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STEPHEN.GERSHEN Total Quality Management
What is Quality ,[object Object],[object Object],[object Object],[object Object],[object Object]
Approaches to define Quality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Approaches to define Quality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Approaches to define Quality ,[object Object],[object Object],[object Object],[object Object]
Attributes of Quality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Attributes of Quality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Evolution of Quality Management
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Evolution of Quality Management ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Evolution of Quality Management ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Evolution of Quality Management
Evolution of Quality Management
Gurus of TQM Dr. W E Deming  Dr. J M Juran  Dr. Philip Crosby
Gurus of TQM Dr. Kaoru Ishikawa Dr. Genichi Taguchi Dr. Masaaki Imai
Gurus of TQM Dr. Shigeo Shingo Dr. Yoshio Kondo Dr .Armand V. Feigenbaum Dr. James Harrington
W E Deming  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
W E Deming 14 Points
W E Deming – PDCA Cycle
Seven Deadly Sins ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Deming’s Prize ,[object Object],[object Object],[object Object],[object Object],[object Object]
Malcolm Baldrige National Quality Award ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Malcolm Baldrige National Quality Award ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
J M Juran ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
J M Juran’s Trilogy
Juran’s 10 Points ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Philip Crosby ,[object Object],[object Object],[object Object],[object Object],[object Object],Do it right the first time Zero Defects Absolutes of QM
Crosby 14 points ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cost of Quality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cost of Quality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Cost of Quality ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Genichi Taguchi ,[object Object],[object Object],[object Object]
Taguchi’s Loss Function ,[object Object]
Taguchi’s Loss Function
Kaoru Ishikawa ,[object Object],[object Object],[object Object],[object Object]
Ishikawa Diagram
Ishikawa Diagram ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Ishikawa Diagram ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Masaaki Imai ,[object Object]
Shigeo Shingo ,[object Object],[object Object],[object Object],[object Object]
Yoshio Kondo ,[object Object],[object Object],[object Object],[object Object]
Toyota Production System ,[object Object],[object Object]
14 Principles of TPS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
14 Principles of TPS ,[object Object],[object Object],[object Object],[object Object],Continue …….
14 Principles of TPS ,[object Object],[object Object],[object Object],[object Object]
“ 4 P” Model of the Toyota Way ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
“ 4 P” Model of the Toyota Way ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Genchi  Genbutsu Respect & Teamwork Kaizen Challenge Where Most “ Lean” Companies are
“ 4 P” Model of the Toyota Way ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Genchi  Genbutsu Respect & Teamwork Kaizen Challenge Toyota’s Terms
Toyota Production System House Leveled Production (Heijunka) Stable and Standardized Processes Visual Management Toyota Way Philosophy ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Best Quality – Lowest Cost – Shortest Lead Time –  Best Safety – High Morale Through shortening the production flow by eliminating waste ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Continuous Improvement
Deming’s PDCA Cycle Check Check Check Check Plan Plan Plan Plan Act Act Act Act Do Do Do Do Across Companies Company Group Project
Creating Flow Eliminate Waste Evaluate  Results (Check) Surface Problems (Plan) Counter  Measures (Do) Create Flow (Act)
Three Ms Muda Waste Muri  Overburden Mura Unevenness
Toyota’s Leader View PHILOSOPHICAL MANAGEMENT TECHNICAL ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],PEOPLE Long – term Asset –> Learned Skills Machinery Depreciates -> Loses Value  People Appreciates -> Continue to Grow
Supply Chain Need Hierarchy Learning Enterprise Enabling Systems Clear Expectations Stable, Reliable Processes Fair and Honorable Business Relations Progressing Need Satisfaction Regressing Need Satisfaction Next Level of Improvement Stability
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Myth vs Reality
Motivational Theories & TPS
 
5 S ,[object Object],[object Object],[object Object],[object Object],[object Object]
5 S’s Sort Clear out rarely used Items by Red Tagging Straighten Organise and Label a Place for Everything Shine Clean It Standardise Create Rules to Sustain the first 3 5’S Sustain Use Regular Management Audits to Stay Disciplined Eliminate Waste
Waste in a Value System Time Casting Transportation Staging Setup Machining Inspection Assembly Staging Raw Material Time Finished Parts Value – Added Time Non-Value-Added  Time (Waste) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Waste in a Truck Assembly Line
Thank You Stephen Gershen 610-409-8230 email me

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