TQM Models

WORLD CLASS

TOTAL EMPLOYEE INVOLVEMENT

(TEI)
LEADERSHIP, TEAMWORK, CONSENSUS,
EMPOWERMENT.

JUST IN TIME /
WASTE
ELIMINATION

PROBLEM
EXPOSURE

TOTAL QUALITY
CONTROL (TQC)

SYSTEMS, SPC,
PDCA, PROBLEM
SOLVING TOOLS

THROUGH CONTINUOUS
IMPROVEMENTS

TQM Models continued

PILLARS OF TQM
VISION
MISSION
CORE
COMPETENCY
STRATEGIES
GOALS /
OBJECTIVES

ORGANISATION
WORKING

7 QC / SPC
BM
6 Sigma
TOOLS &
TECHNIQUES

ISO 9000
ISO 14000
QS 9000
SYSTEM

5S
KAIZEN
JIT
TPM
WCMS

SGAS
QCS
CFTS
CONCURRENT WORKING
PEOPLE

TQM vs Problem

Manufacturing
Problems*
* Unreliable Supply,
Rework/ Reject,
Untrained Staff.

Inventory
Levels

JIT exposes the problems and

Controls Waste in material,
capacity and labour.

Inventory Level

Waste Removed..

To achieve quantum performance

improvements and be a world leader requires
non-traditional thinking

Leader
Response

JIT : A breakthrough approach for achieving

market & business superiority

Responding to Market Demand

Requires a change in the way .
we think about manufacturing

FROM

TO

MAKE

MAKE

PUSH

PULL

BUY

BUY

The consumers act of buying activates the process of manufacturing.

JUST-IN-TIME( JIT )
A structural approach followed by an organization,
focusing on
improving:

Timeliness.
Flexibility.
Productivity.
Quality.
By utilizing various methods of work
simplification and waste reduction.

JIT Continued.
JIT means to manufacture and deliver:

Finished Goods just in time to be sold.

Arrange/ Manufacture Sub- assemblies just in
time for assembling into finished goods.
Arrange/ Manufacture parts and components just
in time to be transformed into sub assemblies.

Waste Definition
According to Toyota, the originator of JIT concept, waste is:
Anything other than minimum amount of equipment ,
material,
parts and working time absolutely essential to
production.
The American defines it as:
Anything other than the absolute minimum
resource of machines, material, manpower and
method to add value to the product.
- Single Supplier.
- Almost Zero Safety Stock.
- No space, people and equipment for rework.
- No excess lead time.
- Minimum Non Value added activities.

Seven Wastes in Operational

Environment

Overproduction.
Waiting for something ( Instruction, material, equipment
readiness).
Material Transport.

Inventory

Inspection, Rework and Scrap.

Equipment Downtime

Set- up Time for Machine/ Facility.

Five Wastes in Office

Environment

Lack Of Planning

Absence of System for Working.

Cumbersome procedures.

Information Storage and Retrieval

Inconclusive style of Working.

The Seven Elements that addresses Elimination of Waste are:

Focused Factory

Group Technology

Quality at Source

J I T Production

Uniform plant loading

KANBAN Production Control System

Minimized Set-up Times

Quality at Source :

Right first time.

Do not accept reject

Do not produce reject

Do not deliver reject

Self inspection

Stop line & use of Pokayoke

ANDON for trouble indication

Team problem solving

JIT Methods

Good Housekeeping.
Visual Control.
Total Productive maintenance. ( TPM )
Pokayoke .i.e. Mistake Proofing
Andon/ Jidoka.
Cellular Layout.
Modern Material handling and transportation.
Lot Size reduction.
Operation with Minimum Stock.
Self Certified Vendors.
Demand Pull and Kanban.
Multiskilled and Flexible workforce.

JIT People

Do not accept reject.

Do not produce reject.
Do not send reject.
Can stop the Line.
Team Member and Flexible.
Understand products and processes.
Measure Selfs output .i.e. Quantity and Quality.