OPMN06B

PRODUCTIVITY AND
QUALITY TOOLS
Presented By: Ma’am CK

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 PRELIM HIGHLIGHTS

TOPIC 1
1. Quality and Productivity Improvement.
1.1 Kaizen approach
1.2 Incremental VS Breakthrough
Improvement
 PRELIM HIGHLIGHTS

TOPIC 2
2. Team Approach in Quality and Productivity
Improvement
2.1 Quality Control Circle
2.2 Team Dynamics
 PRELIM HIGHLIGHTS

TOPIC 3
3. PDCA Concepts and Approach
3.1 Problem Solving Process
3.2 PDCA and 7 QC Tools
3.3 PDCA and Team Problem Solving
what to expect and learn..

OBJECTIVE

Understand the concept of Kaizen.

Create and implement Kaizen program.
Explain the difference between
incremental and break through
improvement
 QUALITY AND
IMPROVEMENT
Improving productivity and quality in your business
typically results in increased customer and employee
satisfaction. Using quality management system
techniques such as process mapping, benchmarking
and Cost-benefit analysis, you can achieve regular
improvement in all your work-flow processes.
 KEY 1
Analyze your processes. Focus not on the people
performing the job but on the tasks they do.
Standardize policies and procedures through your
company to maximize efficiency. Train all
personnel adequately so they can produce high-
quality products and take pride in their work.
 KEY 2

Align your business processes

with other companies in your
industry.
 KEY 3
Develop performance measurements. Benchmark your current
processes, identify problems, predict future outcomes and
measure productivity gains using key performance indicators for
your industry. For example, measure quality and productivity in
your customer support center by measuring the time it takes to
resolve customer issues and the customer satisfaction rate for
those support cases.
 KEY 4
Build quality testing into your processes — not at the end when
it is more expensive to fix. Perform testing on an iterative basis.
Resolve defective component problems as you encounter them
without waiting for the entire testing cycle to complete.
Implement automated testing if possible, because it executes
without human intervention and results in a pass or fail outcome
that is easy to interpret and act upon.
 KEY 5
Set business strategies such as Six Sigma to improve quality and
productivity. Create projects that define a problem, measure the
current process, gather relevant data and analyze the data to
validate the cause-and-effect relations. Determine the root cause
of issues and design interventions to improve or optimize the
processes. Control production so that defects get corrected early
on before they impact your final product.
 KEY 6
Value employee, customer, supplier and business partner feedback and input
regarding solving product or service problems. Measure quality and productivity
gains by increases in customer satisfaction. Use customer feedback to improve
current products and influence the design of new ones. Leveraging customer
requirements in your process redesign efforts can help you focus your efforts on
the most lucrative areas of business in your industry. For example, conduct
surveys or focus groups to gather information to resolve top issues with your
product or service. Prepare a report summarizing findings, and distribute the report
throughout your organization to improve quality and productivity.
WHAT IS KAIZEN
APPROACH?
 KAIZEN APPROACH
Known for being a quality management,
collaboration, and continuous improvement
tool, the Kaizen approach advocates
progressive change management in a
business, while limiting risks.
 KAIZEN APPROACH
Over 30 years ago, Masaaki Imai sat down to ​pen the
groundbreaking book ‘Kaizen: The Key ​to Japan’s Competitive
Success’ (McGraw Hill). Through this book, the term KAIZEN™ was
introduced in the western world. Today KAIZEN™ is recognized
worldwide as an essential pillar of an organization’s long-term
competitive strategy. Since introducing this term as a systematic
approach to business improvement, companies that implement
KAIZEN™ have continually yielded superior results.
KAIZEN APPROACH
 EXAMPLE OF
KAIZEN APPROACH
 5 ELEMENTS
KAIZEN APPROACH
teamwork,
personal discipline,
improved morale,
quality circles,
suggestions for improvement.
 6 STEPS
KAIZEN APPROACH

Identify an opportunity, an objective for improvement,

Explore new ideas by consulting with your employees,
Break the objective down into sub-objectives or deliverables,
Plan the tasks for each sub-objective, without overlapping
human and material resources or timeframes,
Test, monitor progress and adapt the schedule,
Move on to the next objective.
 KAIZEN PROJECT

PLAN ACT
 BREAKTHROUGH
IMPROVEMENT
Breakthrough improvement involves major
improvements in key business areas. These
are often ongoing, long-term problems that
can only be solved through focused,
dedicated resources working for a limited
period of time.
 INCREMENTAL
It is usually achieved through the use of
Kaizen events. It is a process of making
small, consistent adjustments to improve
business performance over time. It involves
breaking down larger goals into smaller,
achievable steps that can be implemented
gradually.
WORKING ASSESSMENT

CREATE A KAIZEN DAILY LIFE

include the before and after daily routine

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