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e-course: TQM2000, 6 Sigma & Poka-Yoke

e-course: TQM2000, 6 Sigma & Poka-Yoke

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Published by Carlo Scodanibbio
An e-course showing how the "zero defects" target of today's TQM can be achieved.

Zero Defects. That's the simple and, at the same time, extremely challenging target set by modern TQM under the Lean Thinking philosophy. Is it achievable? This e-course wants to prove that, YES, it is.

By illustrating the main TQM tools available to all enterprises to get to the target - 100% Testing, the 6 Sigma Methodology and the Poka-Yoke Discipline - in rather great details and with lots of examples and case studies, this e-course gives the basis as well as practical guidelines for the purpose.
The 6 Sigma methodology is presented in a "no-jargon" fashion, in order to be grasped simply and rapidly.
The Poka-Yoke approach is dealt with in a very practical, example-driven way, so that it can become soon effective for the alert reader.
Implications, constraints, field of applicability and pre-requisites for both disciplines are covered and debated.
Besides, the difference existing between the 6 Sigma and the Lean Thinking approach to the improvement of processes subject to remarkable variability is illustrated in a down-to-earth fashion.

Course contents and main topics:
* The concepts of World-Class Performance and World-Class Operations
* Total Quality Management in the years 2000: the core principles. The ultimate target: zero defects.
* TQM 2000: the tools. Why "traditional" Quality Control and Statistical Process Control are rapidly becoming obsolete - 100% Testing: pro's and con's and fields of applicability - 6 Sigma - Poka-Yoke.
* The 6 Sigma Methodology. Basic Definitions - 6 Sigma vs. traditional methodology - The role of 6 Sigma - How to calculate a Process' Sigma Level - Yield to Sigma Conversion Table - Why 6 Sigma? - The approach to improvement of processes: DMAIC - Example of practical application - Remarks on use and deployment of the 6 Sigma methodology.
* Lean Thinking vs. 6 Sigma. Lean Thinking simplicity vs. 6 Sigma complexity. Practical example.
* The Poka-Yoke discipline. Poka-Yoke examples in Product Design. Mistake-proofing in working methods & processes.
* Zero Defects: reality, not myth!

by Carlo Scodanibbio http://www.scodanibbio.com
An e-course showing how the "zero defects" target of today's TQM can be achieved.

Zero Defects. That's the simple and, at the same time, extremely challenging target set by modern TQM under the Lean Thinking philosophy. Is it achievable? This e-course wants to prove that, YES, it is.

By illustrating the main TQM tools available to all enterprises to get to the target - 100% Testing, the 6 Sigma Methodology and the Poka-Yoke Discipline - in rather great details and with lots of examples and case studies, this e-course gives the basis as well as practical guidelines for the purpose.
The 6 Sigma methodology is presented in a "no-jargon" fashion, in order to be grasped simply and rapidly.
The Poka-Yoke approach is dealt with in a very practical, example-driven way, so that it can become soon effective for the alert reader.
Implications, constraints, field of applicability and pre-requisites for both disciplines are covered and debated.
Besides, the difference existing between the 6 Sigma and the Lean Thinking approach to the improvement of processes subject to remarkable variability is illustrated in a down-to-earth fashion.

Course contents and main topics:
* The concepts of World-Class Performance and World-Class Operations
* Total Quality Management in the years 2000: the core principles. The ultimate target: zero defects.
* TQM 2000: the tools. Why "traditional" Quality Control and Statistical Process Control are rapidly becoming obsolete - 100% Testing: pro's and con's and fields of applicability - 6 Sigma - Poka-Yoke.
* The 6 Sigma Methodology. Basic Definitions - 6 Sigma vs. traditional methodology - The role of 6 Sigma - How to calculate a Process' Sigma Level - Yield to Sigma Conversion Table - Why 6 Sigma? - The approach to improvement of processes: DMAIC - Example of practical application - Remarks on use and deployment of the 6 Sigma methodology.
* Lean Thinking vs. 6 Sigma. Lean Thinking simplicity vs. 6 Sigma complexity. Practical example.
* The Poka-Yoke discipline. Poka-Yoke examples in Product Design. Mistake-proofing in working methods & processes.
* Zero Defects: reality, not myth!

by Carlo Scodanibbio http://www.scodanibbio.com

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Published by: Carlo Scodanibbio on May 08, 2009
Copyright:Attribution Non-commercial

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05/11/2014

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April 2009
Copyright: © Carlo Scodanibbio 2009 – All rights reserved
 
A simple copyright statement: you are authorised to install this e-course in one computer station only.You are authorised to print this entire course and copy it for exclusive use by employees of your Organisation.You are not authorised to distribute this e-course - by electronic or other means and supports - outside your Organisation.
 
http://www.scodanibbio.com 
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Key-words: e-course distance learning e-learning course training education continuing leantqm, total, quality, management, customer, client, needs, wishes, expectations, standard,standards, explicit, implied, target, zero, defects, 6, six, sigma, methodology, dmaic, poka,yoke, poka-yoke, mistake, error, proofing
 
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“Total Quality Management 2000: 6 Sigma and Poka-Yoke”Table of Contents
World-Class Performance 3World-Class Operations 6Total Quality Management 7Core TQM principles 9Traditional QC and SPC 11100% Testing 11The 6 Sigma Methodology 12Basic Definitions 136 Sigma vs. traditional methodology 21The role of 6 Sigma 25How to calculate a Process’ Sigma Level 26Yield to Sigma Conversion Table 26Why 6 Sigma? 27The approach to improvement of processes: DMAIC 28Example of practical application 30Remarks 31Lean Thinking vs. 6 Sigma 32The Poka-Yoke discipline 40Poka-Yoke examples in Product Design 43Mistake-proofing in working methods & processes 45Credits 52Enclosures: Quality Function Deployment 52Solution of Exercises 55Excerpts from Carlo Scodanibbio web site 58
TQM 2000: 6 Sigma and Poka-Yoke
 
3
Dear e-Participant,Welcome to this e-Course! I am confident you will find it of interest, beneficial and, at times, also abit entertaining.To begin with, a quick presentation: I am Carlo Scodanibbio, Italian, Engineer, graduated in 1970,and with some 38 years of post-graduate experience in Project Engineering, Plant Engineering,Project Management, Industrial Engineering and Operations Management Consulting.I have been a free-lance Industrial Consultant for the past 28 years, and a HR Trainer for the past18.My field of activity is: World Class Performance in the Small and Medium Enterprises.I have operated in several Countries, including Italy, Romania, Malta, Turkey, Cyprus, Lebanon,Cape Verde, Kenya, Mauritius, Malaysia, India, Saudi Arabia, South Africa and neighbouringCountries.My “real-world” training style is very interactive. I am afraid this won’t be possible in the case of ane-Course, such as this one.And yet, as a participant in this e-Course, you are entitled to contact me for clarifications or further explanations with regard to the topics of this Course.You may do so by e-mail:mail@scodanibbio.com And now let’s start.The title of this Course is:
 
“Total Quality Management 2000: 6 Sigma and Poka-Yoke”
Let me introduce today’s concept of Total Quality Management and its allied disciplines 6 Sigmaand Poka-Yoke: we have to look at it under a wider perspective, the World-Class Performanceperspective.
WORLD-CLASS PERFORMANCE
There is new terminology used today, sometimes abused, sometimes mis-used.The term “
world-class
”, for instance, has become very fashionable. Airlines use it, InsuranceCompanies use it, Car Manufacturers use it… in fact it is widely used.To indicate what?To indicate a “standard”, a “level” which seem to be the
best under the circumstances
.So there are world-class enterprises, world-class services, world-class products…Meaning: that enterprise, that service, that product, is of “world-class” calibre, or “of a standardcomparable to that of the best in the classroom” where the classroom is the entire world.
TQM 2000: 6 Sigma and Poka-Yoke

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