Lesson 6:

Continuous Process
Improvement
 THE JURAN TRILOGY

Joseph M. Juran

• Born on December 24, 1904

• Contribution in the field of

management, particularly quality
management.

• Developer of Juran Trilogy

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 The Juran Trilogy
- is an improvement cycle that - Juan brings out that good
is meant to reduce the cost poor financial results are achieved in an
quality by planning quality into organization through three
the product/process. managerial processes namely,
planning, control and improvement.

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 1.
What is Quality Planning?

in the planning stage, it is critical to define who your customers are and
find out their needs. After you know what the customer need, you're able
to define the requirements for your product/process/service/system, etc.,
and develop it.
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 Quality Quality Control (during operation)
Planning
Control
Control
Sporadic Spike
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Original zone
of
Quality Control
defective
Per cent

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New Zone of
Operations

Cost of Poor quality Quality

Begin

Chronic Waste Control

0
0 Time

Lesson Learn
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 2.

What is quality control?

Quality Control is the process of detecting mistakes in operational

outputs such as products and services. This can involve testing every
single ouput, such as the products off an assembly line.

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 EXAMPLE:
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A factory that produces apple juice

performs a basic test on every
bottle and a detailed test on several
units in every battle.

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 3.
What is quality improvement?

Quality improvement is to identify and prove the need for improvement

from the existing performance levels even though they meet the
target, and devise means and ways to achieve new target and
implement them successfully.

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EXAMPLE:

✘ A manufacturing company of
cellphones produce a new product
with camera quality close to
DSLR.

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 What is Kaizen?

 Is a japanese word which means  Kaizen is a Japanese

“gradual, orderly and continuous strategy for continuous
improvement. improvement.

 Kaizen succeed because it

 Kaizen does not need any capital is a good management
investment, but it requires time practice.
and effort of every employee in the
organization, right from the top  The Juran Trilogy and
management. Kaizen aim at continuous
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improvement.
 • Simply means “Change for the
better”.
• Refers to any activities that
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continually improves all business
functions or process and involves
every employee from the CEO to
the assembly line workers.
• Refers to both the action, plan and
a philosophy.

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 Two Activities of Kaizen

✣ Maintenance ✣ Improvement

- involves activities directed -function that aims at

at maintaining current reversing the current
technological, managerial, standards.
and operating standards.

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 Three Basic Principle of Kaizen

✣ WORK PLACE
EFFECTIVENESS
✣ ELIMINATION OF
WASTE, STRAIN AND
DISCREPANCY

✣ STANDARDIZATION

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 KaiZen's
10 Basic Principles
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 10 Basic Principles of Kaizen

1.) Improve everything 2.) Abolish old, traditional 3.) Accept no excuses and
continuously. concepts. make things happen.

4.) Say no to the status quo of 5.) If something is wrong

implementing new methods and correct it.
assuming they will work.

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 10 Basic Principles of Kaizen

6.) Empower everyone to 7.) Get information and 8.) Before making decisions,
opinion from multiple people. ask "why?" 5 times to get to
take part in problem solving.
the root cause.

9.) Be economical. 10.) Remember improvement has

no limit.

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PDCA AND 7 QUALITY
TOOLS
Kaizen advocates usage of 7 quality tools for problem
solving. It also calls for using PDCA cycle for
improvement of process.

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What is
5s?

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 5s Is ...

is a simple tool for organizing

the need to introduce
the workplace in a clean,
efficient and safe manner to standard operational
enhance productivity, visual practices to ensure
management and to ensure the efficient, repeatable, and
introduction of standardized safeways of working.
working

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 5s Concept

Seiri Seiton Seiso

Seiktsu Shitsuke

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SEIRI
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 Sort

 Cleaning

 Classify
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“
it refers to the sorting of the
clutter from the other items
within the work area that are
actually needed
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SEITON
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 Straighten

Simplify

Set in order

Configure
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“
is the process of taking the
required items that are
remaining after the removal of
clutter and arranging them in an
efficient manner.
 The following could be adopted
for enabling neatness in the organization:

Step 1: Plan to arrange neatly

Step 2: Decide where things should be stored

Step 3: Be consistent in following the rules

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SEISO
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✘ Sweep

✘ Shine

✘ ScrubClean

✘ Check
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“
is the thorough cleaning of
the area, tools, machines
and other equipment.
SEIKETSU
 ✘ Standardize

Place your screenshot here ✘ Stabilize

✘ Conformity
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Ensure common
standards and ways
of working
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�
�
SHITSUKE
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✘ Sustain

✘ Self-discipline

✘ Custom and Practice

Ensuring that the company continue
to continually improve using the
previous stages of 5s.

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 THE SEVEN DEADLY WASTE

✣ Waste from overproduction

✣ Waste of waiting time
✣ Transportation Waste
✣ Processing Waste
✣ Inventory Waste
✣ Waste of motion
✣ Waste from product defect

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 1. Overpduction Waste

✘ This occurs due to failure of production planning when

money is blocked in the unsold product.

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 2. Waste due to waiting

✘ Is a direct measure of quality of the organization.

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 3. Transportation

✘ Unnecessary transportation is a waste.

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 4. Processing Waste

✘ The machinery should be kept in smooth working condition by periodicc

and preventive maintenance to eliminate processing waste.

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 5. Inventory Waste

✘ Supply chain management should be such that

there are no excess materials.

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 6. Waste of Motion

✘ The objective of the organization should be to add

value by every motion of the employee and
machinery.

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 7. Product Defects

✘ The defective parts or supplies cause loss of

money. Thus eliminating scrap through zero
defects is the only sulotion to the problem.

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thanks!

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 GROUP 6

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