PPT ON FALIURE MODE AND EFFECT ANALYSIS (FMEA)
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Defect free execution of a process or product operation is key to efficient working. Defect and product or process severely effect the profitability of operation. It takes 10% to rectify the defect at design stage, while cost to rectify defect at prototype level increases by 100% but this cost goes up by whopping 1000% when defect is identified in the field. Identification and elimination of defect plays a very crucial role in product design or operation for an efficient and effective management of operation. FMEA is a step by step approach of identifying all possible failures in a design, a manufacturing or assembly process, or a product or service that may happen in a workplace. It is a tool to predict what may go wrong with process in future. It is an analytical technique that goes in for combining technology and experience of people o identify foreseen failures in a product or process and planning to eliminate the failure. It eliminates or reduce failures with the highest priority first. FMEA focuses on prevention and helps in improving internal and external customer satisfaction.
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TOYOTA PRODUCTION SYSTEM (TPS) PRESENTATION
The Toyota Production System (TPS) is an integrated socio-technical system, developed by Toyota, that comprises its management philosophy and practices. The TPS organizes manufacturing and logistics for the automobile manufacturer, including interaction with suppliers and customers. The system is a major precursor of the more generic "lean manufacturing". Taiichi Ohno and Eiji Toyoda, Japanese industrial engineers, developed the system between 1948 and 1975.
Originally called "just-in-time production", it builds on the approach created by the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and the engineer Taiichi Ohno. The principles underlying the TPS are embodied in The Toyota Way.
PROCESS FAILURE MODE EFFECTS ANALYSIS (PFMEA) PPT
A Process Failure Mode Effects Analysis (PFMEA) is a structured analytical tool used by an organization, business unit, or cross-functional team to identify and evaluate the potential failures of a process. PFMEA helps to establish the impact of the failure, and identify and prioritize the action items with the goal of alleviating risk. It is a living document that should be initiated prior to process of production and maintained through the life cycle of the product.
PFMEA evaluates each process step and assigns a score on a scale of 1 to 10 for the following variables:
Severity — Assesses the impact of the failure mode (the error in the process), with 1 representing the least safety concern and 10 representing the most dangerous safety concern. In most cases, processes with severity scores exceeding 8 may require a fault tree analysis, which estimates the probability of the failure mode by breaking it down into further sub-elements.
Occurrence — Assesses the chance of a failure happening, with 1 representing the lowest occurrence and 10 representing the highest occurrence. For example, a score of 1 may be assigned to a failure that happens once in every 5 years, while a score of 10 may be assigned to a failure that occurs once per hour, once per minute, etc.
Detection — Assesses the chance of a failure being detected, with 1 representing the highest chance of detection and 10 representing the lowest chance of detection.
RPN — Risk priority number = severity X occurrence X detection. By rule of thumb, any RPN value exceeding 80 requires a corrective action. The corrective action ideally leads to a lower RPN number.
WORK STUDY TIME AND MOTION STUDY PRESENTATION
Work study may be defined as the analysis of a job for the purpose of finding the preferred method of doing it and also determining the standard time to perform it by the preferred (or given) method. Work study, therefore, comprises of two areas of study: method study (motion study) and time study (work measurement).
Role of Work Study in Improving Productivity
In order to understand the role of work study, we need to understand the role of method study and that of time study.
Method study (also sometimes called Work Method Design) is mostly used to improve the method of doing work. It is equally applicable to new jobs. When applied to existing jobs and existing jobs, method study aims to find better methods of doing the jobs that are economical and safe, require less human effort, and need shorter make-ready / put-away time. The better method involves the optimum use of best materials and appropriate manpower so that work is performed in well organized manner leading to increased resource utilization, better quality and lower costs.
WORLD CLASS MANUFACTURING (WCM) PRESENTATION
Manufacturing has evolved considerably since the advent of industrial revolution. In current global and competitive age, it is very important for organization to have manufacturing practice which is lean, efficient, cost-effective and flexible.
World class manufacturing is a collection of concepts, which set standard for production and manufacturing for another organization to follow. Japanese manufacturing is credited with pioneer in concept of world-class manufacturing. World class manufacturing was introduced in the automobile, electronic and steel industry.
CONCEPT GENERATION AND SELECTION PRESENTATION
Product conceptualization is regarded as a key activity in new product development (NPD). In this stage, product concept generation and selection plays a crucial role. This paper presents a product concept generation and selection (PCGS) approach, which was proposed to assist product designers in generating and selecting design alternatives during the product conceptualization stage. In the PCGS, general sorting was adapted for initial requirements acquisition and platform definition; while a fuzzy c-means (FCM) algorithm was integrated with a design alternatives generation strategy for clustering design options and selecting preferred product concepts. The PCGS deliberates and embeds a psychology-originated method, i.e., sorting technique, to widen domain coverage and improve the effectiveness in initial platform formation. Furthermore, it successfully improves the FCM algorithm in such a way that more accurate clustering results can be obtained. A case study on a wood golf club design was used for illustrating the proposed approach. The results were promising and revealed the potential of the PCGS method.
7 QC TOOLS PRESENTATION PPT
The Seven Basic Tools of Quality (also known as 7 QC Tools) originated in Japan when the country was undergoing major quality revolution and had become a mandatory topic as part of Japanese’s industrial training program. These tools which comprised of simple graphical and statistical techniques were helpful in solving critical quality related issues. These tools were often referred as Seven Basics Tools of Quality because these tools could be implemented by any person with very basic training in statistics and were simple to apply to solve quality-related complex issues.
LINE BALANCING PRESENTATION PPT
Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. A constraint slows the process down and results if waiting for downstream operations and excess capacity results in waiting and no absorption of fixed costs.
Match the production rate after all wastes have been removed to the Takt time at each process of the value stream.
ROOT CAUSE ANALYSIS PRESENTATION
Root cause analysis (RCA) is a method of problem solving used for identifying the root causes of faults or problems. A factor is considered a root cause if removal thereof from the problem-fault-sequence prevents the final undesirable event from recurring; whereas a causal factor is one that affects an event's outcome, but is not a root cause. Though removing a causal factor can benefit an outcome, it does not prevent its recurrence with certainty.
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TOYOTA PRODUCTION SYSTEM (TPS) PRESENTATION
The Toyota Production System (TPS) is an integrated socio-technical system, developed by Toyota, that comprises its management philosophy and practices. The TPS organizes manufacturing and logistics for the automobile manufacturer, including interaction with suppliers and customers. The system is a major precursor of the more generic "lean manufacturing". Taiichi Ohno and Eiji Toyoda, Japanese industrial engineers, developed the system between 1948 and 1975.
Originally called "just-in-time production", it builds on the approach created by the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and the engineer Taiichi Ohno. The principles underlying the TPS are embodied in The Toyota Way.
PROCESS FAILURE MODE EFFECTS ANALYSIS (PFMEA) PPT
A Process Failure Mode Effects Analysis (PFMEA) is a structured analytical tool used by an organization, business unit, or cross-functional team to identify and evaluate the potential failures of a process. PFMEA helps to establish the impact of the failure, and identify and prioritize the action items with the goal of alleviating risk. It is a living document that should be initiated prior to process of production and maintained through the life cycle of the product.
PFMEA evaluates each process step and assigns a score on a scale of 1 to 10 for the following variables:
Severity — Assesses the impact of the failure mode (the error in the process), with 1 representing the least safety concern and 10 representing the most dangerous safety concern. In most cases, processes with severity scores exceeding 8 may require a fault tree analysis, which estimates the probability of the failure mode by breaking it down into further sub-elements.
Occurrence — Assesses the chance of a failure happening, with 1 representing the lowest occurrence and 10 representing the highest occurrence. For example, a score of 1 may be assigned to a failure that happens once in every 5 years, while a score of 10 may be assigned to a failure that occurs once per hour, once per minute, etc.
Detection — Assesses the chance of a failure being detected, with 1 representing the highest chance of detection and 10 representing the lowest chance of detection.
RPN — Risk priority number = severity X occurrence X detection. By rule of thumb, any RPN value exceeding 80 requires a corrective action. The corrective action ideally leads to a lower RPN number.
WORK STUDY TIME AND MOTION STUDY PRESENTATION
Work study may be defined as the analysis of a job for the purpose of finding the preferred method of doing it and also determining the standard time to perform it by the preferred (or given) method. Work study, therefore, comprises of two areas of study: method study (motion study) and time study (work measurement).
Role of Work Study in Improving Productivity
In order to understand the role of work study, we need to understand the role of method study and that of time study.
Method study (also sometimes called Work Method Design) is mostly used to improve the method of doing work. It is equally applicable to new jobs. When applied to existing jobs and existing jobs, method study aims to find better methods of doing the jobs that are economical and safe, require less human effort, and need shorter make-ready / put-away time. The better method involves the optimum use of best materials and appropriate manpower so that work is performed in well organized manner leading to increased resource utilization, better quality and lower costs.
WORLD CLASS MANUFACTURING (WCM) PRESENTATION
Manufacturing has evolved considerably since the advent of industrial revolution. In current global and competitive age, it is very important for organization to have manufacturing practice which is lean, efficient, cost-effective and flexible.
World class manufacturing is a collection of concepts, which set standard for production and manufacturing for another organization to follow. Japanese manufacturing is credited with pioneer in concept of world-class manufacturing. World class manufacturing was introduced in the automobile, electronic and steel industry.
CONCEPT GENERATION AND SELECTION PRESENTATION
Product conceptualization is regarded as a key activity in new product development (NPD). In this stage, product concept generation and selection plays a crucial role. This paper presents a product concept generation and selection (PCGS) approach, which was proposed to assist product designers in generating and selecting design alternatives during the product conceptualization stage. In the PCGS, general sorting was adapted for initial requirements acquisition and platform definition; while a fuzzy c-means (FCM) algorithm was integrated with a design alternatives generation strategy for clustering design options and selecting preferred product concepts. The PCGS deliberates and embeds a psychology-originated method, i.e., sorting technique, to widen domain coverage and improve the effectiveness in initial platform formation. Furthermore, it successfully improves the FCM algorithm in such a way that more accurate clustering results can be obtained. A case study on a wood golf club design was used for illustrating the proposed approach. The results were promising and revealed the potential of the PCGS method.
7 QC TOOLS PRESENTATION PPT
The Seven Basic Tools of Quality (also known as 7 QC Tools) originated in Japan when the country was undergoing major quality revolution and had become a mandatory topic as part of Japanese’s industrial training program. These tools which comprised of simple graphical and statistical techniques were helpful in solving critical quality related issues. These tools were often referred as Seven Basics Tools of Quality because these tools could be implemented by any person with very basic training in statistics and were simple to apply to solve quality-related complex issues.
LINE BALANCING PRESENTATION PPT
Line Balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. A constraint slows the process down and results if waiting for downstream operations and excess capacity results in waiting and no absorption of fixed costs.
Match the production rate after all wastes have been removed to the Takt time at each process of the value stream.
ROOT CAUSE ANALYSIS PRESENTATION
Root cause analysis (RCA) is a method of problem solving used for identifying the root causes of faults or problems. A factor is considered a root cause if removal thereof from the problem-fault-sequence prevents the final undesirable event from recurring; whereas a causal factor is one that affects an event's outcome, but is not a root cause. Though removing a causal factor can benefit an outcome, it does not prevent its recurrence with certainty.
AUTONOMOUS MAINTENANCE PRESENTATION
When companies begin to implement Total Productive Maintenance (TPM) they often start by piloting Autonomous Maintenance (AM). This is understandable as AM is one of the key distinguishing features of TPM and also one of the most important activities when understood correctly. To understand AM correctly it needs to be seen as an improvement activity within TPM, rather than production teams taking on maintenance activities.
In the evolution of TPM in Japan, AM grew out of the 5S activities of production teams, as they found that in order to deal with barriers to Quality, Delivery and particularly Cost performance they needed to improve equipment conditions, initially by applying the principles of 5S and QC circles. AM was not the result of a desire to reduce maintenance costs or maintenance departments wishing to hand tasks over to production, rather it was the result of production teams wishing to control and improve their equipment.
PPT ON THE ADVANCED MANAGEMENT AND PLANNING TOOLS
Post 2000, a robust project planning and execution has become key for the success of any organization. Project Success is directly proportional to the effective planning & execution methodology. The Advanced Management Planning Tools are applied to generate and evaluate ideas using different logical methods.
These tools are widely used in various decision-making situations across all industries and are popularly addressed as 7 MP Tools. These tools support in structured brainstorming process to simplify problems. They eliminate the fear of failure from the decision-makers mind. It helps in creating a comfort fit by deepening the ideas.
QUALTY FUNCTION DEPLOYMENT (QFD) PPT
Nowadays, one can witness the rapid changes in technology in industries. In present competitive scenario, customer satisfaction based products and services are key factors for any organization’s growth. To fulfill the customer & organization’s requirements, Quality Function Deployment (QFD) can be used.
It is the systematic approach to plan the solutions of any problem or requirements with the help of competitive analysis and mathematical priorities. It is very useful to make strategic plans to develop new or upgraded version of product as well as services.
POKE YOKE PRESENTATION PPT
As always While doing repetitive work, operators get bored and sometime ignored tasks.
If these ignored task contain maintenance task, it can lead to failure of machines.
They errors may occur due to various reasons like misunderstanding, language barriers, lack of experience, etc.
The idea is to take over repetitive tasks that rely on memory or vigilance and guard against any lapses in focus.
It is a quality assurance technique, where main objective is to reduce defects by correcting or preventing mistakes as soon as possible.
poka-yoke is a system designed to prevent inadvertent errors made by operators performing a process.
Poka-yoke can be seen as one of the three common components of Zero Defect Quality Control performed by Japanese companies
PERT - CPM PRESENTATION
PERT refers to project evaluation review technique while CPM refers to critical path method both these techniques are used in project management . PERT focuses on time estimated i.e. mean , estimated and probablistic tine while the CPM focuses on the longest path.
PPT ON KANBAN PRESENTATION
Production has a lot of process involved in it, from warehouses to final products.
If somehow these process get mixed up, production will hamper.
So, how to classify these process from each other, visual companions can be used .
It is a tool of lean manufacturing and JIT that carries information for production control.
Information is carried In form of small paper card or software data.
Kanban are used as work orders providing operational instructions with line or cell.
This is control system for the to standardize the flow of parts.
JUST IN TIME PRESENTATION (JIT)
With emergence of automation and technology upgradation the production output of the organizations has substantially increased.
High production numbers bring in greater responsibility to manage inventory.
When quantity increases, companies will need more resources to manage it effectively.
Here comes concept of JIT
Just in Time is a concept of utilizing optimum resources while keeping stocks holding as low as possible by receiving inventory on very short cycle time.
It follows principle of production in demand.
Keep resources only to keep production running for few hours only.
PPT ON CLEANING JISHU HOZEN
Cleaning is the process of removing unwanted substances such as dirt, infectious agents, and other impurities from an equipment, object or environment.
The cleaning requires thorough observation and inspection of all the equipment parts, hence it plays a very critical role in all autonomous activities.
Cleaning is the initial step of Jishu Hozen and it can be understood as follows:
Cleaning is inspection.
Inspection is finding problems.
Problems demand restoration to original proper conditions
Improvement to prevent recurrence.
PPT ON BALANCE SCORECARD (BSC)
Globalization is making business operation more complex with greater pressure on time and costs.
Making Business profitable today and tomorrow is a big challenge.
Consistent data management with holistic approach right from whole process from initial planning to last level execution in business operation is most important aspect to survive successfully.
Balance Scorecard is a strategic performance management framework that has been designed to help an organization monitor its performance and manage the execution of its strategy.
Balance Scorecard examines “how to monitor work progress towards goal attainment” so all can react to deviation from the plan.
TRAINING AND DEVELOPMENT PPT
In order to maintain a competitive edge in the marketplace, an organization invests in the training and development of the employees.
In the past (the 1970s & 1980s), training was associated with a classroom, trainer or instructor. After training everyone in the room got the same things. The world has changed and training & development process also.
Training and Development is the framework for the development of employees to upgrade their personal and organizational skills, knowledge and ability.
Training & Development is a process to improve current or future performance of employee’s by increasing their ability to perform through learning, by changing the attitude or increasing their skills and knowledge.
QUALITY MAINTENANCE PPT
There is an important correlation between quality and maintenance. Maintenance management has become the essential part of quality system. It is an investment rather than the cost. Improving the quality of maintenance will lead to improved efficiency and effectiveness. Maintaining perfect equipment means maintaining the perfect quality of products.
It is the sixth pillar of TPM and aims to assure zero defect conditions. It is done by understanding and controlling the process intersections between manpower, material, machines and methods.
It is executed by inspecting and monitoring conditions to eliminate variation. The key is to prevent defects from being produced in the first place, rather than installing rigorous inspection systems to detect the defect after it has been produced.
It is aimed towards higher customer satisfaction or customer delight through highest quality achieved from defect free manufacturing.
OFFICE TPM PPT
Office TPM is the seventh pillar and concentrates on all areas that provide administrative and support functions in the organization. The pillar applies the key TPM principles in eliminating waste and losses from these departments.
Office TPM helps in improving productivity and efficiency in the administrative functions of plant and eliminate losses. This includes analyzing processes and procedures towards increased office automation.
It’s aim is to understand the relationship between office and production activities and to achieve customer delight and zero functional losses through creation of efficient office function.
PPT ON VALUE STREAMING MAPPING (VSM)
The origin of value stream mapping can be traced back to a technique of visual mapping, the Toyota Motor Corporation used to understand the material and information flow within the organization.
Value Stream Mapping is a Lean technique used to analyze the current material and information flow necessary to bring out the products or provide services for the customer.
It (VSM) is a method for illustrating and analyzing the logic of a production process.
Value stream mapping & analysis is a tool that allows to see waste, and plan to eliminate it.
PPT ON VISUAL FACTORY
A new operator might not be able to follow too many precaution or instructions easily on the shop floor. According to a survey, human mind can absorb 80% of data just by seeing it.
Visual communication reduces whole lot of complexity in understanding. Highly visual instructions with photographs and graphics will generally minimize production errors. A visually appealing display improves the communication level.
Visual factory is a set of tools that allow for accurate and efficient information conveyance. Visual factory is the appropriate display of charts, signs and other visual tools. They together help in reducing overall complexity of instructions.
These visual are an effective way of communication to larger target audience in the shop floor. It can be easily understood by any individual in the plant without reading manuals.
It is a part of lean manufacturing, TQM, TPM by Toyota production system initiatives.
It was Introduced by Gwendolyn Galsworth in her 1997 book Visual Systems
PPT ON TOTAL PRODUCTIVE MAINTENANCE (TPM)
TPM is a Japanese concept evolved in 1951. TPM is a robust method of effective machine repairing, maintenance and an organized systematic initiative to increase machine life.
TPM has been recognized widely and accepted by many organizations as a management philosophy for effective asset management.
To improve equipment effectiveness.
To improve efficiency, effectiveness and reliability of maintenance of machines.
To train the staff in relevant maintenance skills.
To achieve early equipment management.
PPT ON SINGLE MINUTE EXCHANGE OF DIES (SMED)
SMED (Single-Minute Exchange of Dies) is a system for reducing equipment changeover time in manufacturing. The essence of the SMED system is to convert as many changeover steps as possible to “external” (performed while the equipment is running), and to simplify and streamline the remaining steps.
SMED – It is a method of reducing time in total equipment changeover.
SMED is the term used to represent the Single Minute Exchange of Die or setup time that can be counted in a single digit of minutes. Its goal is to reduce the setup time from hours down to less than 10 minutes
It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product.
PPT ON SAFETY TPM
Safety is the state of being “safe” the condition of being protected from harm or other non-desirable outcomes. Safety can also refer to the control of recognized hazards in order to achieve an acceptable level of risk.
Safety is the cornerstone of TPM. It involves safety activities that address dangerous conditions and behavior that can cause accidents. This ensures safe workplace so, that is accident free workplace.
Creating such a workplace will require getting rid of three evils “difficulty, dirt, and danger”. These three combined makes unsafe conditions for a workplace.
Workplace organization & discipline, inspections & servicing, and standardization are all essential elements in creating a safe workplace.
PPT ON PREVENTIVE MAINTENANCE
In order to prevent a breakdown or a sudden failure of the equipment in the workplace, organization need to monitor the maintenance of equipment's and prevent problems before it occurs.
It refers to a regular examine and routine maintenance, which helps in keeping equipment up and running.
It is a planned maintenance of the plant and equipment's which is designed to improve equipment life and avoid any sudden failure.
It includes painting, lubrication, cleaning, adjusting and component replacement to prolong the useful life of the production equipment.
PPT ON LEAN MANUFACTURING
Lean Manufacturing is a philosophy of production that emphasizes the minimization of the amount of all resources used in various activities of the enterprise.
It is a systematic approach to identify and eliminate waste through continuous improvement in a manufacturing process. It includes eliminating different wastes, reduced inventory, empowering workers and improved productivity.
The term lean was coined by John Krafcik in 1988.
It can be traced back to ford, when he first setup his line production for t-model ford. Modern lean manufacturing came into existence by Toyota production system initiatives.
PPT ON DESIGN FAILURE MODE AND EFFECT ANALYSIS (DFMEA)
Design Failure Mode and Effect Analysis (DFMEA) is a systematic group of activities used to determine how to recognize and evaluate potential systems, products or process failures.
DFMEA identifies the effects and outcomes of failures, actions that could eliminate or mitigate the failures and provides a historical written record of the work performed.
It is a method used for identifying potential risks introduced in a new or changed design of a product or service.
It analyse the product design before it is released to manufacturing. It identifies design functions, failure modes and their effects on the customer with corresponding severity ranking / danger of the effect.
It also tracks improvements through Risk Priority Number (RPN) reductions by comparing the before and after RPN.
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AUTONOMOUS MAINTENANCE PRESENTATION
When companies begin to implement Total Productive Maintenance (TPM) they often start by piloting Autonomous Maintenance (AM). This is understandable as AM is one of the key distinguishing features of TPM and also one of the most important activities when understood correctly. To understand AM correctly it needs to be seen as an improvement activity within TPM, rather than production teams taking on maintenance activities.
In the evolution of TPM in Japan, AM grew out of the 5S activities of production teams, as they found that in order to deal with barriers to Quality, Delivery and particularly Cost performance they needed to improve equipment conditions, initially by applying the principles of 5S and QC circles. AM was not the result of a desire to reduce maintenance costs or maintenance departments wishing to hand tasks over to production, rather it was the result of production teams wishing to control and improve their equipment.
PPT ON THE ADVANCED MANAGEMENT AND PLANNING TOOLS
Post 2000, a robust project planning and execution has become key for the success of any organization. Project Success is directly proportional to the effective planning & execution methodology. The Advanced Management Planning Tools are applied to generate and evaluate ideas using different logical methods.
These tools are widely used in various decision-making situations across all industries and are popularly addressed as 7 MP Tools. These tools support in structured brainstorming process to simplify problems. They eliminate the fear of failure from the decision-makers mind. It helps in creating a comfort fit by deepening the ideas.
QUALTY FUNCTION DEPLOYMENT (QFD) PPT
Nowadays, one can witness the rapid changes in technology in industries. In present competitive scenario, customer satisfaction based products and services are key factors for any organization’s growth. To fulfill the customer & organization’s requirements, Quality Function Deployment (QFD) can be used.
It is the systematic approach to plan the solutions of any problem or requirements with the help of competitive analysis and mathematical priorities. It is very useful to make strategic plans to develop new or upgraded version of product as well as services.
POKE YOKE PRESENTATION PPT
As always While doing repetitive work, operators get bored and sometime ignored tasks.
If these ignored task contain maintenance task, it can lead to failure of machines.
They errors may occur due to various reasons like misunderstanding, language barriers, lack of experience, etc.
The idea is to take over repetitive tasks that rely on memory or vigilance and guard against any lapses in focus.
It is a quality assurance technique, where main objective is to reduce defects by correcting or preventing mistakes as soon as possible.
poka-yoke is a system designed to prevent inadvertent errors made by operators performing a process.
Poka-yoke can be seen as one of the three common components of Zero Defect Quality Control performed by Japanese companies
PERT - CPM PRESENTATION
PERT refers to project evaluation review technique while CPM refers to critical path method both these techniques are used in project management . PERT focuses on time estimated i.e. mean , estimated and probablistic tine while the CPM focuses on the longest path.
PPT ON KANBAN PRESENTATION
Production has a lot of process involved in it, from warehouses to final products.
If somehow these process get mixed up, production will hamper.
So, how to classify these process from each other, visual companions can be used .
It is a tool of lean manufacturing and JIT that carries information for production control.
Information is carried In form of small paper card or software data.
Kanban are used as work orders providing operational instructions with line or cell.
This is control system for the to standardize the flow of parts.
JUST IN TIME PRESENTATION (JIT)
With emergence of automation and technology upgradation the production output of the organizations has substantially increased.
High production numbers bring in greater responsibility to manage inventory.
When quantity increases, companies will need more resources to manage it effectively.
Here comes concept of JIT
Just in Time is a concept of utilizing optimum resources while keeping stocks holding as low as possible by receiving inventory on very short cycle time.
It follows principle of production in demand.
Keep resources only to keep production running for few hours only.
PPT ON CLEANING JISHU HOZEN
Cleaning is the process of removing unwanted substances such as dirt, infectious agents, and other impurities from an equipment, object or environment.
The cleaning requires thorough observation and inspection of all the equipment parts, hence it plays a very critical role in all autonomous activities.
Cleaning is the initial step of Jishu Hozen and it can be understood as follows:
Cleaning is inspection.
Inspection is finding problems.
Problems demand restoration to original proper conditions
Improvement to prevent recurrence.
PPT ON BALANCE SCORECARD (BSC)
Globalization is making business operation more complex with greater pressure on time and costs.
Making Business profitable today and tomorrow is a big challenge.
Consistent data management with holistic approach right from whole process from initial planning to last level execution in business operation is most important aspect to survive successfully.
Balance Scorecard is a strategic performance management framework that has been designed to help an organization monitor its performance and manage the execution of its strategy.
Balance Scorecard examines “how to monitor work progress towards goal attainment” so all can react to deviation from the plan.
TRAINING AND DEVELOPMENT PPT
In order to maintain a competitive edge in the marketplace, an organization invests in the training and development of the employees.
In the past (the 1970s & 1980s), training was associated with a classroom, trainer or instructor. After training everyone in the room got the same things. The world has changed and training & development process also.
Training and Development is the framework for the development of employees to upgrade their personal and organizational skills, knowledge and ability.
Training & Development is a process to improve current or future performance of employee’s by increasing their ability to perform through learning, by changing the attitude or increasing their skills and knowledge.
QUALITY MAINTENANCE PPT
There is an important correlation between quality and maintenance. Maintenance management has become the essential part of quality system. It is an investment rather than the cost. Improving the quality of maintenance will lead to improved efficiency and effectiveness. Maintaining perfect equipment means maintaining the perfect quality of products.
It is the sixth pillar of TPM and aims to assure zero defect conditions. It is done by understanding and controlling the process intersections between manpower, material, machines and methods.
It is executed by inspecting and monitoring conditions to eliminate variation. The key is to prevent defects from being produced in the first place, rather than installing rigorous inspection systems to detect the defect after it has been produced.
It is aimed towards higher customer satisfaction or customer delight through highest quality achieved from defect free manufacturing.
OFFICE TPM PPT
Office TPM is the seventh pillar and concentrates on all areas that provide administrative and support functions in the organization. The pillar applies the key TPM principles in eliminating waste and losses from these departments.
Office TPM helps in improving productivity and efficiency in the administrative functions of plant and eliminate losses. This includes analyzing processes and procedures towards increased office automation.
It’s aim is to understand the relationship between office and production activities and to achieve customer delight and zero functional losses through creation of efficient office function.
PPT ON VALUE STREAMING MAPPING (VSM)
The origin of value stream mapping can be traced back to a technique of visual mapping, the Toyota Motor Corporation used to understand the material and information flow within the organization.
Value Stream Mapping is a Lean technique used to analyze the current material and information flow necessary to bring out the products or provide services for the customer.
It (VSM) is a method for illustrating and analyzing the logic of a production process.
Value stream mapping & analysis is a tool that allows to see waste, and plan to eliminate it.
PPT ON VISUAL FACTORY
A new operator might not be able to follow too many precaution or instructions easily on the shop floor. According to a survey, human mind can absorb 80% of data just by seeing it.
Visual communication reduces whole lot of complexity in understanding. Highly visual instructions with photographs and graphics will generally minimize production errors. A visually appealing display improves the communication level.
Visual factory is a set of tools that allow for accurate and efficient information conveyance. Visual factory is the appropriate display of charts, signs and other visual tools. They together help in reducing overall complexity of instructions.
These visual are an effective way of communication to larger target audience in the shop floor. It can be easily understood by any individual in the plant without reading manuals.
It is a part of lean manufacturing, TQM, TPM by Toyota production system initiatives.
It was Introduced by Gwendolyn Galsworth in her 1997 book Visual Systems
PPT ON TOTAL PRODUCTIVE MAINTENANCE (TPM)
TPM is a Japanese concept evolved in 1951. TPM is a robust method of effective machine repairing, maintenance and an organized systematic initiative to increase machine life.
TPM has been recognized widely and accepted by many organizations as a management philosophy for effective asset management.
To improve equipment effectiveness.
To improve efficiency, effectiveness and reliability of maintenance of machines.
To train the staff in relevant maintenance skills.
To achieve early equipment management.
PPT ON SINGLE MINUTE EXCHANGE OF DIES (SMED)
SMED (Single-Minute Exchange of Dies) is a system for reducing equipment changeover time in manufacturing. The essence of the SMED system is to convert as many changeover steps as possible to “external” (performed while the equipment is running), and to simplify and streamline the remaining steps.
SMED – It is a method of reducing time in total equipment changeover.
SMED is the term used to represent the Single Minute Exchange of Die or setup time that can be counted in a single digit of minutes. Its goal is to reduce the setup time from hours down to less than 10 minutes
It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product.
PPT ON SAFETY TPM
Safety is the state of being “safe” the condition of being protected from harm or other non-desirable outcomes. Safety can also refer to the control of recognized hazards in order to achieve an acceptable level of risk.
Safety is the cornerstone of TPM. It involves safety activities that address dangerous conditions and behavior that can cause accidents. This ensures safe workplace so, that is accident free workplace.
Creating such a workplace will require getting rid of three evils “difficulty, dirt, and danger”. These three combined makes unsafe conditions for a workplace.
Workplace organization & discipline, inspections & servicing, and standardization are all essential elements in creating a safe workplace.
PPT ON PREVENTIVE MAINTENANCE
In order to prevent a breakdown or a sudden failure of the equipment in the workplace, organization need to monitor the maintenance of equipment's and prevent problems before it occurs.
It refers to a regular examine and routine maintenance, which helps in keeping equipment up and running.
It is a planned maintenance of the plant and equipment's which is designed to improve equipment life and avoid any sudden failure.
It includes painting, lubrication, cleaning, adjusting and component replacement to prolong the useful life of the production equipment.
PPT ON LEAN MANUFACTURING
Lean Manufacturing is a philosophy of production that emphasizes the minimization of the amount of all resources used in various activities of the enterprise.
It is a systematic approach to identify and eliminate waste through continuous improvement in a manufacturing process. It includes eliminating different wastes, reduced inventory, empowering workers and improved productivity.
The term lean was coined by John Krafcik in 1988.
It can be traced back to ford, when he first setup his line production for t-model ford. Modern lean manufacturing came into existence by Toyota production system initiatives.
PPT ON DESIGN FAILURE MODE AND EFFECT ANALYSIS (DFMEA)
Design Failure Mode and Effect Analysis (DFMEA) is a systematic group of activities used to determine how to recognize and evaluate potential systems, products or process failures.
DFMEA identifies the effects and outcomes of failures, actions that could eliminate or mitigate the failures and provides a historical written record of the work performed.
It is a method used for identifying potential risks introduced in a new or changed design of a product or service.
It analyse the product design before it is released to manufacturing. It identifies design functions, failure modes and their effects on the customer with corresponding severity ranking / danger of the effect.
It also tracks improvements through Risk Priority Number (RPN) reductions by comparing the before and after RPN.
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