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TOTAL QUALITY MANAGEMENT
© ABSL Quality Solutions 2007 © STM Power Limited
STM Quality Limited
How often have you used the expressions: “That was a waste of time!” or “That was a waste of money!” or “That was a waste of effort!”
© STM Quality Limited
Wasted Time STM Quality Limited Just imagine if we could collect all the time together that we have wasted in the past How much time would that be? © STM Quality Limited .
Wasted Money STM Quality Limited Just imagine if we could collect all the money together that we have wasted in the past How much money would that be? © STM Quality Limited .
Wasted Effort STM Quality Limited Just imagine if we could collect all the effort together that we have wasted in the past How much effort would that be? © STM Quality Limited .
The Problem With Waste STM Quality Limited The problem with wasted time. money & effort is: When it’s gone… .it’s gone! © STM Quality Limited .
© STM Quality Limited .Eliminating Waste STM Quality Limited So what can we do to eliminate waste? We first need to identify what is & is not waste. then we can look at ways of eliminating or at least reducing waste.
Pressing.Identifying Waste in the Workplace STM Quality Limited Operational Activity Value added Operations Any process that changes the nature. welding.g. This is where we make a profit! © STM Quality Limited . heat treatment. shape or characteristic of the product in line with customer requirements e.
e. Inspection.g. but does not increase product value. This is where we make a loss! © STM Quality Limited . maintenance.Identifying Waste in the Workplace STM Quality Limited Operational Activity Non-Value added Operations Work carried out which is necessary under current conditions. tool change.
OPERATOR TIME WASTE NON-VALUE ADDED VALUE ADDED ELIMINATE MORE TIME FOR OTHER ACTIVITIES NON-VALUE ADDED VALUE ADDED © STM Quality Limited .Value Added and Non-Value Added operations STM Quality Limited The objective is to raise the ratio of Value added operations to non-value added operations and eliminate waste.
7W – The Elimination of Waste STM Quality Limited So. now we understand the difference in value added & non-value added operations. what are the benefits in eliminating all waste? • Reduced costs • Greater Capacity • Bottlenecks are identified © STM Quality Limited .
7W – 7 Types of Waste STM Quality Limited 1 Over-production 2 Inventory 3 Transportation 4 Process 5 Idle Time 6 Operator Motion 7 Bad Quality © STM Quality Limited .
© STM Quality Limited . risk of producing obsolete stock. machine faults. Excessive set-up times.7W – 1. Over-production STM Quality Limited Over-production Producing more than is needed hides a multitude of problems.
all for an activity that adds no value to the product. bar coding & automation. © STM Quality Limited . Inventory STM Quality Limited Inventory Carrying stock attracts cost & storage problems. racking. sophisticated computers.7W – 2. Storage leads to stacking.
These can be improved by changes to the work environment. © STM Quality Limited .7W – 3. Large transport is easily identified but small transport such as manual labour may not be so noticeable. Transportation STM Quality Limited Transportation This may appear unnecessary but does add value.
7W – 4. Process STM Quality Limited Process Adds cost but no value .g.e.trimming & moulding to a level that is beyond the required standard adds extra time that customers do not want to pay for. © STM Quality Limited .
Idle Time STM Quality Limited Idle Time Typically. © STM Quality Limited . waiting for products & services from preceding operations. waiting for work from their previous set-up or waiting for cycles to finish. or meetings to start.7W – 5.
single handed operations where both should be used. All of these take time or use time poorly. Operator Motion STM Quality Limited Operator Motion Typically.7W – 6. stretching unnecessarily or awkwardly and walking between things. none add value. © STM Quality Limited .
If operators fail it is because the process allowed them to fail through inadequate training or because the process was not capable in the first place.7W – 7. © STM Quality Limited . Bad Quality STM Quality Limited Bad Quality Rejects are always produced by systems and procedures created by management.
• Plan our production processes. now we understand the 7 wastes. STM Quality Limited So. we can: • Produce work to the standard required. • Put our efforts to the best possible use. • Train to make quality work every time! © STM Quality Limited . • Use transportation more wisely. • Carry only essential stock.7W – The Elimination of Waste • Produce only what is needed.