World Class Quality Practices

Training Presentation Demo Kit Naman Infotech Centre.

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World Class Quality Practices Product Code: M125 www.globalmanagergroup.com

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Need for world class quality practices Main three reasons are ..

A. Competitive quality pressures Focus of the organizations from “Quality” to “Competitive quality B. Fast changing industry conditions Globalization, privatization and changing customer needs and company own C. Complacency with present performance • • •

constructive level of dissatisfaction with the present performance.

It used to be you had to be “good enough” Now, you must be looking for ways to make your customer happy, and meet their future needs If you aren’t someone else is, and is going to take your business Naman Infotech Centre.

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Benefits Resulting From world class practices • These continual small improvements add up to major benefits.

– – – – – –

Improved productivity Improved quality Better safety Faster delivery Lower costs Greater customer satisfaction.

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The Journey To World Class ENABLERS LEADERSHIP

STRATEGY & POLICY

PEOPLE MANAGEMENT

RESOURCES

PROCESSES

rated Accele ent em Improv

0 - 200 Ignoring

201 - 375 Exploring

376 - 525 Installing

526 - 675 676 - 800 801 - 900 Embedding

IMPLEMENTING

Driving

Integrating

DEVELOPING

901 - 1000 Sustaining

WORLD CLASS

RESULTS CUSTOMER SATISFACTION

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PEOPLE SATISFACTION

IMPACT ON SOCIETY

BUSINESS RESULTS

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Policy

Policy for continuous improvement

9 Practice concepts of zero losses in every sphere of activity.

9 Relentless pursuit to achieve cost reduction targets in all resources 9 Relentless pursuit to improve over all plant equipment effectiveness.

9 Extensive use of PM analysis as a tool for eliminating losses.

9 Focus of easy handling of operators

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Continuous improvement Environment What is the culture and values shift required for to work ?

9Openness 9Harmony 9Inform 9Learning environment 9Empowerment 9No blame 9Making improvements constantly

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What you can expect : • • • • • • • •

Up to 50 - 70% Reduction in Setup Times Up to 20 - 30% Productivity Improvements Up to 50% Improvement in Machine Uptime Up to 50% Reductions in WIP Drastically Reduced Defect Rates Resolution of Ergonomic Issues Reduced Cycle Times A Culture Shift to Continuous Improvement

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World class quality practices includes Regarded as a conceptual "umbrella" consisting of a collection of Japanese practices. includes the following:

Customer orientation Total Quality Control Robotics QC circles Suggestion systems Automation Discipline in the workplace Total Productive Maintenance Naman Infotech Centre.

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Process

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Approach behind KAIZEN are : 9 Think of how to do it, not why it cannot be done.

9 Do not make excuses. Start by questioning current practices.

9 Do not seek perfection. Do it right away even if it will only achieve 50% of target.

9 If you make a mistake, correct it right away.

9 Throw wisdom at a problem, not money.

9 Ask 'WHY?" five times and seek root causes.

9 Seek the wisdom of ten people rather than the knowledge of one.

9 Don't ask workers to leave their brains at the factory gate.

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Methods of kaizen I. Creativity & Innovation ii. Rational model for problem solving iii. Efficient time management iv. 5 S v. Total Productivity Maintenance vi. Just in time vii. Brain storming Naman Infotech Centre.

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SMAIC select select

What What is is wrong? wrong?

Benchmark Baseline Contract / Charter Kano Model Voice of the Customer Quality Function Deployment Process Flow Map Project Management “Management by Fact” – 4 What’s

Measure Measure

Data Data & & Process Process capability capability

7 Basic Tools Defect Metrics Data Collection, Forms, Plan, Logistics Sampling Techniques

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Analyze Analyze

When When and and where where are are the the defects defects

Cause & Effect Diagrams Failure Models & Effect Analysis Decision & Risk Analysis Statistical Inference Control Charts Capability Reliability Analysis Root Cause Analysis 5 Why’s Systems Thinking

Improve Improve How How to to get get to to six six sigma sigma

Design of Experiments Modelling Tolerancing Robust Design

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Control Control

Display Display key key measures measures

Statistical Controls Control Charts Time Series Methods Non Statistical Controls Procedure adherence Performance Mgmt Preventive activities

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Process Improvement model 1.

Operational Analysis of process

F E E D B A C K L O O P

2.Application of Process improvement Principles

3. Benchmarking

4.

PDCA

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Recognizing improvements Why Recognizing improvements?

9 The whole competitive society that we live in is driven by people striving to be recognized.

9 Often recognition is simply having someone else acknowledge your worth.

9 It is something every one wants and strives to obtain.

9 Research has shown that people classify recognition as one of the things they value most.

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Tips for employee reviews • Discuss performance in private.

• View employee reviews as an opportunity for open and honest communication.

• Make the review communication two-way.

• Make the annual or semi-annual formal evaluation a supplement to continuous informal communication.

• Be prepared to deal with strong emotional responses from employees.

• Spend some time on career implications.

• End the review on a positive note.

• Ask employees how the review process can be improved.

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Kobetsu Kaizen Activities

KAIZEN

10 Steps of Kobetsu-Kaizen 1. Step Analysis of Loss 2. Step Kaizen Theme&Target 3. Step Kaizen Team 4. Step Determination of Initial Condition 5. Step Project Plan 6. Step Analysis 7. Step Countermeasures 8. Step Verification 9. Step Standardization 10. Step Homework & Suggestions Naman Infotech Centre.

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Kaizen Case Study – ABC company • ABC company – Filing, organizing, and paper shuffling services – Uses MSD (metallic securing devices) – Increasing complaints from the Paper Shuffling Department (PSD) about MSDs breaking and failing to keep papers together – Customers’ papers can get mixed together – Purchasing wants to eliminate MSD complaints

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How Benchmarking Works Pre-planning

h ‘Diagonal slice’ h Procurement staff h Key internal clients h Selected suppliers h Metrics h Processes h Relationships

Structured Interviews

Data collection & analysis

‘Snapshot’ of today’s procurement operation Performance benchmarked using PMMS Best Practices Profile

Interim Review Gap Analysis Recommendations & Action Plans

Final Review

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Client Report

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PROGRAMME MANAGEMENT UNIT S U P PO R T U N IT D D G (O P ER ATIO N S )

Foc u s Are a s

Un it- 1

SU M AN A GER P R O GR A M M E M AN A GER

Un it- 2 D e pu ty SU M AN A GER

Stra tegy W ork Plan Repo rting Stra tegy W ork Plan Repo rting Stra tegy W ork Plan Repo rting Stra tegy W ork Plan Repo rting Stra tegy W ork Plan Repo rting

F IN A N C E , B U D GE T & PL A N N IN G M A N A GE R

M O N ITO R IN G , R E PO R TIN G & E V A L U A TIO N M A N A GE R

Ass ociates C ertifying body

From Xyz co m pany •M onthly repo rts •Quarterly rep orts •Ann ual Repo rt •M &E Fram e work Developm ent

•Budget proce ss •Donor Fund Tracking •Financial Delegation •Support to M IG Processes •W ork shop •Aud its

M AN A GEM EN T F UN C TIO N S

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Inte gration m anagem ent Scope m ana gem ent Team m anag em ent Risk m anage m ent Procurem ent M anage m ent M OU m anag em ent

Un it re spon ib v leisor for: Spe c ia list sAd

P M BO K Foc u s Are a s

Policy coordination Tim e m anag em ent Cost m anage m ent Progress rep orting Com m unication m ana gem ent Incl. P & R Interfacing

BUSINESS PL A N N IN G S U P PO R T M A N A GE R From Xyz co m pany •BP Support •Local Govern m ent Support •One Stop Sh op •Free Basic S ervices • Project M an agem ent

Stra tegic Plann ing* Busines s pro ce sse s* C hang e m ana gem en t Bes t pr ac tic e

M AN A GEM EN T TEAM

C O N TR A C T GO V E R N A N C E & TE C H N IC A L S U P PO R T M A N A GE R Consulting Associates •Overall reporting •Contract Too l Box Developm ent • Pilot Proces ses • Pilot Proces ses

SUP P O R T F UN C TIO N S

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M125-WORLD CLASS QUALITY PRACTICES CONTENTS OF TRAINING PRESENTATION KIT Chapter-1.0 CONTENTS OF TRAINING PRESENTATION No of slides: 175 A. The entire presentation kit is having 2 main directories as below.

World class quality practices

Presentation (Power point Slides)

Literature (Word Files)

01 Intro 02 Need for continuous improvement 03 Pillars 04 Smaic Model 05 Management Req 06 Methods & Tools 07 Products & Process 08 Implementation Steps 09 Technical Req 10 Deming Rules 11 Success Tips 12 5s In Lab. 13 Getting &Keeping 14 Q7 Tools 15 Scope Of GLP 16 Dos & Don’t 17 Internal Audits

Programs

Case Study 1 Case Study 2 Case Study 3 Case Study 4

01 Intro 02 Philosophy And Frame Work 03 Pillars 04 Smaic Model 05 QMS 06 Methods & Tools 07 Products & Process 08 Implementation Steps 09 Terminology 10 Smarter Working Process 11 Creating Effective Org. 12 Keeping Your Self Org 13 Does &Doesn’t 14 Work Shop 1 15 Work Shop 2 16 Work Shop 3

• • • • • • •

4.0S MAIC Model 4.1 Select 4.2 Measurs 4.3 Analyse 4.4 Improve 4.5 Controls CI Score sheet

PART-A Presentation: Under this directory further files are made in power point presentation as per the chapter listed below.

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Topic wise Power Point presentation in 16 modules as listed below.

1. Introduction It covers what, why and how world class quality practices, benefits, deming’s view of production system, levels of quality & challenges and few examples describe in detail.

2. Philosophy and framework

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M125-WORLD CLASS QUALITY PRACTICES CONTENTS OF TRAINING PRESENTATION KIT

It covers philosophy and frame woks, different views of quality guru’s, steps for quality improvement describe in detail.

3. Pillars It covers components, different pillars describe in details with understanding manner.

4. SMAIC model It covers SMAIC model steps like select, measure, analyse, improve and control describe in detail 5. QMS It covers essences, how it works, performance tier, and 360-degree appraisal for managers, performance diary, and example.

6. Methods and tools It covers different methods, why and how applicable for kaizen, how time management done efficiently and required tools etc describe in detail.

7. Products and process It covers developments, Directions and paradigm in quality thinking.

8. Implementation steps It covers steps for continuous improvement include elimination of major losses, cost analysis, guideline for effective planning, exercises for SWOT analysis, do’s and don’t describe in detail.

9. Terminology It covers quality engineering terminology describe in detail.

10. Smarter working process It covers strategic plan, smarter working process with suitable example describe in detail.

11. Creating effective org.

It covers what, role of creative manager, how to encourage, look with in you for meditation practices and how be effective 12. Keeping your self-org.

It covers about productivity, activity plan with example, how to planning and exercises for that.

13. Does and doesn’t It covers what to do and don’t in good laboratory practices.

14. Workshop1 It is about how to identify quantifiable improvement criteria for different processes describe in detail with suitable example.

15. Workshop 2 It is about 5s in quality assurance test area and good house keeping describe in detail.

16. Workshop 3 It is about continuous safety improvement, deming rules for safety describe in detail.

Case study 1 It is related to kaizen –continuous improvement on ABC Company.

Case study 2 It is related to real life example of GLP followed.

Case study 3 It is related to quality of tea.

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M125-WORLD CLASS QUALITY PRACTICES CONTENTS OF TRAINING PRESENTATION KIT

Case study 4

It is related to ABC production system for standardisation of work.

Part –B Literature: This topic covers write up for the ready reference to the trainer for understanding and reading.

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SECTION Introduction Need for continuous improvement Pillars SMAIC Model Management Req, Method s and tools Products and process Implementation steps Technical req.

Deming rules Success tips 5s in laboratory Getting and keeping org.

Q7 tools Scope of glp Do’s and doesn’t Internal audits

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M125-WORLD CLASS QUALITY PRACTICES CONTENTS OF TRAINING PRESENTATION KIT 2.0 USER FUNCTION

Chapter-2.1 HARDWARE AND SOFTWARE REQUIREMENTS 2.1 Hardware and Software Requirements A. Hardware: •

Our presentation kit can be better performed with the help of P3 and above computers with a minimum 10 GB hard disk space.

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For better visual impact of the power point presentation you may keep the setting of colour image at high colour.

B. Software used in presentation kit •

Hand-outs written in word 98 and window 2000 and Presentation made in Power point programs You are therefore required to have office 2000 or above with word 98 and power point

Chapter-2.2 FEATURES OF PRESENTATION KIT 2.2 Features of Training kit: •

Contains all necessary documents as listed above and comply with the requirements of latest management concepts and more than 1000 man days (9000 hours)

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Written in Plain English

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It will save much time in typing and preparation of training material and slides alone.

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User-friendly and easy to learn.

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Developed under the guidance of experienced experts having experience of more than 200 companies latest management system implementation globally.

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Provides model of a Management system that is simple and free to establish the management concept in the laboratory.

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M125-WORLD CLASS QUALITY PRACTICES CONTENTS OF TRAINING PRESENTATION KIT Chapter-3.0 BENEFITS OF USING OUR TRAINING KIT 1. By using these documents, you can save a lot of your precious time while preparing the management training areas presentation.

2. Take care for all the section and sub sections in implementation of latest management concepts and helps you in establishing better system.

3. The user can modify the presentations as per their industry need and create own management training presentation for their organization 4. Ready made templates and sample documents are available which can reduce your time in document preparation 5. Save much time and cost in conducting training programs 6. You will get better control in your system due to our proven training presentation material.

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