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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