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| LeanAgile®
ISO
Improvement Engine Lean and
Agile program |
| Midwest has been involved
in quality improvement along with registration activities for 8
years. We are proud to integrate the improvement into your
registered quality system, not tack it on as an extra project. We
even know how to integrate Six Sigma programs.
We are likely less doctrinaire than most, but we find as usual thet one
size does not fit anyone let alone all, and the program gas to be matched
with your situation and company culture.
We have 2 basic approaches, which are not exclusive. The first is
the "improvement engine" built into ISO 9001:2000, and the second is a
Toyota Production Systems based program to reduce production time and
costs for tangible goods and services. |
ISO based improvement
The following 16 points highlight some of the ISO 9001:2000 clauses
which, when implemented together as a Quality System, will lead to the
greater success in the Organization. The underlying power is a new "ISO
capability" for top managers to be able to push ahead on all of these
fronts simultaneously, without their direct intervention, but by the
coordinated action of the ISO team.
- General requirements
(4.1). In these clauses top
management has to "identify the organization’s processes … determine
their sequence and interaction…" This requirement helps focus the
organization on those processes which deliver value to the customer.
These will be monitored to see that they are working as expected (see
#13 below). Understanding which process you need to get right is a
critical first step.
- Establish and deploy the quality policy and objectives
(5.3
& 5.4.1). These clauses focus the entire organization on the same
goals. It is optimum to have measurables which each person could tally
up at the end of the day to see how they did. These individual
measurements are totaled by "department" or area, and finally for the.
Top management can see the overall trends, and "drill down" to see the
drivers, and offer congratulations or provide resources as necessary.
Such "pyramid" metrics (from a broad base to one point at the top) are
difficult to devise, but very valuable to drive change across the board.
- Responsibility and authority and Internal communication
(5.5.1
& 5.5.3). People need to be crystal clear about their responsibility
to carry out tasks and their authority to allocate resources and make
decisions. Maintaining people’s roles so that there is clarity, and
maintaining these current in today’s dynamic organizations requires
excellent communication. These aspects are business 101 issues, but
almost every organization needs to improve to prevent politics
interfering with responsiveness.
- Competence, awareness, and training
(6.2.2). An organization is
people, and humans all need help. Building, maintaining and growing the
competence of the employees is the heart of the organization, and a
substantial expense. This area is a great opportunity.
- Infrastructure and work environment
(6.3 & 6.4). People need
the tools of the trade and the environment (including a psychological
environment) to do their best. As with competence above, these areas
present a huge opportunity. Remember, section 6 is the "plan" section
where top management prepares the people to "do" in section 7.
- Planning for product realization
(7.1). Each "product" requires
planning to determine and provide the specific resources people need to
do the work correctly and profitably. An organization typically has many
such plans for various activities. This clause brings these together as
a system, and establishes a new product planning process to introduce
new items. Change is the goal of the ISO program, and this clause
addresses product changes needed to grow sales.
- Customer related processes
(7.2). These clauses are the heart
and soul of ISO 9001. Once you know and agree to provide something, the
rest of ISO is really there to ensure that you know you provided what
you agreed to provide. Review of the customer orders is one of the ways
the organization addresses this issue, and might benefit from the
details of the ISO considerations. This clause also includes customer
communications which are always a problem when personnel are not in the
office.
- Design and development
(7.3). Many organizations do not do
design, but for those who do ISO has a simple formula to recommend. The
section addresses the need to design, verify and validate the product,
and track progress to completion. The design function can be simple or
complex, and this section facilitates control. Time is often a forgotten
issue in the design process.
- Purchasing
(7.4). The organization needs "raw materials" which
go into the products, and spending is always an issue; and this clause
addresses the need to control spending. There is a huge change going on
in the purchasing world relating to just-in-time and "supplier
partnerships." This clause encourages simple goals in navigating through
these changes.
- Service provision
(7.5). These clauses govern the quality,
quantity, and cost of the work people do off-site. Many organizations
have no service in this sense. Addressing service helps ensure that what
happens at the customer location is as well controlled as the work on
the factory floor, with QC, maintenance, and management there for
support.
- Customer satisfaction
(8.2.1). ISO requires that the
organization "monitor information relating to customer perception." When
done well, addressing this clause provides an excellent early warning
system as to how the customers are reacting to changes within the
organization. Change is the purpose of the Quality System, and finding
about unhappiness in a customer after they leave allows little room for
correction during change.
- Internal audit
(8.2.2). A good internal audit "listens" to the
organization and presents a fact-based answer to a question from to top
management, to help them determine the need for change. Audit can be a
routine checking on the status of aspects of the business, or an
emergency response to a problem. In all cases it is a way for management
to obtain information to help them decide and act correctly.
- Monitoring and measurement of processes
(8.2.3). The important
processes within the organization are measured, and the results compared
to plan to see where progress is acceptable, and where resources are
needed. This is another of the ISO feedback loops to keep management
aware of how change is progressing within the organization.
- Monitoring and measuring of product
(8.2.4). This clause
requires that you have information that the service provided to your
customer meet the criteria you agreed to with the customer in 7.2. This
is what most people think of as quality, and it is of crucial importance
in just-in-time, "lean" world. It is useful to point out that the
activities of "inspection" are not value-added to the customer. This
area is of potential significance.
- Control of nonconforming product & analysis of data
(8.3
& 8.4). This clause requires that when someone makes a mistake, the
organization has to do something to ensure that the problem does not get
out to the customer. But this clause allows you to "listen to the
processes" to collate and present what is going wrong (not done right
the first time) so that resources can be provided in a prioritized
manner to prevent reoccurrence. So billing errors, late and absent
employees, computer malfunctions, scheduling problems, machine downtime,
late work, etc. can all be tracked as appropriate to see that change is
happening. It does not take data to see that something changed by half
(twice as many reports are late) but it does take data to detect a
slight.
- Corrective and preventive action
(8.5.2 & 8.5.3). These
clauses require systems for fixing significant problems. This is the
formalization of the organization’s risk management program. The
management question is not that problems exist, but which one is the
next most important for the organization to spend resources on to fix
now? These clauses require that the organization track the formal
projects which management assigns to drive change. Many other aspects of
the standard drive change as well, and the organization has to have a
system to and then make sure it is fixed before moving on to the
following issue.
Meet the requirements of the ISO standard, and a business will have the
organization and focus which will achieve the policy and objectives set by
top management. When these relate to increased sales and reduced costs the
organization profit will increase, and the managers will become true
believers that ISO is an important tool. |
| Lean and Agile
Toyota Production Systems talks about eliminating waste: the 7 normal
kinds of waste (see below), the waste of overproduction, and the waste of
over-stressing your systems. The 7 Toyota classifications of waste
are:
- Rework and nonconforming material
- Waste of over-production
- Waste in processing
- Waste in transporting and moving
- Waste in inventory
- Wasted motion
- Waste in waiting
So what do we do about it?
We work with you to develop a program, which would include variations
on the followng steps:
- Flowchart the selected process from the customer and suppliers and
back to the customer. This will identify the operations. Immediately
look overall at opportunities for reducing steps, waiting, inventory,
etc.
- Establish a baseline of current production, uptime, costs, Cpk,
quality issues, rejects, etc. Accurately determine current levels of
customer satisfaction and identify all customer issues. Document current
activities with digital photos or video.
- Post a summary of the current situation on a project bulletin board
in the manufacturing area. This will be maintained as the project
matures so all can understand the process.
- Start to keep score of hourly production compared to rate, and
report all quality defects found. Start a regular management review of
the score-board.
- Clean-up with the 5S program (Productivity Press), add paint, work
benches, storage, lighting etc. as required by that program. This
activity merges with the next step.
- Determine material flow system: raw materials, finished goods,
supplies, waste, identification, containers, etc. Look for ways to
reduce inventory and motion.
- Plan TPM (Total Preventive Maintenance Productivity Press) to
eliminate all downtime, track downtime improvements.
- Plan SMED (Single Minute Change of Dies Productivity Press) for
rapid tooling changeovers.
- Do FMEA (Failure Mode and Effects Analysis AIAG) to develop
appropriate Mistake-Proofing devices/activities to detect and prevent
passing defective parts.
- Micro-flowchart/time study operations to re-arrange the equipment in
a cellular fashion to reduce travel and movement, plan the operation at
different volumes with the appropriate number of operators.
- Micro-flowchart/time study the cellular operations to further reduce
movement and establish standard work with instructions, incorporating
the Mistake-Proofing, TPM, and SMED results.
- Watch the production/quality numbers on the scorecard and eliminate
the issues which prevent making rate or create any defects. Keep
improving standardized work instructions/TPM/SMED.
- Reduce inventory and prefect the pull (KanBan) minimal inventory
system.
- Partner with suppliers to reduce their inventory and incorporate
their quality results.
- Plan continuous improvement activities to improve the rate. Audit to
ensure accuracy of standard work instructions. Review FMEA to further
reduce likely failures.
- Select the next area for improvement, reiterate process. The
machining areas with small or one-piece production will be slightly more
challenging in that the "standard" work will have to become similar to
an auto repair shop where they are allocated hours. However, the rest of
LeanAgile™ applies. Do not forget the office areas, sales, quoting,
design, purchasing, where LeanAgile™ can make a big difference.
If you are interested, contact us! |
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For More Information Contact: tony@midwestquality.com or 800
464-9008 |