CHAPTER 10

• Problem solving - is one of the basic procedures of TQM.
• standard approach - In order to be successful, problem-solving efforts should follow a
• An important aspect of problem solving in the TQM approach is eliminating the cause so that the problem does not recur.
• opportunities for improvement - This is why users of the TQM approach often like to think of problems as
• plan-do-study-act (PDSA) cycle - is the conceptual basis for problem-solving activities.
• plan-do-study-act (PDSA) cycle - Representing the process with a circle underscores its continuing nature.
• plan-do-study-act (PDSA) cycle also referred to as either the Shewhart cycle or the Deming wheel
• pdsa cycle

  A) management commitment

  B) recognize problema

  C) form quality improvement teams

  D) define problems

  E) develop performance measures

  F) analyze problems

  G) determine possible causes

  H) implement solution

  I) evaluate solution

  J) ensure performance

  K) continuous improvement

  
• Plan - Begin by studying the current process. Document that process. Then collect data on the process or problem. Next, analyze the data and develop a plan for improvement. Specify measures for evaluating the plan.
• Do - Implement the plan, on a small scale if possible. Document any changes made during this phase. Collect data systematically for evaluation.
• Study - Evaluate the data collection during the do phase. Check how closely the results match the original goals of the plan phase.
• Act - If the results are successful, standardize the new method and communicate the new method to all people associated with the process. Implement training for the new method. If the results are unsuccessful, revise the plan and repeat the process or cease this project.
• pdsa cycle - Employing this sequence of steps provides a systematic approach to continuous improvement.
• kaizen aka continuous improvement
• kaizen - Japanese term for a gradual approach to ever higher standards in quality enhancement and waste reduction, through small but continual improvements involving everyone from the chief executive to the lowest level workers.
• kaizen - is a policy of constantly introducing small incremental changes in a business in order to improve quality and/or efficiency.
• kaizen cycle

  A) identify a problem or opportunity

  B) analyze the process

  C) develop an optimal solution

  D) implement solution

  E) study the results and adjust

  F) standardizze the solution

  
• good change - Kaizen can be roughly translated from Japanese to mean
• Dr. W. Edwards Deming - The philosophy behind kaizen is often credited to
• Dr. Deming - was invited by Japanese industrial leaders and engineers to help rebuild Japan after World War II.
• Five Elements of KAIZEN

  Teamwork

  Personal discipline

  Improved morale

  Quality circles

  Suggestions for improvement
• key features of kaizen

  A) based on many, small changes

  B) ideas come from workers

  C) major capital investments

  D) r and d

  E) improve their own performance

  F) ownership of their work and motivation

  
• goal of kaizen is to eliminate waste in the process
• benefits ok kaizen

  Making job easier and safer

  Making job more productive

  Removing donkeywork from the job

  Removing irritation from the job

  Improving product quality and Saving time and cost
• Just in Time - An inventory strategy companies employ to increase efficiency and decrease waste by receiving goods only as they are needed in the production process, thereby reducing inventory costs.
• just in time

  A) sales

  B) design

  C) procurement

  D) nesting

  E) production

  F) shipping

  
• Just-in-time (JIT) - is an inventory strategy that strives to improve a business’s return on investment by reducing in-process inventory and associated carrying costs.
• Just-in-time (JIT) - This saves warehouse space and costs. However, the complete mechanism for making this work is often misunderstood.
• Just-in-time - manufacturing was a concept introduced to the United States by the Ford motor company.
• 5S Process - is a structured program to systematically achieve total organization, cleanliness, and standardization in the workplace.
• 5S Process - A well-organized workplace results in a safer, more efficient, and more productive operation. It boosts the morale of the workers, promoting a sense of pride in their work and ownership of their responsibilities.
• 5s process

  A) sort

  B) set in order

  C) shine'

  D) standardize

  E) sustain

  
• seiri - refers to the act of throwing away all unwanted, unnecessary, and unrelated materials in the workplace. Even the number of necessary items in the workplace must be kept to its absolute minimum.
• seiri - Because of this,, simplification of tasks, effective use of space, and careful purchase of items follow.
• seiton or orderliness
• seiton - is all about efficiency. This step consists of putting everything in an assigned place so that it can be accessed or retrieved quickly, as well as returned in that same place quickly. The correct place, position, or holder for every tool, item, or material must be chosen carefully in relation to how the work will be performed and who will use them. Every single item must be allocated its own place for safekeeping, and each location must be labeled for easy identification of what it's for.
• Seiso - the third step in "5S", says that 'everyone is a janitor.' Seiso consists of cleaning up the workplace and giving it a 'shine'. Cleaning must be done by everyone in the organization, from operators to managers. No area should be left uncleaned. Everyone should see the 'workplace' through the eyes of a visitor - always thinking if it is clean enough to make a good impression.
• seiketsu, more or less translates to 'standardized cleanup'.
• seiketsu - It consists of defining the standards by which personnel must measure and maintain 'cleanliness'. Personnel must therefore practice 'seiketsu' starting with their personal tidiness. Visual management is an important ingredient of seiketsu. Personnel are trained to detect abnormalities using their five senses and to correct such abnormalities immediately.
• Shitsuke, means 'Discipline.'