Agenda
Welcome!What is Lean Six Sigma, ISO 9001:2008The WORMPIIT – The Eight Types of WasteBenefits of Reducing WasteStanding in the CircleHow Reducing Waste Benefits Your Sustainability
ProgramHow ISO 9001:2008 and Lean Six Sigma Work
TogetherCustomer SatisfactionQuestions
Lean Six Sigma
Why Lean Six Sigma?
ISO 9001:2008
The WORMPIIT
The Eight Types of Waste
WaitingOverproductionReworkMotionProcessing Intellect InventoryTransportation
Muda - Japanese for waste
Eight Types of Waste
Taiichi Ohno, the major contributor to the Toyota Production System, identified seven types of waste. He is considered the grandfather of Lean Manufacturing.
Jeffrey Liker, professor at University of Michigan added the eight, intellect.
Most recently, a ninth type of waste, energy has been discussed.
WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS
Work in the process has stopped.
Ensure adequate staffing at bottleneck
Cross-train employees so work continues when someone is absent
Make sure supplies are available where needed
Ensure equipment is properly maintained
Maintain safe work environment
The WORMPITT – Waiting
WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS
Engaging more resources than needed to deliver to your customer.
The worst type of waste because it hides or causes all others, especially inventory.
Establish process maps considering the downstream customer
Create workplace standards for each process
Create signal devices to prevent over processing, i.e. FIFO Lanes
The WORMPITT – Overproduction
WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS
Any form of scrap, mistakes, errors or corrections resulting from work not being done correctly the first time.
Ensure employees are competent and trained
Create error-proof processes
Create work instructions with the people who perform the work
Create and use checklists
Practice Corrective and Preventive Action
The WORMPIIT - Rework
WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS
Any extra movement by people that does not add value.
Arrange work areas to shrink movement
Place part trays near employees
Place necessary documents at work stations
Use color coding as much as possible
The WORMPIIT - Motion
WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS
Having to do anything more than is needed.
Remove unnecessary steps in a process
Consider enterprise resource planning software
Stop unnecessary signoffs and reviews
Use design for manufacturability
The WORMPIIT - Processing
WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS
Any supply that is in excess / unavailable.
Includes raw materials, WIP or finished goods.
Capital outlay that has not produced income.
Produce only enough to satisfy your downstream customer
Ensure that work arrives at the downstream process when it is required and is not waiting
The WORMPIIT - Inventory
WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS
Any supply that is in excess / unavailable.
Includes raw materials, WIP or finished goods.
Capital outlay that has not produced income.
Produce only enough to satisfy your downstream customer
Ensure that work arrives at the downstream process when it is required and is not waiting
The WORMPIIT - Inventory
WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS
Employees ideas, creativity and abilities are not fully tapped or even considered. Their other abilities are not explored.
Treat your employees as your greatest asset
Establish Quality Circles
Set up Employee Suggestion Systems
Create employee teams to solve process problems
LISTEN, LISTEN………… AND LISTEN!
The WORMPIIT - Intellect
WHAT IS IT?WHAT IS IT? SOLUTIONSOLUTION
Movement of work or paperwork from one step to the next step in the process.
Make the distance to where something is moved as short as possible.
Consider work cells and co-located teams.
The WORMPIIT - Transportation
Eight Types of Waste
Benefits of Eliminating WasteSignificantly lower costsHigher profit marginsMore effective, efficient processesExceeding high qualityMore engaged employeesDelighted customers!
Standing in the Circle
Genchi Genbutsu – Go and see at the actual place of workTaiichi Ohno used this to train new employees
An employee was directed to stand and observe an operation very carefully and identify waste within the operation and the conditions that cause the waste to exist.
If you don’t look, how do you know where the waste is?
ISO 9001:2008ISO 9001:2008 Lean Six SigmaLean Six Sigma
Plan
Do
Check
Act
DefineMeasureAnalyze ImproveControl
How ISO 9001:2008 and Lean Six Sigma Work Together
How ISO 9001:2008 and Lean Six Sigma Work Together
With quality objectives required by ISO, LeanSix Sigma provides methods to achieve them:
Prevention of defects at all stages from design through customer service;
Statistical techniques for establishing, controlling and verifying process capability and product
characterization; Investigation of the cause of defects relating to
product, process and quality system; and Continuous improvement of the quality of
products and services.
Type of Waste Type of Waste SustainabilitySustainability
TransportationInventory
ReworkWaiting
Energy
Reduction in fuel usage
No need to maintain unnecessary real estate
Reduction on scrap and waste sent to landfills
Use people and machines efficiently
Reduction in use of electricity, gas and water
How Reducing Waste Benefits your Sustainability Program
SustainabilitySustainability Social ResponsibilitySocial Responsibility
Reduction in fuel usage
No need to maintain unnecessary real estate
Reduction on scrap and waste sent to landfills
Use people and machines efficiently
Reduction in use of electricity, gas and water
Lower carbon footprintProtect public landsDedicate a parkReduce Mount
TrashmoreRecycle, reuse, returnMore energy focused on
the final outputConserve energy for the
most productive use
Sustainability complements Social Responsibility
Customer Satisfaction
Do you have Quality AND Sustainability programs? Do you have an Environmental Policy? If so, have you communicated this to your customers?
Clients expect lower prices today and there is no better way to make that happen than to cut waste. It’s better than cutting jobs!
Align lean and ISO activities with your corporate SRO policy. Let the community know what you are doing.
Include information on your cost-cutting programs on your website. Show results! Your customers may get ideas that help them as well and they will see your commitment as well.
Resources
American Society for Qualitywww.asq.org
International Organization for Standardizationwww.iso.org
Environmental Protection Agencywww.epa.gov
Getting Business Fit by Gary Kingwww.fitcert.com
Questions
Questions?
Thank you!
Remember what Gandhi said,
“You must be the change you want to see.”
Need help? Visit www.isochick.com