DSA-Delivery Sch Achiv
ITR-Inventory Turn Ratio
OEE-Overall Equip Effect
FSU-Floor Space Utilization
VAP-Value Added Per Person
MBF-Machine Breakdown FREQ
• OQC/NCR/CC-Not Right First Time
• 6-Sigma–Defects Management
• Five S–Visual Management
• VSM–Value Stream Mapping
• Kaizen/Kaizen Blitz
• Flow–Spaghetti Diagram
• Cell Manufacturing
• Kanban–Inventory Control
• TPM–Total Productive Maint
• QCO–Quick Change Over
• Poka Yoke – Mistake Proofing
• Hijeunka – Level Scheduling
• FMEA–Failure Mode Effect Anayl
• ECS–Energy Cost Savings
Top X Charts
Suppliers TO QC
Stores TO QC
Floor TO QC
Subcon TO QC
Customers TO QC
QC TO Floor/Supplier
Increase QC Productivity
Only QC Ok products sell
Reduce Rejection related costs
Enhances inventory management,
Minimising waste, rework, rejects
Make vs Buy Strategy optimization
Reduction in scrap costs
Reduction in rework costs
Reduction in obsolence costs
Increase Machine Utilization
Increase Plant Utilization
Reduce QC Delays/costs
QC Points/Reject Codes
1. Quality Planning
2. Customer Complains
3. Quality Loss Calc
4. OEE Monitoring
5. Root Cause Analysis
1. QC Recording
2. Quality Check Scheduling
3. Breakdown Detection
4. Industry 4.0 IOT
5. Quality Planning
1. QC Failures
2. Energy Costs
3. Manpower Costs
4. Accidents Costs
5. Product Quality
1. Production Rejects
2. Startup Rejects
3. Delays in QC Checks
4. Unplanned/small Stops
What is QMS-Quality Management System?
A quality management system (QMS) is defined as a formalized system that documents processes, procedures, and responsibilities for achieving quality policies and objectives. The purpose of a quality management system is to meet customer needs, satisfy regulatory requirements and create efficient processes.
What is QC-Quality Control?Quality control (QC) is a procedure or set of procedures intended to ensure that a manufactured product or performed service adheres to a defined set of quality criteria or meets the requirements of the client or customer. QC is similar to, but not identical with, quality assurance (QA).
What is QA-Quality Assurance?
Quality assurance (QA) is a way of preventing mistakes and defects in manufactured products and avoiding problems when delivering products or services to customers; which ISO 9000 defines as "part of quality management focused on providing confidence that quality requirements will be fulfilled".
What are difference between QC and QA?The difference between quality assurance and quality control is that Quality Control is product oriented, while Quality Assurance is process oriented. ... While QC ensures the results of what you have done are as per your expectations. Both QC and QA are interdependent to each other.
How do you perform QA-Quality Assurance?
Following inputs to the perform quality assurance process:
Project management plan. ...
Quality metrics. ...
Quality control measurements. ...
Work performance information. ...
Change requests. ...
Project management plan updates. ...
Project document updates. ...
Organisational process assets updates.
What is Lean Quality Management System?
•Identify, Reduce & where possible eliminate waste continually across value chain.
Building a Lean ISO Quality Management System (QMS) is about focus – less is more! ... A Lean ISO Quality Management Systems is focused on constantly eliminating waste to drive down costs, increase quality and hit OTD 100% of the time.
The seven principles of Lean development are: Eliminate Waste, Build Quality In, Create Knowledge, Defer Commitment, Deliver Fast, Respect People, and Optimize the Whole.
What are different types of Waste which Lean QMS Removes?
Waiting, Overproduction, Reject / Rework, Motion of employees, Processing Unnecessary Inventories, Transportation, Underutilized human potential - skills, talents, and ideas, Transportation, Over Production, Over Processing, Defects etc.
How to implement Lean Quality Management System?
Devide All Activity Into Two Categories :
1. Value Added Activity
2. Non Value Added Activity
3 Value added activities include:
1. Customer is willing to pay
2. Change, transformation, conversion is taking place
3. First time right as per customer requirement
Anything other than above 3 is considered WASTE or Non Value Added Activity.
What is "5s" Quality Management Lean System?
The 5S system of visual management has improved organization and efficiency in many workplaces including manufacturing environments and offices. This system consists of five pillars—Sort, Set in Order, Shine, Standardize, Sustain—that make maintaining the workplace in good condition a visual process.
5s, or any lean system, helps to eliminate waste, streamline production, and optimize efficiencies. When you adopt 5s thinking, you make a commitment to put safety, organization and effectiveness ahead of production deadlines, profits and output.
How to implement 5s QMS Lean using ERP Software?
1. Setup Visual Planning Board Montior in Plant/Office:
The MobileERP App visualizes essential work tasks on a shared touch-screen monitor or a tablet on the shop floor so that everyone has the same up-to-date information. When you have completed a duty, mark it done by clicking the button. Did you find anything that could work better or need to be fixed? Move the slider to propose an improvement.
2. Implement Continuous Improvements via collaborative MobileERP Software:
How do you know if a change is an improvement?
In Lean Thinking, we try to use the scientific method to evaluate each experiment and ensure learning.
Therefore, we have built the PDCA method right into the workflow of the MobileERP App.
A priority matrix helps the teams decide what improvements to work on and follow their progress.
3. Implement Checklists, audits, and data visualizations using MobileERP Software:
Create checklists for critical tasks to ensure that all steps are performed according to the standards.
Define max-min values or control lines for your data and display readings and historical data on the dashboard.
Check and record safety, 5S scoring, or preventive maintenance right into the application.
4. Track daily goals using MobileERP Software
Daily goals are used to bring problems up to the surface and provide input to deviations and improvements, an essential part of the Lean Management System.
To help you use daily goals for improvements, we have implemented an easy-to-follow workflow;
Performance-> Deviation -> Short-term Corrective Action -> Long-term Improvements
5. Improve Safety Management using MobileERP Software
The Green Cross (or Safety Cross) is used as a calendar to see and discuss safety problems.
In the MobileERP App, you will not only be able to track incidents but also find the root cause and document a countermeasure.
6. Implement Preventive Maintenance using MobileERP Software
The key to high availability and low-maintenance costs is the early detection of faults.
In the MobileERP App, you can create tasks and checklists for preventive maintenance, inspections, and cleaning.
Did you find something broken? Generate a work request and use a smartphone to include an image.
Choose a responsible team, from the email that will be sent to you, and track the work request as it gets approved, planned, and completed.
Plan and schedule the work order using drag-and-drop
7. Adding "Gamification" elements
Our mission is to make repetitive tasks a little more interesting. Using the new knowledge from the “gamification” field, we will try to include elements that make work more engaging.
To increase our core drive for social interaction, we have implemented possibilities to comment, “like”, and give a shout-out to others.
A progress bar will show how much your team has done, and you can compare your performance with other teams.
Suggestions for improvement are recorded in the app, and digital rewards can be given for a group or team member.
What is Kaizen QMS System?
KAIZEN = CONTINUAL IMPROVMENT
Easy to solve VS Difficult to Solve SYSTEM
Easy to Identify VS Difficult to Identify SYSTEM.
What is 6-Sigma QMS System?
Six Sigma is a measurement of defects and variation.For a business or a manufacturing process, the sigma value is a metric used to indicate how well the process is performing.
At present most companies, when their processes are under control, are able to achieve 3 sigma capability which represents 99.7% performance i.e 3 defects per 1000. With rapid technological advances and development of complex products, this level of quality is no longer acceptable.
Executives at the business level can use Six Sigma for improving market share, increasing profitability and organizations long term viability.
Managers at operations level can use Six Sigma to improve yield and reduce the labor and material cost.
At the process level engineers can use Six Sigma to reduce defects and variation and improve process capability leading to better customer satisfaction.
How to implement 6-Sigma QMS System?
Following Tools help you Define, Measure, Analyze Improve, Control (DMAIC) proceess through which 6-sigma or any project can be implemented.
1. Define: Where is the Problem?
2. Measure: What is the Problem?
Download MobileERP designed 6-sigma parameter measurement tool report
3. Analyze: What is Causing the Problem?
4. Improve: Making the Problem GO Away
5. Control: Making the Problem STAY Away!
What is Kanban QMS System?
Kanban is Japanese for “visual signal” or “card.” Toyota line-workers used a kanban (i.e., an actual card) to signal steps in their manufacturing process. The system’s highly visual nature allowed teams to communicate more easily on what work needed to be done and when. It also standardized cues and refined processes, which helped to reduce waste and maximize value.
Kanban helps you harness the power of visual information by using sticky notes on a whiteboard to create a “picture” of your work. Seeing how your work flows within your team’s process lets you not only communicate status but also give and receive context for the work. Kanban takes information that typically would be communicated via words and turns it into brain candy.
How to implement Kanban QMS ERP System?
Entire MobileERP and all its processes are implemented as per Kanban based system. MobileERP is the only ERP System in world which follows 100% Kanban Methodology.
There are 4 STEPS:
1. Visualize Work
By creating a visual model of your work and workflow, you can observe the flow of work moving through your Kanban system. Making the work visible—along with blockers, bottlenecks and queues—instantly leads to increased communication and collaboration.
2. Limit Work in Process
By limiting how much unfinished work is in process, you can reduce the time it takes an item to travel through the Kanban system. You can also avoid problems caused by task switching and reduce the need to constantly reprioritize items.
3. Focus on Flow
By using work-in-process (WIP) limits and developing team-driven policies, you can optimize your Kanban system to improve the smooth flow of work, collect metrics to analyze flow, and even get leading indicators of future problems by analyzing the flow of work.
4. Continuous Improvement
Once your Kanban system is in place, it becomes the cornerstone for a culture of continuous improvement. Teams measure their effectiveness by tracking flow, quality, throughput, lead times and more. Experiments and analysis can change the system to improve the team’s effectiveness.
What processes are implemented in MobileERP using Kaban?
Following processes are implemented in various ways via Kanban. You will see it in details here on this website when you click that flow.