Cindy Novak Quality Expo 092209 Presentation

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ISO 9001:2008 and Lean Six Sigma in Manufacturing for the Better Good

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Cindy Novak Quality Expo 092209 Presentation

  1. 1. CINDY NOVAK, CQIA QUALITY EXPO SEPTEMBER 22, 2009 ISO 9001:2008 and Lean Six Sigma in Manufacturing for the Better Good
  2. 2. Agenda <ul><li>Welcome! </li></ul><ul><li>What is Lean Six Sigma, ISO 9001:2008 </li></ul><ul><li>The WORMPIIT – The Eight Types of Waste </li></ul><ul><li>Benefits of Reducing Waste </li></ul><ul><li>Standing in the Circle </li></ul><ul><li>How Reducing Waste Benefits Your Sustainability Program </li></ul><ul><li>How ISO 9001:2008 and Lean Six Sigma Work Together </li></ul><ul><li>Customer Satisfaction </li></ul><ul><li>Questions </li></ul>
  3. 3. Lean Six Sigma <ul><li>Why Lean Six Sigma? </li></ul>
  4. 4. ISO 9001:2008
  5. 5. The WORMPIIT <ul><li>The Eight Types of Waste </li></ul><ul><ul><li>W aiting </li></ul></ul><ul><ul><li>O verproduction </li></ul></ul><ul><ul><li>R ework </li></ul></ul><ul><ul><li>M otion </li></ul></ul><ul><ul><li>P rocessing </li></ul></ul><ul><ul><li> I ntellect </li></ul></ul><ul><ul><li> I nventory </li></ul></ul><ul><ul><li>T ransportation </li></ul></ul>Muda - Japanese for waste
  6. 6. Eight Types of Waste <ul><li>Taiichi Ohno, the major contributor to the Toyota Production System, identified seven types of waste. He is considered the grandfather of Lean Manufacturing. </li></ul><ul><li>Jeffrey Liker, professor at University of Michigan added the eight, intellect. </li></ul><ul><li>Most recently, a ninth type of waste, energy has been discussed. </li></ul>
  7. 7. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTIONS </li></ul><ul><li>Work in the process has stopped. </li></ul><ul><li>Ensure adequate staffing at bottleneck </li></ul><ul><li>Cross-train employees so work continues when someone is absent </li></ul><ul><li>Make sure supplies are available where needed </li></ul><ul><li>Ensure equipment is properly maintained </li></ul><ul><li>Maintain safe work environment </li></ul>The WORMPITT – Waiting
  8. 8. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTIONS </li></ul><ul><li>Engaging more resources than needed to deliver to your customer. </li></ul><ul><li>The worst type of waste because it hides or causes all others, especially inventory. </li></ul><ul><li>Establish process maps considering the downstream customer </li></ul><ul><li>Create workplace standards for each process </li></ul><ul><li>Create signal devices to prevent over processing, i.e. FIFO Lanes </li></ul>The WORMPITT – Overproduction
  9. 9. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTIONS </li></ul><ul><li>Any form of scrap, mistakes, errors or corrections resulting from work not being done correctly the first time. </li></ul><ul><li>Ensure employees are competent and trained </li></ul><ul><li>Create error-proof processes </li></ul><ul><li>Create work instructions with the people who perform the work </li></ul><ul><li>Create and use checklists </li></ul><ul><li>Practice Corrective and Preventive Action </li></ul>The WORMPIIT - Rework
  10. 10. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTIONS </li></ul><ul><li>Any extra movement by people that does not add value. </li></ul><ul><li>Arrange work areas to shrink movement </li></ul><ul><li>Place part trays near employees </li></ul><ul><li>Place necessary documents at work stations </li></ul><ul><li>Use color coding as much as possible </li></ul>The WORMPIIT - Motion
  11. 11. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTIONS </li></ul><ul><li>Having to do anything more than is needed. </li></ul><ul><li>Remove unnecessary steps in a process </li></ul><ul><li>Consider enterprise resource planning software </li></ul><ul><li>Stop unnecessary signoffs and reviews </li></ul><ul><li>Use design for manufacturability </li></ul>The WORMPIIT - Processing
  12. 12. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTIONS </li></ul><ul><li>Any supply that is in excess / unavailable. </li></ul><ul><li>Includes raw materials, WIP or finished goods. </li></ul><ul><li>Capital outlay that has not produced income. </li></ul><ul><li>Produce only enough to satisfy your downstream customer </li></ul><ul><li>Ensure that work arrives at the downstream process when it is required and is not waiting </li></ul>The WORMPIIT - Inventory
  13. 13. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTIONS </li></ul><ul><li>Any supply that is in excess / unavailable. </li></ul><ul><li>Includes raw materials, WIP or finished goods. </li></ul><ul><li>Capital outlay that has not produced income. </li></ul><ul><li>Produce only enough to satisfy your downstream customer </li></ul><ul><li>Ensure that work arrives at the downstream process when it is required and is not waiting </li></ul>The WORMPIIT - Inventory
  14. 14. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTIONS </li></ul><ul><li>Employees ideas, creativity and abilities are not fully tapped or even considered. Their other abilities are not explored. </li></ul><ul><li>Treat your employees as your greatest asset </li></ul><ul><li>Establish Quality Circles </li></ul><ul><li>Set up Employee Suggestion Systems </li></ul><ul><li>Create employee teams to solve process problems </li></ul><ul><li>LISTEN, LISTEN………… AND LISTEN! </li></ul>The WORMPIIT - Intellect
  15. 15. <ul><li>WHAT IS IT? </li></ul><ul><li>SOLUTION </li></ul><ul><li>Movement of work or paperwork from one step to the next step in the process. </li></ul><ul><li>Make the distance to where something is moved as short as possible. </li></ul><ul><li>Consider work cells and co-located teams. </li></ul>The WORMPIIT - Transportation
  16. 16. Eight Types of Waste <ul><li>Benefits of Eliminating Waste </li></ul><ul><li>Significantly lower costs </li></ul><ul><li>Higher profit margins </li></ul><ul><li>More effective, efficient processes </li></ul><ul><li>Exceeding high quality </li></ul><ul><li>More engaged employees </li></ul><ul><li>Delighted customers! </li></ul>
  17. 17. Standing in the Circle <ul><li>Genchi Genbutsu – Go and see at the actual place of work </li></ul><ul><li>Taiichi Ohno used this to train new employees </li></ul><ul><li>An employee was directed to stand and observe an operation very carefully and identify waste within the operation and the conditions that cause the waste to exist. </li></ul><ul><li>If you don’t look, how do you know where the waste is? </li></ul>
  18. 18. <ul><li>ISO 9001:2008 </li></ul><ul><li>Lean Six Sigma </li></ul><ul><ul><li>P lan </li></ul></ul><ul><ul><li>D o </li></ul></ul><ul><ul><li>C heck </li></ul></ul><ul><ul><li>A ct </li></ul></ul><ul><li>D efine </li></ul><ul><li>M easure </li></ul><ul><li>A nalyze </li></ul><ul><li> I mprove </li></ul><ul><li>C ontrol </li></ul>How ISO 9001:2008 and Lean Six Sigma Work Together
  19. 19. How ISO 9001:2008 and Lean Six Sigma Work Together <ul><li>With quality objectives required by ISO, Lean </li></ul><ul><li>Six Sigma provides methods to achieve them: </li></ul><ul><li>Prevention of defects at all stages from design through customer service; </li></ul><ul><li>Statistical techniques for establishing, controlling and verifying process capability and product characterization; </li></ul><ul><li>Investigation of the cause of defects relating to product, process and quality system; and </li></ul><ul><li>Continuous improvement of the quality of products and services. </li></ul>
  20. 20. <ul><li>Type of Waste </li></ul><ul><li>Sustainability </li></ul><ul><li>Transportation </li></ul><ul><li>Inventory </li></ul><ul><li>Rework </li></ul><ul><li>Waiting </li></ul><ul><li>Energy </li></ul><ul><li>Reduction in fuel usage </li></ul><ul><li>No need to maintain unnecessary real estate </li></ul><ul><li>Reduction on scrap and waste sent to landfills </li></ul><ul><li>Use people and machines efficiently </li></ul><ul><li>Reduction in use of electricity, gas and water </li></ul>How Reducing Waste Benefits your Sustainability Program
  21. 21. <ul><li>Sustainability </li></ul><ul><li>Social Responsibility </li></ul><ul><li>Reduction in fuel usage </li></ul><ul><li>No need to maintain unnecessary real estate </li></ul><ul><li>Reduction on scrap and waste sent to landfills </li></ul><ul><li>Use people and machines efficiently </li></ul><ul><li>Reduction in use of electricity, gas and water </li></ul><ul><li>Lower carbon footprint </li></ul><ul><li>Protect public lands </li></ul><ul><li>Dedicate a park </li></ul><ul><li>Reduce Mount Trashmore </li></ul><ul><li>Recycle, reuse, return </li></ul><ul><li>More energy focused on the final output </li></ul><ul><li>Conserve energy for the most productive use </li></ul>Sustainability complements Social Responsibility
  22. 22. Customer Satisfaction <ul><li>Do you have Quality AND Sustainability programs? Do you have an Environmental Policy? If so, have you communicated this to your customers? </li></ul><ul><li>Clients expect lower prices today and there is no better way to make that happen than to cut waste. It’s better than cutting jobs! </li></ul><ul><li>Align lean and ISO activities with your corporate SRO policy. Let the community know what you are doing. </li></ul><ul><li>Include information on your cost-cutting programs on your website. Show results! Your customers may get ideas that help them as well and they will see your commitment as well. </li></ul>
  23. 23. Resources <ul><li>American Society for Quality </li></ul><ul><li>www.asq.org </li></ul><ul><li>International Organization for Standardization </li></ul><ul><li>www.iso.org </li></ul><ul><li>Environmental Protection Agency </li></ul><ul><li>www.epa.gov </li></ul><ul><li>Getting Business Fit by Gary King </li></ul><ul><li>www.fitcert.com </li></ul>
  24. 24. Questions <ul><li>Questions? </li></ul>
  25. 25. Thank you! <ul><li>Remember what Gandhi said, </li></ul><ul><li>“ You must be the change you want to see.” </li></ul><ul><li>Need help? </li></ul><ul><li>Visit www.isochick.com </li></ul>

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