This document summarizes lectures from a course on Lean Manufacturing and Total Quality Management. It discusses topics like Jidoka, Poka Yoke, standard work, 5S, quality function deployment, statistical process control, total productive maintenance, and the Toyota Way. Discussion questions are provided to engage students on applying these lean concepts in their own organizations and industries.

1. BITS Pilani
Hyderabad Campus
Lean Manufacturing
Naga Vamsi Krishna Jasti
Assistant Professor
Department of Mechanical Engineering

2. BITS Pilani
Hyderabad Campus
Lean Manufacturing

3. BITS Pilani, Hyderabad Campus3 May 1, 2018
Topics to be covered
 Topics in Taped Lectures 7and 8
 Discussion on Taped Lecture 7
 Discussion on Taped Lecture 8
 Brief discussion on Taped Lecture 9
 Brief discussion on Taped Lecture 10
 Discussion Questions for next week
MM ZG522 - Total Quality Management

4. BITS Pilani, Hyderabad Campus4 May 1, 2018
Tapped Lecture-7
We begin Lecture 7 with Jidoka. Problems in
production occur because of various reasons
including human error, quality of incoming parts,
machine problems, etc.
By requiring that the system be shut down before
we proceed, in Jidoka, we ensure that the problem
is not repeated in the future.
Next we discuss Poka Yoke or error proofing.
Poka Yoke involves incorporating elements into the
design of the system that eliminates the possibility
of making a mistake. Also, if a mistake is made, it is
not sent downstream.

5. BITS Pilani, Hyderabad Campus5 May 1, 2018
Tapped Lecture-7
 Poka-yoke reduces a worker's physical and mental
burden by eliminating the need to constantly check for
the common errors that lead to defects.
 Next, we discuss standard work in the lecture.
 Standard work is a very important component of Lean
Manufacturing and consists of three elements; takt time,
work sequence, and in-process stock
 Standard work is very necessary, as without standard
work we would not be able to measure performance,
promise delivery dates, plan capacity, train people, or
make improvements in the processes.

6. BITS Pilani, Hyderabad Campus6 May 1, 2018
Tapped Lecture-8
MM ZG522 - Total Quality Management
 Next, we introduce 5S.
 5S is an organized approach to housekeeping which
helps improve operations, productivity, morale and
appearance of a workplace.
 5S stand for 5 Japanese terms which stand for the
following:
 –Sort
 –Set in place
 –Shine
 –Standardize
 –Self Discipline

7. BITS Pilani, Hyderabad Campus7 May 1, 2018
Tapped Lecture-8
 Lecture 8 is devoted to 5S.
 The 1st S, i.e., Sort requires us to critically assess which
of the items that are present in the plant and offices, is
really necessary, and which can be got rid of.
 By critically examining items from the stand point of
necessity and their workability, we can eliminate a lot of
unnecessary parts, inventory and free up precious
space.
 Red tags are a useful way of helping identify
unnecessary items or items in disrepair.

8. BITS Pilani, Hyderabad Campus8 May 1, 2018
Tapped Lecture 8
 Standardizing and sustaining 5S efforts is very difficult,
because it involves the changing of people’s habits.
 Although 5S is very simple to explain and understand,
it is by no means easy to implement.
 It does not involve technology and does not require
investment of capital. But it does require strong
management commitment and perseverance.
 Most companies find that it may take 3-6 months to
start seeing some benefits from 5S.
MM ZG522 - Total Quality Management

9. BITS Pilani, Hyderabad Campus9 May 1, 2018
Discussion questions
 Do you think that an approach like Jidoka is applicable in
your organization? What do you see as its main benefit?
 How would you propose convincing management about
the need to fix problems instead of covering them up?
 Can you suggest an example of error proofing at your
place of work? In daily life?
 How important do you think is standard work? Why?
 Some people think standardization robs people of their
creativity. What do you think?
 Has your company tried to practice 5S? What has been
the outcome?
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10. BITS Pilani, Hyderabad Campus10 May 1, 2018
Discussion questions
 Does your organization have unnecessary
materials/equipment occupying space? What is done
about it?
 How well are things organized for ease of use at your
company?
 Who is responsible for housekeeping at your
organization?
 What do you think are the biggest barriers to sustain
5S efforts in your organization? In any organization?
MM ZG522 - Total Quality Management

11. BITS Pilani, Hyderabad Campus11 May 1, 2018
Tapped Lecture 9
 In lecture 9, there are two main topics; Quality and
Maintenance.
 Quality has undergone significant change since it was
first used in mass manufacturing.
 It has gone from inspection to customer satisfaction
and it is the customer who determines what is quality.
 There are a number of interpretations of quality
depending on the attribute focused on.
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12. BITS Pilani, Hyderabad Campus12 May 1, 2018
Tapped Lecture 9
 In order to ensure customer satisfaction and delight,
companies need to be able to translate customer
requirements into workable product and process
designs.
 Quality Function Deployment (QFD) is a matrix
approach for translating customer requirements into
specific product features and process configuration.
 In addition to product and process design, we should
ensure that our processes be under control.
 Statistical Process Control (SPC) ensures that we
detect any extraordinary deviation in the process
immediately so that we may take corrective action.
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13. BITS Pilani, Hyderabad Campus13 May 1, 2018
Tapped Lecture 9
 The second topic covered in the lecture was
Maintenance.
 Maintenance, too, has undergone a major change
over the years going from Breakdown Maintenance to
Total Productive Maintenance
 Companies are starting to realize that keeping
machines maintained is far more effective at meeting
customer requirements.
 Overall Equipment Effectiveness (OEE) is a measure
that takes into account machine uptime, the quality of
the parts produced, as well as the performance.
MM ZG522 - Total Quality Management

14. BITS Pilani, Hyderabad Campus14 May 1, 2018
Tapped Lecture 9
 TPM requires that we involve the workers in routine
maintenance tasks so that the maintenance
department can focus on higher value adding
activities.
 Getting workers involved in regular maintenance
ensures that the smallest problems are detected
early, and that prevents bigger problems later.

15. BITS Pilani, Hyderabad Campus15 May 1, 2018
Tapped Lecture 9
 “If adequate maintenance has been done,
replacement with a new machine is never cheaper,
even if maintaining the older one entails some
expense. If we do decide to replace it, we should
realize that we have either been misled by our
calculations and made the wrong decision or that our
maintenance program has been inadequate”
From”Toyota Production System: Beyond Large Scale
Production”
MM ZG522 - Total Quality Management

16. BITS Pilani, Hyderabad Campus16 May 1, 2018
Tapped Lecture 9
 Lecture 10 is devoted to the first 7 of the 14 Points of
Toyota Way.
 Toyota Way is a document that was developed by
Toyota during the 1990s and early 2000s. This was in
response to the feeling that the Toyota Production
System was a collection of tools and techniques. Most
companies that tried to emulate Toyota by
implementing some tools were unable to see major
benefits.
 Toyota Way is an attempt by Toyota to capture some
of the changes required in the management approach
without which the techniques of TPS are not effective.
MM ZG522 - Total Quality Management

17. BITS Pilani, Hyderabad Campus17 May 1, 2018
Tapped Lecture 9
 There are in all 14 Principles of which the first 7 are
discussed in Lecture 10,
 There is a striking similarity between the 14 Principles
and the 14 Points of Deming.
 The first Principle says that we need to focus on long
term thinking even if it means short term losses. Short
term goals cause managers to use shortcuts to make
themselves look good, but may be detrimental to the
long term health of the organization.
 The second Principle says that we should create
continuous flow to bring problems to the surface.
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18. BITS Pilani, Hyderabad Campus18 May 1, 2018
Tapped Lecture 9
 This is contrary to common practice of hiding
problems for fear of punishment.
 The third Principle calls for the use of pull system to
avoid overproduction.
 Pull production requires that companies do not
produce with the idea of keeping machines busy, but
based on specific customer demand.
 The fourth Principle suggests the levelling of
production.
MM ZG522 - Total Quality Management

19. BITS Pilani, Hyderabad Campus19 May 1, 2018
Tapped Lecture 10
 Leveling production creates a rhythm which can make
the supply chain more in sync with the processes. It
also eliminates Unevenness and Overburden.
 Principle 5 suggests that we stop the process to fix
problems and to get quality right the first time.
 This ensures that problems do not keep festering and
recurring when they can cause more damage.
 Principle 6 calls for standardization which ensures
consistency in production.
 Principle 7 talks about using visual control so that no
problems are hidden.
MM ZG522 - Total Quality Management

20. BITS Pilani, Hyderabad Campus20 May 1, 2018
Discussion questions
 How does your organization approach the topic of
quality? How is it measured?
 Who is responsible for quality in your organization?
 What specific measures are taken to address quality
issues in your organization?
 Is maintenance planned in your organization? How?
 Is OEE used to measure effective use of equipment?
 What would you suggest to improve quality and
maintenance in your organization?
MM ZG522 - Total Quality Management

21. BITS Pilani, Hyderabad Campus21 May 1, 2018
Discussion questions
 Has lean or any other approach been applied in your
organization? If so, at what level was it applied?
 How successful is your organization in implementing
new systems? What are the reasons for the
success/failure?
 To what extent does management see its role in the
implementation of operational systems?
 What do you think are the biggest barriers to sustain
new efforts in your organization?
MM ZG522 - Total Quality Management

22. BITS Pilani, Hyderabad Campus22 May 1, 2018
Thank you