DEVELOPING EXCELLENT QUALITY MINDSET

INTRODUCTION FOR DEVELOPING EXCELLENT QUALITY MINDSET

Optimizing Quality and Productivity performance is every organization’s vision and mission to maximize return on investment. It starts with the mindset.  Successful world-class organizations today have a culture that is capable of breakthrough change in their employee’s mindset to continuously improve on quality and productivity.  World Class organizations lay down stringent, yet achievable levels of operations, whereby it strives to achieve the highest possible productivity and total quality effectively, but at the lowest cost possible.

This change in mindset can only happen if companies become “Learning Organizations” and every employee strive as a team to achieve ‘World Class’ status.   Today the world is looking at the Japanese high standard of quality and productivity mindset as an example, especially the success of Toyota Production System (TPS) or LEAN Practices in improving quality, reducing costs through the elimination or reduction of wastes (MUDA), variability (MURA) and over-burden (MURI).  This training program is the first step in helping individuals to explore the possibilities on how your organization can make this a reality.  This program helps change the mindset and encourage the workers to continuously improve themselves, to take simple, systematic, low cost yet effective and successful steps to improve quality and productivity at their own workplace.

COURSE OBJECTIVE

At the end of the course, participants will be able to:

• Describe the principles & benefits of Quality and Productivity practiced by World Class organizations.
• Identify management approaches that satisfy customers through:
  • Quality concept of ISO
  • Elimination of Wastes, produce high quality products/services at the lowest cost.
  • Speed of delivery, and innovation.
• Identify what is KAIZEN Mindset and apply KAIZEN principles and practices at the GEMBA.
• Practice 5S Workplace Organization techniques.
• Implement World-Class Visual Management techniques.
• Identify practical ways to eliminate the 7+1 types of Wastes (TIMWOODS) at the workplace
• Practice using quality tools in identifying areas of improvement.

COURSE CONTENT

INTRODUCTION:

• Define Quality and Productivity.
• Benefits of Quality & Productivity enhancements?
• Achieving World Class status.  What do we need to do as a team?
• Workers’ mindset and responsibilities towards productivity & quality improvements.

ROLE OF QUALITY LEADERS

• Examples from World Class Organization: LEAN, Toyota Production System (TPS) – – well known for its productivity & quality.  How and why?
• Strategic leadership’s impact on quality direction
• Elimination of Wastes (MUDA), Variability in process (MURA) & Over-burden workload (MURI)
• How reduction of MUDA, MURA, MURI can improve productivity & quality.

KAIZEN MINDSET & GEMBA KAIZEN PRACTICES

• KAIZEN Mindset and principles.
• GEMBA KAIZEN practices:
  • Continuous Improvements at the workplace.
  • Low-cost, commonsense, fast results and proven quality improvement methods
• The power of Total Employees Involvement (TEI) and Teamwork toward World-Class quality levels.

5S WORKPLACE ORGANIZATION

• 5S Workplace Organization – – foundation to eliminate wastes.
• 3S : Sort, Set-In-Oder, Shine
• Standardization and Sustaining 5S practices.
• Practical Gemba Kaizen activities: Visual Management practices in the workplace

ELIMINATION OF WASTES (MUDA)

• Identifying and eliminating the 7+1 Types of wastes in the workplace
• Types of Wastes (TIMWOODS):
  • Transportation, Inventory, Motion
  • Waiting, Over-produced, Over-processed, Defects
• Practical Gemba Kaizen: Simple KANBAN system to control inventory.

STANDARDIZATION & USE OF ISO QUALITY SYSTEM

• What is work Standardization?
• Improvements (PDCA) Vs Standardization (SDCA) Cycle.
• ISO system & practical uses of 7 QC Tools to monitor process, track and eliminate wastages.
• Total Employees Involvement (TEI) to reduce employees’ work over-burden