Driving and Sustaining Quality &
Innovation in Manufacturing Processes
Quality Presentation - EFY
Thursday, January 19, 2012
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Contents
• Driving Quality Through Business
Processes
• Defining Business Processes
• Employee Involvement & Empowerment
• Defining Business Measures
• Measures Review Mechanism
• Continual Improvement & Process
Innovation
• Continual Improvement By Involvement
• Business Process Reengineering
• Benchmarking
• Reward & Reorganization
Date :16th Feb 2012
Devang Khamar
Head Quality , Environment & Six sigma
Driving & Sustaining Quality & Innovation - EFY
Thursday, January 19, 2012
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Driving Quality Through Business Processes
Driving & Sustaining Quality & Innovation - EFY
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Defining Business Processes
Business processes are set of work activities and associated
resources that produces something of value to a customer.
Organizations Direction
Business Process Manual
Mission
Why Organization Exist
Core Values
Interaction of Business
Processes
Rules & Procedures
Level-1
Level-2
What Organization Believe In
Instructions
Level-3
Forms
Vision
Level-4
What Organization Want to Be
Process Approach
Driving & Sustaining Quality & Innovation - EFY
Thursday, January 19, 2012
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Employee Involvement & Empowerment
Employees Involvement in to Organizations Business Processes is Giving
Empowerment in their defined work area.
Organizations Direction
Business Process Manual
Employee Involvement &
Empowerment
Mission
Top Management
Why Organization Exist
Interaction of Business
Processes
Core Values
What Organization Believe In
Organizations Rules
& Policies
Level-1
(Management Team,
Business Owners & Customers)
Level-2
Middle Management
(Process Owners, Line Managers
Instructions
& Leaders)
Level-3
Executors
Forms
Vision
Level-4
(Line Engineers & Operators)
What Organization Want to Be
Joining forces for improvement
Driving & Sustaining Quality & Innovation - EFY
Thursday, January 19, 2012
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Setting up of Right Business Measures
Business Measures must support Business Mission and the
Vision.
Measures can be categorized in to Major 4 Categories
- Financial
- Customer
- Internal
- Learning & Growth
Measures Needs to be set at all levels in “SMART” Manner
- S : Specific
- M : Measurable
- A : Achievable
- R : Realistic
- T : Time Bound
Focus Drives Success
Driving & Sustaining Quality & Innovation - EFY
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Review Mechanism
•
It is a structured and Time Bound Process to review
Business Measures
• Pre-defined Meeting schedules
• Structured & clearly defined agenda
• Active participation from the accountable area /
process owners
• It shall be Transparent, efficient, inclusive and
impartial
• Track the action points closer with owner & within
agreed time lines
The Power of Focus
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Driving & Sustaining Quality & Innovation - EFY
Thursday, January 19, 2012
Continual Improvement & Process Innovation
Driving & Sustaining Quality & Innovation - EFY
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Continual Improvement
Tools & Techniques
• Continual Improvement is an integral part of operations to improve the
operations in the business & to be competitive in the market.
Tools & Techniques
Description
Levels of Involvement
7 QC Tools
Quality Circles
5S
Single Minute Exchange of Die (SMED)
MUDA
Poka Yoke
Statistical Process Control (SPC)
Kiazen
Daily Work Management (DWM)
Benchmarking
Total Productive Maintenance (TPM)
Total Quality Management (TQM)
Lean Six Sigma
Problem Solving Tools
Small Group Activity
Workplace organization
Effective Change over of Product
Waste Elimination
Mistake / Error Proofing
Process Monitoring & Control
Small Improvements
Daily performance review
Implement Best Practices
Improve Assets effectiveness
Involvement by All
Breakthrough Improvement
Process Owner, Line Leader, Operator
Operators
All employees
Line Leaders, Operators
Line Leaders, Operators
Process Owner, Line Leader,
Operators
Process Owner, Line Leader, Operator
All employees
Process Owner
Asset Owners
All employees
Process Owner, Line Manager, Leaders
Think different, Think Out Of Box
Driving & Sustaining Quality & Innovation - EFY
Thursday, January 19, 2012
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Elcoteq Way of Innovation & Continuous Improvement
Innovation Strategy
6
Continuous
Improvement
Projects (CIPs)
Lean Sigma
Knowledge Quiz
Awareness Events
Kaizen
Poka Yoke
Small Group Activity
(SGA)
5S
Driving & Sustaining Quality & Innovation - EFY
Management Commitment
Quarterly CIP Contest
Rewards & Recognition
Quarterly Plant Communication
Meeting
- Platinum , Gold , Silver Awards
For 6 Contest
- Highest Performer in Quiz (Top3)
Monthly Innovation Round
Monthly Innovation Round
Quarterly SGA Contest
- Kaizen & Poka Yoke Star
- Best SGA Awards
- External Rewards
Industry Contest (QCFI)
Quarterly Plant Communication
Meeting
Weekly Management Round
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- 5S Champion
- Best 5S Area (Team)
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Process Innovation
•
BPR
Business Process Re-engineering (BPR) is fundamental thinking &
redesign of the business processes, to achieve a dramatic
improvement in Critical Success Factors like Cost reduction, Quality
Enhancement, Service Improvement & Cycle time Reduction.
•
Why Business Process Reengineering ?
- Economy is liberalized.
- Today’s Market is going Global.
- Customers are become Choosy.
- Competition is getting Hot.
- Companies cannot afford any more profit less turnover….
So the companies do not reengineer their business processes will simply
go out of Business in next few years.
BPR is no more a choice but it is a necessity in today’s Business
Driving & Sustaining Quality & Innovation - EFY
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Business Process Reengineering
Defining the scope
of the reengineering
Project / Process
•
•
Collect the data for the
Study the process
with Customer,
Employees,
Competitors &
new technology
Define the Objective
•
Based on the historical
•
Create plan based
on gaps & Implement
the solution
(Redesign)
•
Creation of the
business processes.
information define the
with customer,
roadmap to fulfill the
Analysis of the
“to be” state.
employees,
gaps between current
Allocate the resources
competitors for their
process, technologies.
business processes
•
inputs.
based on the data.
•
Learn the processes
Process
Selection of the
bottleneck processes.
•
•
Implement the
Collects inputs from
solutions to get the
the new technologies
desired results.
in the business.
(Redesign the process)
The Power of Focus for revolutionary improvement
Driving & Sustaining Quality & Innovation - EFY
Thursday, January 19, 2012
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Benchmarking
Practices
Process Innovation
• Benchmarking is an art of finding out in a systematic & legal
way the best practices of successful Processes and Implement
them to reach higher level of Excellence.
Types of Benchmarking
Benefits of Benchmarking
•
Helps Organization to learn from
Experience of others
Strategic
•
Gives Organization a comparison to
“Best in the world”
Process
Types of
Benchmarking
Product
•
Is a Proactive Solution
•
Gives organization a Relative
performance comparison vs.
competitors
Performance
•
Speeds up the Improvement
activities….
Driving & Sustaining Quality & Innovation - EFY
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Benchmarking Practices
Identification of
Areas for
Improvement
•
•
Identify the areas for
Process
Identify the
Improvement points
&
Roadmap
Define the team &
Organize / Execute
the visit
•
Identify the team for
•
Summarize the
Implement & Monitor
the result
•
Document the
improvement (Bottle
study (All related
observations &
implementations
Neck Process)
Process Owners)
Learning by each
for sustenance
Define the Clear
member
Survey the similar
•
process / practice
industries
•
Learning Plan
•
•
Monitor the process &
Formulate the time
Measures for continual
Organize & Execute
bound action plan with
improvement
a well planned Visit.
clear measures for
Improvement
Share your Experience with others to generate new
Innovative Approaches
Driving & Sustaining Quality & Innovation - EFY
Thursday, January 19, 2012
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Rewards & Reorganization
• Companies strength is motivated work force
• Rewards and recognition is a powerful tool for employee motivation and
performance
• Shows the Top Management Commitment for the Performing Employees
• Effects long-term Positive cultural change
• Team Rewards Builds solid Team work
• Improves employee retention to organization
• Improves employee Loyalty
• Helps to sustain the continual improvement & Innovation culture
“Thank you for the Good Work”
Driving & Sustaining Quality & Innovation - EFY
Thursday, January 19, 2012
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Continual Improvement
is a Ongoing Process
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