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Definition of TQM
• Toyota :: Activities to build a corporate
structure that enhances the vitality of people
and the organ...
Definition of TQM
• Deming Prize Committee :: A systematic
activity 7 that contributes to achieving
corporate purposes2 by...
Definition of TQM
1. Customers : include not only buyers but also
stakeholders such as users, consumers and
beneficiaries....
Definition of TQM
3. Products and Services :: include products
(finished products, parts and raw materials)
and services a...
Definition of TQM
4. Provide :: means activities, from production
to delivery of ‘’products and services’’, such
as survey...
Definition of TQM
5. Running all corporate units effectively and efficiently :
Under the appropriate organization / busine...
Definition of TQM
6. Corporate Purpose :: Aim for growth and
long-term appropriate levels of profits to the
company by per...
Definition of TQM
• Systematic activity :: is an activity which
defines clear mid-to-long term vision/strategy
and appropr...
3 Basic Concepts of TQM
TQM
Customer-
focused
Continuous
Improvement
Full
Participation
Purpose :: Enhance the vitality of...
10
3 Basic Concepts of TQM
What is TQM ?
What are TQM Activities ?
Everybody
In every division
At every stage
Systems
Using the QC Philosophy and app...
House of TQM
12Engr. Kawsar Alam Sikder
Reinforcement of Corporate Structure
History of TQM in Japan
• 1924 – 1944 : Statistics began to be applied in
the industry field (Primarily in the US)
– 1924 ...
History of TQM in Japan
• 1950-1954 : The importance of variations caused
by statistical quality control emphasized.
– 195...
History of TQM in Japan
• 1960 – 1964 : Quality control on full –
participation basis advocated “All staff from
workers at...
History of TQM in Japan
• 1980-1984 : Quality Control (TQM) widely used in
new lines of business.
• 1985 – 1989 : Japanese...
Differences between
ISO 9000 and TQM
Item ISO TQM
Purpose Conformance to requirements Ensuring customer satisfaction,
Impr...
Differences between
ISO 9000 and TQM
Item ISO TQM
Advantages  Standardization thoroughly
achieved through written documen...
Policy & Daily Management
19Engr. Kawsar Alam Sikder
The Idea of Quality
20Engr. Kawsar Alam Sikder
The Idea of Management
Relationship between SDCA & PDCA
21Engr. Kawsar Alam Sikder
Keys to Success in TQM
• Leadership of top group (Clarification of the
relationship between management strategy
and TQM)
•...
Keys to Success in TQM
• Continual / Adaptive activity (Not partying,
but be flexible)
• Quality is the first priority (Re...
Keys to Success in TQM
• Utilization of methods (Your own way does
not work; acquire the QC method)
• “3-gen shugi” or “Pr...
Deming Prize
• The Deming prize was established in 1951 to
honor the accomplishment of late W.E.
Deming who contributed gr...
26Engr. Kawsar Alam Sikder
27Engr. Kawsar Alam Sikder
Basic Items :: QC Point of View
• Quality First :
– “Good or bad of quality is decided by the
customer ! “
– Improvements ...
Basic Items :: QC Point of View
Customer Oriented (Market in):
– To be always conscious of what the customer
wants and wh...
Customer in :: Japanese Style
30Engr. Kawsar Alam Sikder
Basic Items :: QC Point of View
• Post Process is customer :
– Each of you needs to think in the shoes of post
process, ex...
32Engr. Kawsar Alam Sikder
Basic Items :: QC Point of View
• Fact Control ( Management based on facts) :
– To judge something, it is critical to use ...
34Engr. Kawsar Alam Sikder
35Engr. Kawsar Alam Sikder
36Engr. Kawsar Alam Sikder
Basic Items :: QC Point of View
• Upstream Management :
– When failures occur, there must be some cause in the
process or ...
Basic Items :: QC Point of View
• Recurrence Prevention :
 Pursue the root cause and apply the recurrence
preventive acti...
Basic Items :: QC Point of View
• Respect for Humanity :
– it means, to recognize the autonomy (to be able to act
independ...
40Engr. Kawsar Alam Sikder
41Engr. Kawsar Alam Sikder
42Engr. Kawsar Alam Sikder
The Good
43Engr. Kawsar Alam Sikder
5 S at Toyota Motors
44Engr. Kawsar Alam Sikder
5 S in Office
45Engr. Kawsar Alam Sikder
Ideal Situation or Objective
46Engr. Kawsar Alam Sikder
47Engr. Kawsar Alam Sikder
Region Where Problems are Found
• Customer Satisfaction
• Quality
• Productivity
• Cost
• Delivery
• Safety
• Morale
• Soc...
49Engr. Kawsar Alam Sikder
50Engr. Kawsar Alam Sikder
51Engr. Kawsar Alam Sikder
52Engr. Kawsar Alam Sikder
53Engr. Kawsar Alam Sikder
Cause & Effect Diagram
54Engr. Kawsar Alam Sikder
55Engr. Kawsar Alam Sikder
56Engr. Kawsar Alam Sikder
Seven Keys to skillful standardization
and control
• Raise everybody’s quality-consciousness.
• Track down the causes of d...
Meihoku Kogyo Co., Ltd
• Producing C.H.Q. Wire (for Automobiles)
• Established 1947
• Capital : 60 Million Yen
• Sales : 1...
Meihoku Kogyu Co., Ltd
TQM Activities
• Policy Management
–President’s policy paper
–Medium Term Corporate planning
–PDCA ...
Meihoku Kogyu Co., Ltd
TQM Activities
• Continuous Improvement
–Participation by all
–My Suggestion Camping
–1 Suggestion ...
Meihoku Kogyu Co., Ltd
TQM Activities
• Daily Management
– 4S1K Activities
– 4S from 5S, 1K stand for Kiritsu i.e. Discipl...
Meihoku Kogyu Co., Ltd
TQM Activities
• Quality Management
– Built in Quality is motto
– Feeling Happy and being proud of ...
Meihoku Kogyu Co., Ltd
TQM Activities
• Human Capital Development
– Follow 93/5 % Rule i.e. 93% employee pass QC
Genius ce...
TOYOTA .. Motomachi Plant
History
• 1867 .. Sakichi Toyota was born
• 1937 .. Toyota Motor Co., Ltd was established
• 1959...
TOYOTA .. Motomachi Plant
Production Process
• Stamping : Steel sheets are cut and stamped to form body
parts.
• Welding :...
TOYOTA : Welding
66Engr. Kawsar Alam Sikder
Toyota :: Process
67Engr. Kawsar Alam Sikder
TPS .. Toyota Production System
• Primary Purpose of TPS : To eliminate waste
(muda) and satisfy customer needs at the low...
Main Pillars of TPS
• JIT (Just in Time) : Just only Exact
– Making flow of process by reduction of lead time of
productio...
TPS Pillar : JIDOUKA
• ANDON : An electrical board lights up to show at
a glance the current state of work operations.
• P...
TOYOTA
General Observation
• Strategy : Obtain brilliant results from average
people operating brilliant processes. But mo...
Superconductiong Maglev &
Railway Park
Engr. Kawsar Alam Sikder 72
Superconductiong Maglev &
Railway Park
Engr. Kawsar Alam Sikder 73
Superconductiong Maglev &
Railway Park
• History of Railway in Japan ::
– 1872 : the first line from Tokyo to Yokohama.
– ...
Kaizen
 KAIZEN is a basic component of
Total Quality Management (TQM).
 After the World War II, KAIZEN
contributed most ...
Kaizen
 KAIZEN employs simple ideas and
common sense
 KAIZEN is more a mind-set than a
technique. A mind set that “there...
Example of Kaizen
77Engr. Kawsar Alam Sikder
Example of Kaizen
78Engr. Kawsar Alam Sikder
Example of Kaizen
79Engr. Kawsar Alam Sikder
Example of Kaizen
80Engr. Kawsar Alam Sikder
Summery
• TQM (Deming Prize Committee ):: A
systematic activity 7 that contributes to
achieving corporate purposes2 by run...
Summery :: Basic Concepts of TQM
• Customer Focused ::
 Customer First / Satisfaction
 Process Control & SDCA
 Post Pro...
Summery :: Basic Concepts of TQM
• Full Participation::
 QC Circle Activities
 Reward for Kaizen / QC Activities
 Sugge...
TQM in Bangladesh
Engr. Kawsar Alam Sikder 84
Vegetable Cooked
in China
Chinese Vegetable
Bangladesh Version
Try it from now onwards
Engr. Kawsar Alam Sikder 85
Open Discussions
86Engr. Kawsar Alam Sikder
87Engr. Kawsar Alam Sikder
Engr. Kawsar Alam Sikder
engr.kawsar@gmail.com
+8801713453432
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Total quality management

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Total quality management

  1. 1. Definition of TQM • Toyota :: Activities to build a corporate structure that enhances the vitality of people and the organization, and is capable of flexibly responding to changes in the business environment. 1Engr. Kawsar Alam Sikder
  2. 2. Definition of TQM • Deming Prize Committee :: A systematic activity 7 that contributes to achieving corporate purposes2 by running all corporate units effectively and efficiently 5 to provide4 products and services3 with a quality2 that satisfies customers1 in a timely fashion and at appropriate prices. 2Engr. Kawsar Alam Sikder
  3. 3. Definition of TQM 1. Customers : include not only buyers but also stakeholders such as users, consumers and beneficiaries. 2. Quality : indicates usability ( functions, psychological characteristics, etc), reliability and safety; the impact to third parties, society, environment and future generations should be also considered. 3Engr. Kawsar Alam Sikder
  4. 4. Definition of TQM 3. Products and Services :: include products (finished products, parts and raw materials) and services as well as everything provided to customers, including systems, software, energy and information. 4Engr. Kawsar Alam Sikder
  5. 5. Definition of TQM 4. Provide :: means activities, from production to delivery of ‘’products and services’’, such as surveys, research, planning, development, design, production preparation, purchasing, manufacturing, implementation, inspection, acceptance of order, transportation, sales and marketing, and also includes activities of maintenance and after-sales service, and disposal and recycling of such products and services. 5Engr. Kawsar Alam Sikder
  6. 6. Definition of TQM 5. Running all corporate units effectively and efficiently : Under the appropriate organization / business management, all divisions and all staff in all levels of an organization work together to quickly achieve corporate purpose along with the integration of management systems so as to utilizes as few management resources as possible. These management systems include quality assurance as a main system, along with cost, volume, delivery period, environment and safety. This operation requires the development of people who are equipped with the core technology, speed and vitality, grounded in a value that respects humanity, fact-based management / improvement of PDCA (Plan/Do/Check/Act) using statistical methods in process and business operations, and reconstruction of the management system by effectively utilizing the appropriate scientific approaches and information technology. 6Engr. Kawsar Alam Sikder
  7. 7. Definition of TQM 6. Corporate Purpose :: Aim for growth and long-term appropriate levels of profits to the company by permanently and continuously satisfying customers. It also includes employee satisfaction as well as benefits improvement for all those involved in the business, such as community, business partner, and shareholders. 7Engr. Kawsar Alam Sikder
  8. 8. Definition of TQM • Systematic activity :: is an activity which defines clear mid-to-long term vision/strategy and appropriate quality strategy/policy, conducted under a strong sense of mission and leadership carried out by top management in order to achieve corporate mission (purposes). 8Engr. Kawsar Alam Sikder
  9. 9. 3 Basic Concepts of TQM TQM Customer- focused Continuous Improvement Full Participation Purpose :: Enhance the vitality of people and the organization and improvement the quality of the work. Customer-in Always stand in the customer’s shoes, and work for customers. Improvement activity = Creation activity Possess the belief that there is no reform without improvement Autonomy and overall optimization Everyone, from top management to members on the frontlines, shares the same values, objectives and information in their work. Everyone exercises their autonomy and creativity, and fulfills their roles while increasing their abilities. 9Engr. Kawsar Alam Sikder
  10. 10. 10 3 Basic Concepts of TQM
  11. 11. What is TQM ? What are TQM Activities ? Everybody In every division At every stage Systems Using the QC Philosophy and approach Utilizing QC methods and information Methods Q (Quality) : Better quality C (Cost) : Lower costs D (Delivery) : More reliable delivery S (Safety) : Consistent safety M (Morale) : Higher morale E (Environment) : Environment conservation Objectives 11Engr. Kawsar Alam Sikder
  12. 12. House of TQM 12Engr. Kawsar Alam Sikder Reinforcement of Corporate Structure
  13. 13. History of TQM in Japan • 1924 – 1944 : Statistics began to be applied in the industry field (Primarily in the US) – 1924 : W.A. Shewhart devised the control chart as a tool for concretely distinguishing assignable cause & chance cause variation. – 1931 : Shewhart written “Economic Control of Quality of Manufactured Products”. • 1945 – 1949 : The roots of quality control (TQM) land on Japan – The Japanese Standards Association (JSA) established & research, seminar conducted. 13Engr. Kawsar Alam Sikder
  14. 14. History of TQM in Japan • 1950-1954 : The importance of variations caused by statistical quality control emphasized. – 1951 : Deming Prize established in Japan. – 1951 : “Quality Control Handbook” by J.M. Juran published & seminar held on 1954. • 1955 – 1959 : The idea that quality is built in during the process emphasized. – 1955 : “Control Chart Method” by Kaoru Ishikawa Published. – 1959 : the Lectures of W.A. Shewhart held in various locations. 14Engr. Kawsar Alam Sikder
  15. 15. History of TQM in Japan • 1960 – 1964 : Quality control on full – participation basis advocated “All staff from workers at the frontlines to management participate in quality control activities” – 1960 : November of each year designated as “Quality Month”. • 1965 – 1969 : Japanese style quality control (TQM) blossomed. – 1969 : The world’s first “International Conference on Quality Control (ICQC) held in Tokyo. 15Engr. Kawsar Alam Sikder
  16. 16. History of TQM in Japan • 1980-1984 : Quality Control (TQM) widely used in new lines of business. • 1985 – 1989 : Japanese Style TQM recognized overseas. • 1985 : Six Sigma advocated by Crosby and introduced into Motorola, Inc. • 1990 – 1994 : International standard for Quality control (TQM) established. • 1995 – 1999 : Quality Control (TQM) reconstructed. • 2000 – 2004 : TQM integrated with various management systems. 16Engr. Kawsar Alam Sikder
  17. 17. Differences between ISO 9000 and TQM Item ISO TQM Purpose Conformance to requirements Ensuring customer satisfaction, Improvement of Corporate Structure Initiative Purchaser’s demand Supplier’s initiative Level Status quo Improvement emphasized Execution Written agreement Self-initiative respected Quality Inspection/verification-oriented Built-in quality during the process. 17Engr. Kawsar Alam Sikder
  18. 18. Differences between ISO 9000 and TQM Item ISO TQM Advantages  Standardization thoroughly achieved through written document Can communicate with other companies using a common language  Helps solve problems logically throughout the work process. Leads to improvement in all divisions and employees. Disadvantage s  The minimum working range  Prone to a format oriented approach. Not connected with performance improvements.  May increase systems which will not be implemented.  Could encourage format bound activities Likely to respond to events. Problems  Generates unwanted documents by placing too much stress on standardization.  Too much concern with revision of the standards manual, neglecting improvement.  Requires introduction of the system to organizationally promote improvement activities.  Must develop personnel who can carry out specific improvement activities. 18Engr. Kawsar Alam Sikder
  19. 19. Policy & Daily Management 19Engr. Kawsar Alam Sikder
  20. 20. The Idea of Quality 20Engr. Kawsar Alam Sikder
  21. 21. The Idea of Management Relationship between SDCA & PDCA 21Engr. Kawsar Alam Sikder
  22. 22. Keys to Success in TQM • Leadership of top group (Clarification of the relationship between management strategy and TQM) • Participation by all divisions ( Correct understanding of TQM and education / training for everyone). • Systematic management (engaged in an united efforts; clear definition of roles of each division and control points) 22Engr. Kawsar Alam Sikder
  23. 23. Keys to Success in TQM • Continual / Adaptive activity (Not partying, but be flexible) • Quality is the first priority (Receive gratification from satisfying customers; “Quality” is the common language and promise) • Process-oriented (Follow the PDCA cycle to achieve not immediate results but the results beyond that) 23Engr. Kawsar Alam Sikder
  24. 24. Keys to Success in TQM • Utilization of methods (Your own way does not work; acquire the QC method) • “3-gen shugi” or “Principle of the triple facts” (collect factual data) • Clarification of casual relations (Seek a cause. Bad consequences result from the cause) • Respect for humanity (Everyone fails once in a while. Establish good criteria). 24Engr. Kawsar Alam Sikder
  25. 25. Deming Prize • The Deming prize was established in 1951 to honor the accomplishment of late W.E. Deming who contributed greatly to Japan’s proliferation of statistical quality control after World War II, and helped Japan build its foundation by which the level of Japanese product quality has been recognized as the highest in the world. It is the world’s supreme award in the field of total quality management (TQM) 25Engr. Kawsar Alam Sikder
  26. 26. 26Engr. Kawsar Alam Sikder
  27. 27. 27Engr. Kawsar Alam Sikder
  28. 28. Basic Items :: QC Point of View • Quality First : – “Good or bad of quality is decided by the customer ! “ – Improvements by cost-first (quality second) may exhibit temporary profit but will eventually lose the trust from customers. 28Engr. Kawsar Alam Sikder
  29. 29. Basic Items :: QC Point of View Customer Oriented (Market in): – To be always conscious of what the customer wants and what the desired products are. – Put yourself in customer’s shoes, and grasp not only the apparent needs but also the potential needs. – Act to satisfy their needs.  Always act and judge from customer’s perspective. 29Engr. Kawsar Alam Sikder
  30. 30. Customer in :: Japanese Style 30Engr. Kawsar Alam Sikder
  31. 31. Basic Items :: QC Point of View • Post Process is customer : – Each of you needs to think in the shoes of post process, execute your own work responsibly and deliver the work to the next person.  Guarantee you own work yourself. • PDCA (Management ) Cycle : – Repeat the PDCA cycle again and again to enhance the way of work. 31Engr. Kawsar Alam Sikder
  32. 32. 32Engr. Kawsar Alam Sikder
  33. 33. Basic Items :: QC Point of View • Fact Control ( Management based on facts) : – To judge something, it is critical to use facts (data) as the base rather than relying only on experience or guessing.  Grasp the fact, judge on the fact, and act on the fact. Genchi Go to the actual site of the problem Genbutsu See/Observe the actual object well Genjitu Convert the result of observation to data, and grasp the actuality (fact). 33Engr. Kawsar Alam Sikder
  34. 34. 34Engr. Kawsar Alam Sikder
  35. 35. 35Engr. Kawsar Alam Sikder
  36. 36. 36Engr. Kawsar Alam Sikder
  37. 37. Basic Items :: QC Point of View • Upstream Management : – When failures occur, there must be some cause in the process or upstream process.  Quality assurance by design/production (upstream) is more important than quality assurance by inspection (downstream). • Priority Focused : – Focus your eyes to the item most influential and most effective among many elements that can cause problems. Use Pareto Chart.  Win a large achievement by the limited labor. 37Engr. Kawsar Alam Sikder
  38. 38. Basic Items :: QC Point of View • Recurrence Prevention :  Pursue the root cause and apply the recurrence preventive action to stop the same trouble to happen again ! • Dispersion Management : – It is important to observe the dispersion of data. The outcome of production can show dispersion even if the same conditions. Use Histogram to understand better.  The basic of quality control is management of Dispersion. 38Engr. Kawsar Alam Sikder
  39. 39. Basic Items :: QC Point of View • Respect for Humanity : – it means, to recognize the autonomy (to be able to act independently with own will) and creativity (to be able to improve and create something) of each employee, rather than regarding them as only labor force. – QC Circle activity is to bring out the humanity of each employee, promote the business improvements by helping each person to grow, and to help people and company to grow together.  Improvements can let people and company grow and develop together. 39Engr. Kawsar Alam Sikder
  40. 40. 40Engr. Kawsar Alam Sikder
  41. 41. 41Engr. Kawsar Alam Sikder
  42. 42. 42Engr. Kawsar Alam Sikder
  43. 43. The Good 43Engr. Kawsar Alam Sikder
  44. 44. 5 S at Toyota Motors 44Engr. Kawsar Alam Sikder
  45. 45. 5 S in Office 45Engr. Kawsar Alam Sikder
  46. 46. Ideal Situation or Objective 46Engr. Kawsar Alam Sikder
  47. 47. 47Engr. Kawsar Alam Sikder
  48. 48. Region Where Problems are Found • Customer Satisfaction • Quality • Productivity • Cost • Delivery • Safety • Morale • Social Responsibility 48Engr. Kawsar Alam Sikder
  49. 49. 49Engr. Kawsar Alam Sikder
  50. 50. 50Engr. Kawsar Alam Sikder
  51. 51. 51Engr. Kawsar Alam Sikder
  52. 52. 52Engr. Kawsar Alam Sikder
  53. 53. 53Engr. Kawsar Alam Sikder
  54. 54. Cause & Effect Diagram 54Engr. Kawsar Alam Sikder
  55. 55. 55Engr. Kawsar Alam Sikder
  56. 56. 56Engr. Kawsar Alam Sikder
  57. 57. Seven Keys to skillful standardization and control • Raise everybody’s quality-consciousness. • Track down the causes of defects and mistakes and take action to prevent them recurring. • Lock the new working methods permanently into place. • Follow work standards closely. • Lock the control methods permanently into place. • “Apply the brakes” by making use of control tools. • Disseminate the new methods through education and training. 57Engr. Kawsar Alam Sikder
  58. 58. Meihoku Kogyo Co., Ltd • Producing C.H.Q. Wire (for Automobiles) • Established 1947 • Capital : 60 Million Yen • Sales : 14.3 Billion Japanese Yen (2014) • Operating Profit : 4 Billion Yen • 4th place out of 29th Domestic Companies (9% share) • Deming prize winner in 2013 for TQM • Toyota approved Supplier .. Lexus • Start TQM at 2010 58Engr. Kawsar Alam Sikder
  59. 59. Meihoku Kogyu Co., Ltd TQM Activities • Policy Management –President’s policy paper –Medium Term Corporate planning –PDCA practices –Developed into individual goals 59Engr. Kawsar Alam Sikder
  60. 60. Meihoku Kogyu Co., Ltd TQM Activities • Continuous Improvement –Participation by all –My Suggestion Camping –1 Suggestion per week per persons must –1000 yen for good suggestion –19 teams for QC Circle activity 60Engr. Kawsar Alam Sikder
  61. 61. Meihoku Kogyu Co., Ltd TQM Activities • Daily Management – 4S1K Activities – 4S from 5S, 1K stand for Kiritsu i.e. Discipline – Securing Quality & Safety through 4S1K activities – Scoring daily basis, Evaluate monthly – 1K Means : M & M Activity • M = Moral & M = Manner – Daily Safety Petrol by Concern Officer – Day start with Exercise, Read out behavior Principles & morning meeting – Every body follow Pedestrian Crossing / Path 61Engr. Kawsar Alam Sikder
  62. 62. Meihoku Kogyu Co., Ltd TQM Activities • Quality Management – Built in Quality is motto – Feeling Happy and being proud of your job – Next Process is our Customer – Operation Standard with photo – Process check sheet with 4 M analysis – Report of Kaizen after complete the work 62Engr. Kawsar Alam Sikder
  63. 63. Meihoku Kogyu Co., Ltd TQM Activities • Human Capital Development – Follow 93/5 % Rule i.e. 93% employee pass QC Genius certificate & 5% of total hours spend for education. – Establish HACHI Studio for education – Competence score sheet maintain in production – Skill upgrade record sheet maintain – Award for 1) best Kaizen 2) best suggestion 63Engr. Kawsar Alam Sikder
  64. 64. TOYOTA .. Motomachi Plant History • 1867 .. Sakichi Toyota was born • 1937 .. Toyota Motor Co., Ltd was established • 1959 .. Motomachi Plant started production • Overseas Plants : 53 companies in 28 countries & regions • No of staff : 68,240 (consolidated 338,875) • Main Products of Motomachi Plant : Estima, Crown, Mark X 64Engr. Kawsar Alam Sikder
  65. 65. TOYOTA .. Motomachi Plant Production Process • Stamping : Steel sheets are cut and stamped to form body parts. • Welding : 96% work done by Robot. Robots weld about 400 body parts to form a car. The latest welding line can handle multiple models on a single line & produce precisely finished car bodies. • Painting : After the body is washed, undercoat, intermediate and topcoat are applied to create a high quality surface. Water based paint has made this process even more environmentally friendly. • Assembly : engines, wheels & other parts are installed. Than tested & verified in the final inspection before shipped. 65Engr. Kawsar Alam Sikder
  66. 66. TOYOTA : Welding 66Engr. Kawsar Alam Sikder
  67. 67. Toyota :: Process 67Engr. Kawsar Alam Sikder
  68. 68. TPS .. Toyota Production System • Primary Purpose of TPS : To eliminate waste (muda) and satisfy customer needs at the lowest possible cost with consideration and respect for humanity of employees. • 1943 .. Parts suppliers co-operative park established • 1963 .. Kanban System Established ( Taiichi Ohno inventor) • 1992 .. Release Fundamental Principles of Toyota 68Engr. Kawsar Alam Sikder
  69. 69. Main Pillars of TPS • JIT (Just in Time) : Just only Exact – Making flow of process by reduction of lead time of production. – Decide tack time by required quantity ( Tack time = operational Time/Required quantity) – A later process takes parts from an earlier process. Kanban is the control tool to make JIT possible. • JIDOUKA : Quality in built Process – Prevent from Making Defective Parts – Don’t Flow defects to later Process. – Quickly handle abnormal condition. 69Engr. Kawsar Alam Sikder
  70. 70. TPS Pillar : JIDOUKA • ANDON : An electrical board lights up to show at a glance the current state of work operations. • POKA-YOKE (Mistake Proofing) : Poka-Yoke was applied by Shigeo Shingo in the 1960s to industrial processes designed to prevent human errors. • Standardized Work : Standardized work is standard to produce product and tool for efficient production and kaizen. 70Engr. Kawsar Alam Sikder
  71. 71. TOYOTA General Observation • Strategy : Obtain brilliant results from average people operating brilliant processes. But most companies obtain mediocre or worse results from brilliant people working around broken processes. • SOP : Every where , even visit • Visit did not hamper production. • Robotic activities in all case, work should done in specific time frame with good quality. 71Engr. Kawsar Alam Sikder
  72. 72. Superconductiong Maglev & Railway Park Engr. Kawsar Alam Sikder 72
  73. 73. Superconductiong Maglev & Railway Park Engr. Kawsar Alam Sikder 73
  74. 74. Superconductiong Maglev & Railway Park • History of Railway in Japan :: – 1872 : the first line from Tokyo to Yokohama. – 1987, 1st April : Established Central Japan Railway company (JR Central). – 1240 QC Circle (Small group / Challenge Tokai) activities. • History of Railway in Bangladesh :: – 15th November of 1862. First line between Dorshona of Chuadnaga district to Jogotee of Kushtia. Total distance was 53.11 km. • Why we are behind ?? 74Engr. Kawsar Alam Sikder
  75. 75. Kaizen  KAIZEN is a basic component of Total Quality Management (TQM).  After the World War II, KAIZEN contributed most to the development of Japan. 75Engr. Kawsar Alam Sikder
  76. 76. Kaizen  KAIZEN employs simple ideas and common sense  KAIZEN is more a mind-set than a technique. A mind set that “there is always a better way of doing something.” 76Engr. Kawsar Alam Sikder
  77. 77. Example of Kaizen 77Engr. Kawsar Alam Sikder
  78. 78. Example of Kaizen 78Engr. Kawsar Alam Sikder
  79. 79. Example of Kaizen 79Engr. Kawsar Alam Sikder
  80. 80. Example of Kaizen 80Engr. Kawsar Alam Sikder
  81. 81. Summery • TQM (Deming Prize Committee ):: A systematic activity 7 that contributes to achieving corporate purposes2 by running all corporate units effectively and efficiently 5 to provide4 products and services3 with a quality2 that satisfies customers1 in a timely fashion and at appropriate prices. • QC Activities :: QCDSME :: Quality, Cost, Delivery, Safety, Morale, Environment 81Engr. Kawsar Alam Sikder
  82. 82. Summery :: Basic Concepts of TQM • Customer Focused ::  Customer First / Satisfaction  Process Control & SDCA  Post Process Customer • Continuous Improvement ::  5 S  Kaizen (PDCA) QC Tools // Genchi .. Genbutsu Root Cause Analysis to prevent Recurrence. 82Engr. Kawsar Alam Sikder
  83. 83. Summery :: Basic Concepts of TQM • Full Participation::  QC Circle Activities  Reward for Kaizen / QC Activities  Suggestions Box & Reward  Develop Human Capital • Others ::  TQM / QC Board / Visual Board  Self Service & Harmony  Courtesy 83Engr. Kawsar Alam Sikder
  84. 84. TQM in Bangladesh Engr. Kawsar Alam Sikder 84 Vegetable Cooked in China Chinese Vegetable Bangladesh Version
  85. 85. Try it from now onwards Engr. Kawsar Alam Sikder 85
  86. 86. Open Discussions 86Engr. Kawsar Alam Sikder
  87. 87. 87Engr. Kawsar Alam Sikder Engr. Kawsar Alam Sikder engr.kawsar@gmail.com +8801713453432

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