GCS27

  Process Failure Mode Effects Analysis (PFMEA) is used by manufacturers to detect potential failures that are rooted in the physical process of producing a part.  Each step of the process is carefully analyzed to identify every possible thing that could go wrong. PFMEA follows a similar process as   DFMEA , but looks at failures derived strictly from the process as opposed to design. Planning for mishaps that could occur in the manufacturing process allows preparedness for all scenarios.  PFMEA allows manufacturers to build in process safeguards to offset   potential failures   from occurring. A PFMEA should be conducted when any of the following occur: Modification to an existing process Introduction of new technology, equipment, or process steps to production Relocation of a process to a new facility The primary objective of PFMEA is to identify potential failures associated with the manufacturing process such as human error, equipment malfunctions, and...

  Voice of the Customer: Customer feedback both positive and negative including likes, dislikes, problems and suggestions.   Voice of the Process Statistical data that is feedback to the people in the process to make decisions about the process stability and/or capability as a tool for continuous improvement. T-test used to test means or location effects. For example, used to compare the mean output of Line A vs. the mean output of Line B. [Statistical inference tests to compare the quality of different products / processes and compare the performance of different groups.   Takt Time Takt is the heartbeat of a lean system. It is the rate of customer demand. It is the tool to link production to the customer by matching the pace of production to the pace of actual final sales. It defines the rate which material and product flow through the value stream. First, you calculate actual takt times for each product and part (takt time = total time available for production...

  What is waiting waste? Definition - Waiting waste describes the resources lost as people wait for information, a meeting, a signature, a returned phone call, a copier or computer that is broken, and so on. People cannot add value to the product or service while they are waiting. Example – Waiting on hold for a telephone call, a meeting to start, numbers, direction from a supervisor, and so on, is examples of waiting waste. Typical solution/Result - This is one of the common “accepted” wastes. If a high-level manager is annoyed by a specific instance, some training or coaching may be given but long-term change will not occur. The Offices Kaizen -In an Office Kaizen environment, two avenues are used: 1.        Each intact work group uses the LDMS to monitor and improve its efficiency; over time, each intact work group begins to see that waiting is waste and will gradually reduce it ; and 2.          A chan...

  Assignment Waste Definition - The effort used to complete an unnecessary or in appropriate task is assignment waste Example:   A high –level manager tells a subordinate to prepare a report that details the process improvement department’s training activities ‘’ in case the boss asks for it in the review meeting” Typical Solution/Result: A glowing, “make everything look good” presentation is prepared that is most likely not used. If it is not used, the report preparation was a complete, one time waste. If the report is used, the boss may like it, believe the deception, think that things are going well, and require all departments to submit such a report each month. The boss then spends time reviewing the reports and giving direction (requiring more like and reports)instead of leading real, continuous improvement by implementing Office Kaizen. The waste is immense and horrific. The Office Kaizen Solution: The Office Kaizen approach is to install the lean daily managem...

  What is Goal Alignment Waste? Definition: -- Goal alignment waste is the energy expended by people working at cross –purposes and the effort required to correct the problem and produce a satisfactory outcome. Example: An edict is issued to reduce travel expenses because sales have dropped off. The travel department implements policies that require all personnel to use tickets issued by the travel department at the lowest available ticket price. This forces sales people to take extra flight legs, leave home earlier, get home later, and schedule fewer appointments in a week and so on. Complaints quickly follow, along with some resignations from highly skilled sales personnel who can easily find another job and be “treated better” Typical Solution/ Result:  Sales, Human Resources, and Travel are told to “work together” and come up with an answer. After several months and many meetings, a thick volume of procedures is produced. Several sales people have already qu...

  Surface Wastes.... The Silent Killers There are four categories of surface wastes that contains 26 specific type of waste. I. PEOPLE WASTES T here are five people wastes that occur because organizations fail to harness the potential that resides in all work groups.  Keep in mind that an instance of people waste does not carry with it any blame or attributions. Human beings have certain skills and behave in highly predictable ways. When people waste occurs, it is the fault of leadership for not properly structuring the work environment. 1.         Goal Alignment Waste 2.        Waiting Waste 3.        Assignment Waste 4.        Motion Waste 5.        Processing Waste   II. PROCESS WASTES There are 12 process wastes. These wastes arise during the operation of business as a result of process design and execution...

  How to Collect Data The purpose of collecting data A great deal of data can be collected in factory situations. First consider the purpose of collecting these data. When we introduce a particular method of doing a job, it is natural to consider whether the method is appropriate or not. The decision is usually based on past results and experience, or perhaps on conventional methods. However in case of factory work, where data are collected through the actual manufacturing process, the procedural methods are introduced on the basis of the information obtained. The manufacturing procedure will be most effective if a proper evaluation is made, and on-the-job data are essential for making a proper evaluation. Data and subsequent evaluation will form the basis for actions and decisions. As factory operations will vary with the manufacturing procedure involved, data should be classified in terms of the various purposes. 1.    Data to assist in understanding the actua...