Best Practices + Problem Solving

2.  A best practice is a technique or methodology that, through
experience and research, has proven to reliably lead to a
desired result.
 A commitment to using the best practices in any field is a
commitment to using all the knowledge and technology at one's
disposal to ensure success.
 While best practices generally dictate the recommended course
of action, some situations require that such practices be
followed.
 The term is used frequently in the fields of health care,
government administration, the education system, project
management, hardware and software product development, and
elsewhere.

3. Problem solving is:
 a systematic process which
 defines a problematic situation (where there is a gap between
actual and expected or the situation is vague, or there is
something that is unsatisfactory) and identifies the problem as an
opportunity
 for which a resolution or solution is needed to be
implemented by an individual or group
 and which finally, and crucially should be worth while solving.

4.  Reduced Setup Times: All setup practices are wasteful because
they add no value and they tie up labour and equipment. By
organizing procedures, using carts, and training workers to do their
own setups, Toyota managed to slash setup times from months to
hours and sometimes even minutes.
 Small-Lot Production: Producing things in large batches results
in huge setup costs, high capital cost of high-speed dedicated
machinery, larger inventories, extended lead times, and larger
defect costs. Because Toyota has found the way to make setups
short and inexpensive, it became possible for them to economically
produce a variety of things in small quantities.

5.  Employee Involvement and Empowerment: Toyota organized
their workers by forming teams and gave them the
responsibility and training to do many specialized tasks. Teams
are also given responsibility for housekeeping and minor
equipment repair. Each team has a leader who also works as
one of them on the line.
 Quality at the Source: To eliminate product defects, they must
be discovered and corrected as soon as possible. Since workers
are at the best position to discover a defect and to immediately
fix it, they are assigned this responsibility. If a defect cannot be
readily fixed, any worker can halt the entire line by pulling a
cord (called Jidoka).

6.  Pull Production: To reduce inventory holding costs and lead
times, Toyota developed the pull production method wherein the
quantity of work performed at each stage of the process is dictated
solely by demand for materials from the immediate next stage.
The Kanban scheme coordinates the flow of small containers of
materials between stages. This is where the term Just-in-Time (JIT)
originated.

7. The suggestions which are being recommended in the
following points are based on our observation after the
visit to the company. Some of the techniques or practices
that we learned from the Toyota and that could be
implemented at Amul for achieving better results are as
follow:
 One of the major issue was that of high inventory at the
plant itself. This resulted in high inventory cost and
extended lead times. To over come this they need to
produce in smaller lots which will help lowering inventory
costs and more value to the customer chain.

8.  Secondly in order to have a reduced lead time and lower
inventory cost they need to follow the concept of JIT,
wherein which they only need to produce only when there
is a requirement at the next stage.
 Next they need to in order to produce high quality goods
they need to motivate and make the workers responsible
for the quality and cleanliness. The is of quality as source
and employee involvement. Cleanliness is very crucial
factors as they into the manufacturing of dairy products.
 Building healthy relations is of great importance. In their
case the supplier for the most important raw material i.e.
the milk are the farmers. Good relations will ensure
effective implementation of JIT.

9.  Best practices had helped Toyota to become world leader
in the automobile industry and set benchmark for the other
industry competitors.
 How benchmarking is helping companies to deliver more
value to the customers.
 Learning and implementing best practices can also take
place from other industry domain as in our case.
 Implementation of best practices helps in better
productivity.