Total Quality Pillars: Lean Manufacturing & Toyota System
Total Quality Pillars
Key Pillars of Total Quality
- Customer Satisfaction: Product and service innovation.
- Economic Efficiency: Control processes, eliminate waste, optimize resource utilization.
- Internal Operation: Shared vision, focused goals, skills development and continuous learning.
Product Revolution: Market-driven approach (listen to the customer). PV = PC + Bo. Bo = Pv-Pc. M (maintain and improve).
Types of Waste
- Production waste
- Excessive waiting time
- Transportation waste
- Process waste
- Inventory waste
- Motion waste
- Defect waste
- Underutilized human potential
Toyota System Tools
Kanban system, production leveling, SMED (setup reduction), standardized operations, flow-oriented plant layout, multi-skilled workers, improvement activities, visual control systems.
Just-in-Time (JIT)
Adapt rapidly to demand fluctuations in quality and quantity.
Key Applications
- One-piece flow
- 5S implementation (Organize, Sort, Shine, Standardize, Sustain)
- Minimize work-in-process, connect contiguous processes, create U-shaped lines, assign multi-skilled workers, change from sitting to standing work
- Small batch production (SMED)
- Standardized operations
- Level production speed to sales (takt time)
- Empowerment (Jidoka)
- Kanban card introduction
Process Management
Transform a series of phenomena into an optimal product or service for internal or external clients. Basic process control principles: Inspection is inefficient and expensive. Clients determine product key characteristics (KCs). The process of developing KCs affects the product. Product variations are inevitable. To meet specifications, reduce deviations from KCs.
Process Phenomena: Inspection -> Storage -> Waiting -> Transportation.
Jidoka
Immediate action when a problem occurs to prevent defects. Applications: Transfer human labor to machines, develop error detection mechanisms. Benefits: Immediate defect detection, problem cause investigation, cost reduction, defect prevention, one-piece flow, security, eliminate unsafe conditions, motivation, unlock human creativity.
Layout Optimization
Process-Oriented Layout: Objective is high volume production, large lots, efficient management. Optimize material flow, minimize machine investment, adapt to intermittent demand, supervise operations with expertise, minimize waste, facilitate maintenance. Disadvantages: Overproduction, transportation waste, defects, long lead times, difficult communication, non-standardized material flow, operator workload.
Product-Oriented Layout: Continuous flow, rapid balancing, material flow based on process sequence, rapid communication, multi-functional operators, reduced response time, optimized space utilization, reduced work-in-process, eliminate transportation waste. Problems: Large machinery, lack of capacity, defects, absenteeism, lack of knowledge, variations in quality and demand.
Lean Manufacturing Principles
Value: Focus on what the customer is willing to pay for. Value Stream: Map all steps in the process. Flow: Create value without interruption. Pull: Produce based on actual demand. Implement lean tools for continuous improvement.
MRO (Maintenance, Repair, and Operations)
One-piece flow, eliminate non-value-added time, reduce space needs, limit work-in-process, control production and lead time. Establish a manufacturing cell using 5S, TPM, takt time, one-piece flow, and standardized work.
5S Methodology
Sort, Set in Order, Shine, Standardize, Sustain.
Total Productive Maintenance (TPM)
Maximize equipment efficiency, availability, and production output. Manage equipment losses: breakdowns, setup and adjustments, micro-stops, reduced speed, quality defects, and process design issues.
One-Piece Flow (OPF)
Creates cells for material transport, reduces lead time and inventory, improves quality and reduces costs. Benefits: Immediate defect detection, reduced lead time, minimized resource waste, streamlined production flow.
Standardization
Benefits: Cost savings, accident reduction, knowledge sharing, error reduction, improved product quality, better communication between shifts, operator empowerment, training foundation, variability control. Pull system benefits: Produce only what is needed, automated scheduling, synchronized processes, flexible response to demand changes, improved quality, TPM, SMED, OPF.
Standardized Work Phases
- Analyze operations
- Apply time and motion study principles
- Identify the best layout
- Identify safety and critical points
- Implement and debug
- Document and standardize
- Make standards visible