DENG 605:

QUALITY SYSTEMS AND PROCESS IMPROVEMENT

Module 6:
UNDERSTANDING THE CONCEPT
OF CONTINUOUS IMPROVEMENT
June 25, 2023

Reporter:
MAUREAL, Alex
OUTLINE:
I. The Concept of Continuous Improvement
 What is continuous Improvement?
 Key Elements of Continuous Improvement

II. Introduction to Lean Principles

 Definition of Lean Principles
 Key Lean Principles
 Common Lean Tools and Techniques

II. Application of Lean Principles in Process Improvement

 Benefits of Applying Lean Principles
 Case Study / Success Stories

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
The Concept of Continuous Improvement
What is continuous Improvement?
also known as continuous improvement process (CIP) or continuous improvement
management (CIM), is a systematic approach that focuses on constantly enhancing
processes, products, or services within an organization. It is based on the idea that small,
incremental improvements made consistently over time can lead to significant
advancements and positive outcomes.

Continuous improvement originated from the principles of Total Quality Management

(TQM) and Lean Manufacturing, which emerged in the mid-20th century. These
approaches emphasized the importance of eliminating waste, reducing defects, and
optimizing efficiency in order to achieve higher levels of customer satisfaction and
organizational success.

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
The Concept of Continuous Improvement
What are the Key Elements of Continuous Improvement?

• Culture of Learning: Continuous improvement requires a culture that fosters learning, innovation, and
adaptability. Organizations need to encourage employees at all levels to identify areas for improvement
and empower them to propose and implement solutions.
• Process-Oriented Thinking: It involves analyzing and improving processes across the entire value
chain, from production and operations to customer service and support. By examining each step of the
process, organizations can identify bottlenecks, redundancies, and inefficiencies, and implement
changes to streamline operations.
• Data-Driven Decision Making: Continuous improvement relies on data and metrics to drive decision-
making. Organizations need to collect and analyze relevant data to identify trends, patterns, and areas
requiring improvement. This data-driven approach helps in setting performance targets, monitoring
progress, and making informed decisions about improvement initiatives.
• Kaizen Philosophy: Kaizen, a Japanese term meaning "change for the better," is central to the concept
of continuous improvement. It emphasizes the importance of small, incremental changes made by
every individual within the organization. Kaizen encourages employees to seek improvement
opportunities, share ideas, and actively participate in problem-solving.

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
The Concept of Continuous Improvement
What are the Key Elements of Continuous Improvement?

• Iterative Approach: Continuous improvement is an ongoing, iterative process that involves

cycles of planning, executing, evaluating, and refining. Organizations set improvement
goals, implement changes, assess the outcomes, and then use that feedback to further
refine their processes and continue the improvement journey.
• Engagement and Collaboration: Successful continuous improvement initiatives require
the active involvement and collaboration of all stakeholders, including employees,
managers, and even customers. Engaging employees in improvement activities not only
improves morale and job satisfaction but also taps into their knowledge and experience to
drive meaningful change.
• Embracing Change: Continuous improvement recognizes that change is necessary for
growth and staying competitive in a dynamic business environment. Organizations must be
open to new ideas, receptive to feedback, and willing to adapt their processes and
strategies to address emerging challenges and seize opportunities.

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
The Concept of Continuous Improvement

Continuous improvement is applicable across various industries and sectors,

including:
 manufacturing
 healthcare
 software development,
 customer service, and more.

By embracing this concept, organizations can:

 foster a culture of excellence
 achieve operational efficiencies
 enhance customer satisfaction, and
 drive long-term success.

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
Introduction to Lean Principles
Lean principles are a set of guiding concepts and philosophies derived from the Toyota
Production System (TPS), a renowned manufacturing methodology developed by Toyota.
These principles aim to:
 improve efficiency
 eliminate waste, and
 optimize processes in order to deliver maximum value to customers.

Lean principles can be applied across various industries and sectors, not just limited to
manufacturing.

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
5 Core Lean Principles
1. Value: Define value from the customer's perspective and focus on activities that
directly contribute to it.
2. Value Stream: Map the entire value stream, visualizing all steps and activities
required to deliver a product or service.
3. Flow: Create a smooth, uninterrupted flow of work by minimizing interruptions,
bottlenecks, and delays.
4. Pull: Establish a pull-based system where work is initiated based on customer
demand, reducing overproduction.
5. Perfection: Strive for continuous improvement, seeking perfection in processes
through incremental changes.

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
Lean Tools and Techniques
Some commonly used Lean tools and techniques for process
improvement:

 5S: Sort, Set in Order, Shine, Standardize, Sustain.

 Kaizen: Encourage continuous improvement through small, incremental
changes.
 Kanban: Visualize and manage workflow to optimize resource utilization
and minimize inventory.
 Value Stream Mapping: Analyze and map the flow of materials and
information to identify improvement opportunities.
 Just-in-Time (JIT): Produce and deliver items in the right quantity, at the
right time, to reduce waste and inventory.

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
Benefits of Lean Principles in Process Improvement

Advantages organizations can gain by applying Lean principles to process

improvement:

 Waste Reduction: Eliminate non-value-added activities, such as overproduction,

waiting, defects, and excess inventory.
 Improved Efficiency: Streamline processes, reduce lead times, and enhance resource
utilization.
 Enhanced Quality: Identify and eliminate defects, improving the reliability and
quality of products or services.
 Customer Satisfaction: Align processes with customer needs and expectations,
delivering higher value and improved experiences.
 Cost Savings: Reduce waste, optimize resources, and improve productivity, resulting
in cost savings.

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
Case Study

Implementation of Lean Principles in Healthcare Services

Implementation of Lean Principles in Government Services

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
 DENG 605:
QUALITY SYSTEMS AND PROCESS IMPROVEMENT

Module 6:
LEAN TOOLS AND
TECHNIQUES
June 25, 2023

Reporter:
VILLEGAS John Jowhell
OUTLINE: Lean Tools and Techniques
I. Lean Management - Lean Tools and Techniques
II. Lean Tools and Techniques
a. Kaizen
b. Single Piece Flow
c. Poka-Yoke
d. Visual Management
e. 8 Lean Wastes
f. SMART Goals
g. Bottleneck Analysis
h. Value Stream Mapping
i. 5S Methodology
III. Challenges and Best Practices in Implementing Lean Tools

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
I. Lean Tools and Techniques 1/2
LEAN Management (originated from the TOYOTA Production System)

management philosophy and approach focusing on

maximizing value while minimizing waste and inefficiencies;
systematic and holistic approach to problem-solving and decision-making

LEAN TOOLS & TECHNIQUES

support the implementation of lean principles
(waste identification / process improvement / problem-solving)
Polytechnic University of the Philippines – Open University System
DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
I. Lean Tools and Techniques 2/2

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.a Kaizen 1/2
Kaizen: (Kai – improvement; Zen – for betterment)
“continuous Improvement” or
“small incremental improvements”
BENEFITS:
- improves processes by eliminating waste;
- Promotes personal growth of employees
- improves kaizen quality, safety, cost structures,
delivery, environment

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.a Kaizen 2/2
Kaizen: (Kai – improvement; Zen – for betterment)
“continuous Improvement” or
“small incremental improvements”

Example:
Practical Course in Construction Engineering Technology in CMDF, Cavite (5 days)
PLAN – Trainer / Transportation / Food / Accommodation / Faculty Coordinator
DO – conduct the training
CHECK – consistently contact FC / open-communication / use Gform for feedback from trainees
ACT – change of food provider

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.b Single Piece Flow 1/1

Single Piece Flow

- sequence of a product or service through a process that is a single
unit is produced at a time
- opposite of batch production
BENEFITS:
- detects defects earlier and more accurately
- can get more flexibility for customization and
meeting customer demands
- can easily predict the shipment timing

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.c Poka-Yoke 1/1
Poka-Yoke
- Mistake proofing or error prevention
- Prevents defects from being made

BENEFITS:
- saves time and money by preventing
defects
- prevents human error
- highlights a defect so that it is not passed
to the next operation

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.d Visual Management 1/1
Visual Management
- communication technique that
uses visual aids to pass messages
more effectively more effectively
and very fast
- ability to manage everything in
your factory or areas by visually
BENEFITS:
- can display problems in a simpler way and very effective
- clearly indicates targets and goals
- increase the effectiveness of communication

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.e 8 Lean Wastes 1/1
8 Lean Wastes

BENEFITS:
- increases productivity
- Creates a safer working
environment
- Reduce downtime
- Improve efficiency and
effectiveness

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.f SMART Goals 1/1
SMART
- method to set the goal or target in a effective manner
- the goals should be clearly defined and communicated

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.g Bottleneck Analysis 1/1
- bottleneck means “constraint”
- the bottleneck in operation is understood by stage of operation
that takes the longest time in the whole operation
- reduce the speed of the whole operation
- reduce the efficiency of the entire manufacturing process

BENEFITS:
- By removing bottleneck, efficiency and
profit can increase
- Can optimize the cycle time
- Increase productivity and plant capacity

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.h Value Stream Mapping 1/2
- method of analyzing the current state of a process and designs the future
state of the process and it focuses on the opportunity for improvement by
eliminating different wastes from processes
- Includes process, from the supplier end to reach at the customer end
- MAIN THREE PARTS: Map Current State; Design Future State; Create
Transformation Plan

BENEFITS:
- addresses underlying issues
- helps identify wastes and eliminate wastes
- identify inefficiencies in the process

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.h Value Stream Mapping 2/2

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
II.i 5S Methodology 1/1
- System for organizing spaces
so work can be performed
effectively and efficiently with
safely

BENEFITS:
- Increase productivity through
effectiveness
- Reduction in delays
- Improved quality and safety
- Set-up times reduces
- Safer work environment

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
III.a Challenges in Implementing Lean Tools 1/1

1. Resistance to Change
2. Lack of Leadership Support
3. Inadequate Training and Education
4. Silo Mentality
5. Lack of Metrics and Performance
Measurement

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
III.b Best Practice in Implementing Lean Tools 1/1

1. Engage employees
2. Start with Pilot Projects
3. Provide Adequate Training and Education
4. Create a Continuous Improvement Culture
5. Establish Visual Management
6. Sustain and Reinforce

Polytechnic University of the Philippines – Open University System

DENG 605 – Quality Systems and Process Improvement Doctor in Engineering Management
 Thank you for your kind

attention!

DENG 613 – Special Topics in Engineering Management Polytechnic University of the Philippines – Open University System
Doctor in Engineering Management