Lps06 lquality

8/13/2018 LEAN QUALITY GVC ThS Nguyễn Như Phong nguyenphong.bksg@gmail.com; www.isem.edu.vn Kỹ thuật Hệ thống Công nghiệp ĐH BÁCH KHOA – ĐHQG TPHCM (Tài liệu giảng dạy cho ISE) 2018 LEAN QUALITY         Lean quality Lean quality framework Complexity Mistakes Mistake Proofing Variation Six Sigma Lean Six Sigma 11 April 2003 Nguyễn Như Phong 8/13/2018 LEAN QUALITY  Perfection   The last of the L principles Goal covers   Quality Delivery, flexibility, safety Nguyễn Như Phong 11 April 2003 Lean quality  Toyota-L-temple pillars   JIT Jidoka –   11 April 2003 closely related Q especially pokayoke a mayor way of  exposing waste &  improving Q throung surfacing surfacing problems Nguyễn Như Phong 8/13/2018 Lean quality  The pillars mutually supportive  Improve Q  improve JIT performance  Improve JIT  improve Q     less disruption & smooth flow Reduce batch size  faster detection & less rework Pull sys – a Q tool Layout influence Q  improved communication 11 April 2003 Nguyễn Như Phong Lean quality  Quality   One of interrelated concepts  Standard work, TPM, 5S, visibility Foundation stone L stability 11 April 2003 Nguyễn Như Phong 8/13/2018 Lean quality framework  Hinckley –  Perfection in Q approached in ways  Reduction in complexity    in prod & proc design Reduction of variation Prevention & reduction of mistakes  Form part of Jidoka 11 April 2003 Nguyễn Như Phong Lean quality framework  possible sources of problems each approaches      Man, Machine, Material, Methods, MInformation 11 April 2003 Nguyễn Như Phong 8/13/2018 Lean quality framework  Hinckley –  most effective order tackle Q problems     Fist address the prod., then proc., finally related tools & equipment within each category  First simplify, Then mistake proof,  Finally control variation   then convert adjustments settings Nguyễn Như Phong 11 April 2003 COMPLEXITY  Complexity   both prod & proc Prod complexity    No components Difficulty of assembly Proc complexity   11 April 2003 No operations Difficulty of each operation Nguyễn Như Phong 8/13/2018 Complexity  Hinckley – Boothroyd, Dewhurst  Prod defect rate  strongly related assembly complexity 11 April 2003 Nguyễn Như Phong Prod Complexity  Methods  QCC – Quality Control of Complexity  DFSS – Design Six Sigma  GT – Group Technology  DFx – Design x 11 April 2003 Nguyễn Như Phong 8/13/2018 Prod Complexity  QCC  Methods developed by Hinckley  The frequency of mistakes increases   with increasing assembly complexity QCC method    Constructing a tree diagram assembling a prod Time required complete the assembly estimated Alternative designs evaluated based on time Nguyễn Như Phong 11 April 2003 Prod Complexity  DFSS –   Design Six Sigma Defined set of steps – IDDOV       Identify – Define Develop Optimize Verify Similar project organization 11 April 2003 Nguyễn Như Phong 8/13/2018 Prod Complexity   Identify – Define  Clarify C & CNs  Tools: Kano model, QFD Develop  Brainstorming & identification of alternatives & evaluation  Techniques:    TRIZ, Pugh Analysis, FMEA 11 April 2003 Nguyễn Như Phong Prod Complexity   Optimize  Taguchi method design & tolerance optimization  DOE parameter design Verify  How the prod perform in the field  Looking at the manu proc capability  Conducting experiment on prototype & pilot tests  Tools: PCA, SPC, Pokayoke 11 April 2003 Nguyeãn Nhö Phong 8/13/2018 Prod Complexity  GT  Set of procedure   aimed at simplifying prod.s wo compromising cust choice Identify similarities in function  to reduce prod & proc proliferation  First search a database prod.s w similar functions Make selection from a predefined set  The dramatic impact  Various GT coding & classification sys     rather than unlimited choice on part proliferation, inv, routing, quality to assist both prod&proc designers 11 April 2003 Nguyễn Như Phong Prod Complexity  DFx     DFA - Design Assembly DFM - Design Manufacture Key set of techniques lean processing simplicity Impact time, cost, inv, quality 11 April 2003 Nguyeãn Nhö Phong 8/13/2018 Proc Complexity   May independent from prod complexity Tools reduce proc complexity        Part presentation SOP 5S Simplified material flows & layout TPM SMED Visual control Nguyễn Như Phong 11 April 2003 MISTAKES  The control-of-mistake toolbox     5S SOP Pokayoke Self inspection    Operator performs an inspection immediately after the manu step made Successive inspection  11 April 2003 The next operator checks the previous step/steps Nguyễn Như Phong 10 8/13/2018 Mistake Proofing  MPD types  Contact  Fixed value    Make contact / physical shape - inhibit mistakes Make it clear when parts missing / not used Motion step  Automatically ensure correct no steps taken Nguyễn Như Phong 11 April 2003 Mistake Proofing  Failsafe classification  areas   Process control model   Man, machine, material, method, info input, process, output, feedback, result All candidates MP 11 April 2003 Nguyễn Như Phong 14 8/13/2018 Mistake Proofing  Grout  Areas for pokayoke considered       Worker vigilance required Likely mis-positioning Difficult SPC Ext failure costs dramatically exceed IFCs Mixed model & JIT production Potential valuable process variance info lost  inhibiting improvement 11 April 2003 Nguyễn Như Phong Mistake Proofing  Hinckley - mistake categories Defective material, Information, Mis-adjustment, Omission, Selection errors  Mistake proofing solutions & the most suitable 11 April 2003 Nguyễn Như Phong 15 8/13/2018 Mistake Proofing  Hinckley - most useful MPDs: Guide pins, Limit switch, MP jigs, Counter, Checklist 11 April 2003 Nguyễn Như Phong VARIATION  Principle approach variation reduction –  Foundation tools variation limitation:       SS TPM, 5S, standard work, CO reduction Tools variation control:   SPC, precontrol 11 April 2003 Nguyễn Như Phong 16 8/13/2018 Variation   Low hanging fruit  Before starting out on sophisticated SS program  made reasonable progress w 5S, visibility, SW, TPM SPC  Good technique variation monitoring & control  Monitoring proc not prod  Good & capable proc  good prod  Not reliable monitoring / controlling  at levels of 5/6 sigma, 1% Nguyễn Như Phong 11 April 2003 SIX SIGMA  SS    Derive from the spread of the normal distribution SS performance – close perfection Structured problem solving methodology   11 April 2003 Reducing the no defects Reducing prod & proc variation Nguyễn Như Phong 17 8/13/2018 Six Sigma  Starting point    Specific methodology: DMAIC    Belief in cross-function process SIPOC model: Supplier-Input-Process-Output-Customer Define – Measure – Analysis – Improve – Control Similar to the Deming/Shewhart PDCA cycle SS progresses on a PBP basis & process oriented   Fairly narrow proj Cust requirement at an early stage Nguyễn Như Phong 11 April 2003 Six Sigma  SS features  Bias toward data     Measuring proc variation trying narrow & shift the variation within the CR Strong financial bias Strongly based on statistics 11 April 2003 Nguyễn Như Phong 18 8/13/2018 Six Sigma  GE SS key principles        Critical Q Defect Process capability Variation Stable operation DFSS Driven by qualified people     Green belts Black belts Master black belts Champions 11 April 2003 Nguyễn Như Phong My SS Case Studies in www.isem.edu.vn Ứng dụng Six Sigma cải tiến chất lượng trình sản xuất cơng ty Scancom VN 2009 Nguyễn Thanh Xn, Đồn Đức Nghĩa K2005, K2004 Ứng dụng Six Sigma cải tiến chất lượng q trình sản xuất cơng ty SeaBest 2010 Nguyễn Tài Xuân, Trần Bảo Khánh Ứng dụng Six Sigma cải tiến chất lượng q trình sản xuất cơng ty may NBC 2014 Đỗ Thành Trung K2009 Ứng dụng Six Sigma cải tiến chất lượng q trình sản xuất cơng ty Philips VN 2014 Huỳnh Thanh Phong, Lưu Minh Tuấn K2009 Ứng dụng Six Sigma cải tiến chất lượng trình sản xuất công ty 3D Long Hậu 2015 Trần Thanh Phong K2010 Ứng dụng Six Sigma cải tiến quy trình bằm gỗ tràm công ty CP Thúy Sơn 2016 Nguyễn Văn Phú K2010 Ứng dụng Six Sigma cải tiến quy trình sản xuất cty Scancia Pacific 2016 Dương Minh Tồn K2012 Ứng dụng Six Sigma cải tiến quy trình sản xuất cty Điện Quang 2016 Nguyễn Xuân Cư K2012 Friday, April 11, 2003 Nguyễn Như Phong 19 8/13/2018 My SS Case Studies in www.isem.edu.vn 10 11 12 13 14 Ứng dụng Six Sigma cải tiến quy trình sản xuất cty May Nhà Bè 2016 Hồng Minh Cơng K2012 Ứng dụng Six Sigma cải tiến quy trình sản xuất cty CAN Sport 2017 Phạm Quang Anh Tuấn K2012 Ứng dụng Six Sigma cải tiến quy trình sản xuất cty Hồng Nam 2017 Ngụy Viết Tiến K2012 Ứng dụng Six Sigma cải tiến quy trình sản xuất cty Trương Nguyễn 2017 Nguyễn Hồng Sơn K2012 Ứng dụng Six Sigma cải tiến quy trình sản xuất cty gỗ Minh Dương 2017 Lưu Văn Nghĩa K2011 Ứng dụng Six Sigma cải tiến chất lượng quy trình sản xuất cty Lai Cung Én Phúc Sang 2018 Trần Minh Trí K2011 Friday, April 11, 2003 Nguyễn Như Phong LEAN & SIX SIGMA   Lean & Six Sigma: compete / emerge ? Lean    Often tend ignore variation Less strong at detailed problem solving Six Sigma   Not much about complexity / mistakes Downplay the role of foundation lean techniques 11 April 2003 Nguyễn Như Phong 20 8/13/2018 Lean & Six Sigma  Strong Deming connection  main themes  Removal of waste  Lean  Reduction of variation  SS 11 April 2003 Nguyễn Như Phong Lean & Six Sigma  to powerful & widely used approaches clashed & merged       Lean Sigma Fit Sigma SS plus Power Lean LSS Quick Sigma 11 April 2003 Nguyễn Như Phong 21 8/13/2018 Integrating Lean & Six Sigma   Fashionable integration Dean & Smith, 2000: “LeanSigma ustilizes SS & lean principles reduce both defects & lead time w the speed of kaizen” Nguyễn Như Phong 11 April 2003 Integrating Lean & Six Sigma  Lean Sigma projects  added     lean principles, VS mapping, kaizen methodology produce result  11 April 2003 2-3 times faster than normal SS projects Nguyễn Như Phong 22 8/13/2018 Integrating Lean & Six Sigma  Mike Wader (2000) – Lean Sigma programs  Lean used remove waste & NVA activities SS used to control the variation  Combining tools & data sets  Avoid the battle funding bw L& SS programs    within the value adding portion of the process to produce a comprehensive improvement program Nguyễn Như Phong 11 April 2003 Integrating Lean & Six Sigma  Drickhamer (2002)  How the adoption of Lean techniques   prior to the application of SS projects can provide real benefit   11 April 2003 removing the elitist strain from SS tackling the low hanging fruit w Lean Nguyễn Như Phong 23 8/13/2018 Integrating Lean & Six Sigma Area Lean Six Sigma Objectives Reduce waste, Improve value Reduce variation, Shift variation inside CR Framework principles DMAIC Focus Value Stream Project / process Improvement Many small improvement Everywhere simultaneously A small no large proj One at a time Typical goals Cost, Quality, Delivery, Lead time Sigma level Money saving 11 April 2003 Nguyeãn Nhö Phong Integrating Lean & Six Sigma Area Lean Six Sigma People involved Team led by Lean expert BB supported by GB Time horizon Long term, Continuous Short term PBP Tools Often simple Complex integrate Complex statistical Typical early steps Map the VS Collect data on proc Variation Impact Large, system-wide Individual proj Large saving Prob Root causes Via Why Via DOE 11 April 2003 Nguyễn Như Phong 24 8/13/2018 Conclusions from LSS cases    Build on a firm foundation  5S  SW Take waste out first  especially low hanging waste SS add a powerful dimension in traditional Lean areas  especially more complex issues 11 April 2003 Nguyễn Như Phong Conclusions from LSS cases  The rigor of SS training   likely benefit many Lean improvement intitiatives simply giving team members   added skill in data interpretation & analysis Lean has much say SS during SS projects   VS analysis & deployment Waste identification, SMED, pull, cell design, … 11 April 2003 Nguyễn Như Phong 25 8/13/2018 Conclusions from LSS cases   Begin & end many SS projects w Lean VSM & policy deployment –   powerful way direct improvement initiatives Organizational politics  more important than the approach used 11 April 2003 Nguyễn Như Phong LSS Papers in www.isem.edu.vn An Application of Customized LSS to Enhance Productivity at a Paper MC 08 Application of Lean Six Sigma in Healthcare – A Graduate Level Directed Project Experience 13 Application of Lean Six-Sigma Methodology to Reduce the Failure Rate of Valves at Oil Field 01 Applying Lean Six Sigma for Waste Reduction in a Manufacturing Environment 11 CS on the Lean Six Sigma Management for IT Service Management Project of G Commercial Bank 14 Integration Of Six Sigma And Lean Production 02 Integration Of Six Sigma And Lean Production System For Service Industry 03 Friday, April 11, 2003 Nguyễn Như Phong 26 8/13/2018 LSS Papers in www.isem.edu.vn 10 11 12 13 14 Implementation of SSP for LM To reduce the rework waste in Transformer manufacturing unit 12 Implementing Lean Six Sigma: A Case Study In Concrete Panel Production 07 Implementing the LSS Framework in a SME – A Case Study in a Printing Company 06 Improving service quality by capitalising on an integrated LSS methodology 04 LSS Application for Sustainable Production: ACS for Margarine Production in Zimbabwe 10 Successfully Integrating Lean and Six Sigma Improvement Initiatives 05 Use of LSS to improve operating room efficiency 09 Friday, April 11, 2003 Nguyễn Như Phong My LSS Case Studies in www.isem.edu.vn Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cơng ty KSVN 2012 Nguyễn Xn Thạnh, Phạm Hướng Linh K2007 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cơng ty TC 2012 Nguyễn Đăng Quang, Nguyễn T Mỹ Phụng K2007 Ứng dụng Lean Six Sigma cải tiến quy trình FA cơng ty FOV- 2014 Nguyễn Lê Xuân Nữ K2009 Ứng dụng Lean Six Sigma cải tiến q trình JP cơng ty FOV- 2014 Lê Thị Yến Nhi K2009 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cơng ty Sika 2014 Mai Nguyễn Hoài Châu K2009 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cơng ty Sáng Tạo 2014 Bùi Thị Linh Phương, Nguyễn Thị Huyền Anh K2009 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất công ty Green Feed VN 2015 Huỳnh Thanh Tùng K2010 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cơng ty Gạch Thanh Bình 2015 Hồng Văn Đạt K2010 Friday, April 11, 2003 Nguyễn Như Phong 27 8/13/2018 My LSS Case Studies in www.isem.edu.vn 10 11 12 13 14 15 16 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cơng ty Thép Sóng Thần 2015 Lê Quốc Bảo, Nguyễn Huỳnh Thái Thuận K2010 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất công ty may NBC 2015 Nguyễn Đại Minh, Hoàng Thiện Mỹ K2011 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cơng ty khí KMT 2015 Nguyễn Hồng Sơn, Đặng Chí Thạnh K2011 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất xylanh tròn cty Trương Nguyễn 2017 Phạm Văn Lư K2013 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất xylanh vuông cty Trương Nguyễn 2017 Trần Thanh Nhất Tùng K2013 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cty cổ phần may mặc Bình Dương 2017 Nguyễn Thành Phát K2013 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cty May Nhà bè 2017 Nguyễn Văn Tài K2013 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cty Schneider-Electric VN 2018 Nguyễn Thi Lâm Nghĩa K2014 Ứng dụng Lean Six Sigma cải tiến quy trình sản xuất cty May Nhà Bè 2018 Thiều Nam Phong, Nguyễn Đăng Quang K2014 Friday, April 11, 2003 Nguyễn Như Phong 28