Process Approach

PROCESS APPROACH

“There will be no output without input”

MODEL FOR PROCESS DEFINITION

1. Input/s to the process

a)Bill of materials

b)Specification for each material

c)Requirements for inspection for

the incoming materials

d)Procedure for receipt of materials

MODEL FOR PROCESS DEFINITION

2. Output/s of the processa)The products or service to be

deliveredb)Documents to be deliveredc)The specification for all the aboved)Method of measurements for

verifying conformance to the specifications

e)Criteria for acceptance / rejection

3. The process or task

ETX MODEL

• Training for Process

Orientation

• Measure Process

• Improve Process

Continuously

SUBBURAJ’S 6S MODEL FOR PROCESS IMPROVEMENT

• Study• Streamline• Simplify• Standardize• Synergize• Strengthen

Educating and convincingPeriodic counseling and assuringMonitoring

CUSTOMER SUPPLIER CHAINS

• Increased Inspection Adds Cost, not Value

• Identify Internal Customers and Suppliers

• Customer-supplier Chains• Educate• Customer Orientation Includes

Internal Customers


Advantage of Customer-supplier Chains

a) It improves communication w/in the organization.

b) It reduces communication gap.c) It helps in documenting the process flow.d) It helps in defining the specifications not

only for the overall input and output, but also for the entire process.

e) It helps in finalizing verification methodology throughout the process with clear accept/reject criteria.


f) It facilitates immediate feedback from colleagues rather than time lapsed feedback from customers thorough the channel of hierarchy.

g) The management can easily identify problem areas clearly, easily and deal with them specifically instead of going for global solution across the organization.

h) It helps in building quality throughout the organization.

i) It enables the management to have absolute control over quality with optimal expenditure.

j) Above all, it helps the management to understand it’s own organization and operations better, leading the effective planning, management and improvement.

SUPPLY CHAIN MANAGEMENT

Supply Chain – series of links and shared processes that exist between the suppliers and customers.

Supply Chain Management (SCM) – is a task of optimizing all activities throughout the supply chain.

•Demand Planning•Manufacturing Planning and

Scheduling•Supply Planning•Transportation Planning

JUST-IN-TIME (JIT) MANUFACTURING

“a philosophy that focused attention on eliminating waste by purchasing or

manufacturing just enough of the right items Just-In-Time”

• Production and supply of required number of parts when needed.

• JI DOKA (self-actualization)


Objectives of Just-In-Time• Development of optimal process and be

competitive• Streamlining of operations and eliminating

unwanted processes• Continuous improvement• Reducing the levels of wasted materials, time

and effort• Increasing efficiency of production process


Benefits of Just-In-Time• Reduction of wastes• Reduction of Work-In-Progress (WIP)• Establishing proper customer-supplier

relationship• Reduction of lead-time• Less-inventory of raw materials• Improvement in flexibility• Lower cost and high productivity• Enhanced customer satisfaction due to lower

price owing to elimination of wastes


• Improved employee morale owing to a perfect system without waiting

• Improved satisfaction of shareholders due to high profit

• Reduced space requirements on account of total elimination of WIP and buffer stock of materials, sub-assemblies and products

• Improved productivity and improved quality

LEAN MANUFACTURING

• Kanban SystemsoReducing costs by eliminating

waste/scrapoTry to create work sites that can respond

to changes quicklyoFacilitate the methods of achieving and

assuring quality controloDesign work sites according to human

dignity, mutual trust and support and allowing workers to reach their maximum potential.

i.Withdrawal Kanbanii.Production Kanban

LEAN MANUFACTURING

Advantages of Kanban Process• A simple and understandable process• Provides quick and precise information• Low costs associated with the transfer of

information• Provides quick response to changes• Avoids overproduction• Minimizes waste• Control can be maintained• Delegates responsibility to line workers

LEAN MANUFACTURING

• Cellular Manufacturingit is a group of workstations, machines

or equipment arrangement such that a product or sub-assembly can be processed progressively.

• Single Piece Flowit is a technique used to manufacture

components in a cellular environment.

ZERO DEFECTS

Is it Possible to Achieve Zero Defect?

Factors:Determination Required & Right Mindset

Required

Principles• Do not Accept Work from Others Which is not

up to the Standards• Do not Pass on the Work to Others Saying

that will be Good Enough• Do not Put Off Till Later• Do not Put the Blame on Others

ZERO DEFECTS

• Perfect System Required• Cultural Change Required• Never Ending Enthusiasm Required• Training Required• Management Commitment Required