Menampilkan postingan dari 2011

The importance of Information Monthly and Daily Information

Toyota is a member of two types of information on suppliers: First is a monthly production plan which has been determined previously notified to suppliers in the middle of the month before. By using the monthly production plan has been determined in advance, the supplier will determine the date of the following plans: 1. Cycle time of each process 2. Routine operation reorder raw labor allocation in accordance with a cycle time in each process. 3. The number of spare parts and materials to be ordered on the sub suppliers 4. The number of kanban for each sub-suppliers

Supplier Kanban and sequence schedule used by the supplier

Sometimes a very powerful businessmen may order its suppliers to deliver parts on time (JIT). In this case, if the plant on the retailer to implement Kanban system without changing its own production system. Kanban system will be something that is heavy for its suppliers. Although the kanban system is a very effective way to realize the concept of JIT. This system should not be applied to the supplier without any change in the overall production system user company. Kanban system is only a subsystem of the Toyota production system requires a total reorganization of the existing production system.

classification of major types of kanban

Classification onf major types of kanban

Production Instruction Kanban


Retrieval Kanban

Retrieval Kanban

The number of kanban must be minimized

Because the number of kanban inventory reflects the maximum of the part, then it should be kept to a minimum. The total amount of each kanban cultivated fixed. Therefore, when the average daily demand has increased, lead time should be reduced. This requires a reduction in cycle time from standard operating routine to change the allocation of labor adjustment.

Kanban should be used to adapt to fluctuations in demand

Fitting well with the kanban production refers to the most interesting properties of the kanban system: The ability to adapt to sudden changes in demand or production of an emergency. Companies that do not use kanban system will lack a vehicle to act on it, changes in demand are not expected. Centralized control system used to determine production schedules and issue simultaneous production process; therefore, that sudden changes in demand will require at least seven to ten day intervals before the schedule can be updated and issued to the plant, the time interval for the computer to compile and calculate the most recent data. As a result, various production will face disconnection from time to time, mashing the changing needs of production; this issue will form a production process is less smooth.

Defective products should never be collected to the next process

Kanban system that would self-destruct unless all three rules are followed. If some part is damaged encountered, then the next process in itself makes the line stopped because there is no extra units of inventory and send the defective part to the previous process. Lines like this dismissal of the next process is very clear and visible to everyone. Also, faulty operation must be eliminated to ensure the withdrawal of rhythmic than the previous process. Standardization of work, therefore, one of the kanban system is an absolute requirement.

Attract the necessary product of the previous process in the amount of necessary time

Successful implementation of this rule depends on the underwriting of workers that the system is useful and easy to administer. This rule will probably be found with many obstacles because it requires a complete change from the previous production system. Sub rule which became part of this rule are: – Any withdrawal without going through the kanban should be banned – Any withdrawal greater than the number of kanban should be banned – A kanban must be attached to the physical product. Refinement of production or increase daily production, is a necessary condition for a withdrawal and small-lot production of a continuous process, and most importantly, apply rules 1. Smoothing of production, for example: only if the kanban system is applied to pull parts from outside companies subcontract, then the kanban is a very dangerous weapon and uses the original will be lost. Subcontractors need of supplies, equipment, and manpower in large numbers to respond to fluctuating demand from manufacture

Is kanban it?

Kanban is a tool to achieve the production of the JIT (just in time). Is a card that is usually placed on a rectangular vinyl envelope. Two commonly used types of kanban: kanban demand (withdrawal kanban) and the kanban production orders (production-ordering kanban). Kanban request specifies the type and number of products in which the process which then must be requested from the previous process, while the kanban production order specifies the type and amount of product from the previous process that must be produced. Production-ordering Kanban is often called in-process Kanban or simply the production kanban.

Rules of Kanban

To realize the purpose of JIT kanban, the following rules must be followed: 1. Advanced process must draw the necessary product of the previous process in the required amount of time required 2. Previous process must produce their products in the amount drawn by the next process 3. Defective products should never be collected to the next process 4. The number of kanban must be minimized 5. Kanban should be used to adapt to fluctuations in demand for small

Kanban functions

Kanban functions can be described as follows: 1. Stimulate the emergence of workforce initiatives in the field 2. As a means of controlling information 3. controlling inventory 4. Adding a sense of belonging among workers 5. Simplify management mechanisms work 6. Enables visual management work in the field

Pull System for JIT Production

Toyota’s JIT production is a method to adapt to changes due to disturbances and changes in demand by making all the necessary processes to produce goods at the time it takes the required amount. The first requirement for JIT production is to make all the process of knowing the exact timing and amount needed. In the usual system of production control, the above requirements be met by issuing a variety of production schedules on all the process: The process of manufacturing spare parts and also on the line of rafts. This process produces spare parts spare parts in accordance with the schedule, using a push system, meaning the former to supply spare parts to the next process. However, this method will make it difficult adjustment quickly to changes caused by disturbances arising in some process or due to fluctuations in demand. With ordinary systems, to adapt to various changes during the month, the company must modify the production schedules for each process simultaneously; the approach

JIT and Automation

Since the JIT system is used, usually only shows the possibility of automation in some respects. Because it is not uncommon for companies that use JIT to follow him with possession of advanced manufacturing technology. Automation company to: (a) increase production capacity, (b) increase efficiency, (c) improve the quality and service, (d) lower the processing time, (e) increase the output. Automation increases the ability to track costs on various products individually. as an example of FMS cells, is a fellow of the automated JIT manufacturing cells. So. some costs which are costs not directly in the traditional environment is now a direct cost.

JIT manufacturing

JIT manufacturing uses a more centralized approach than that found in traditional manufacturing. The use of JIT manufacturing system having an impact on: 1. Improving Traceability (Traceability) costs. 2. Improving the accuracy of product cost. 3. Reducing the need for allocation of central service costs (service departments) 4. Changing behavior and the relative importance of direct labor costs. 5. Affect the pricing system and process basic orders. The basics of JIT manufacturing and the difference with traditional manufacturing: 1. Compared with traditional JIT manufacturing. JIT manufacturing is a demand pull system (Demand-Pull). JIT manufacturing goal is to produce a product only if the product is needed and only for the number of requests of buyers (customers). Some differences with the traditional JIT manufacturing include: a. Low Inventory b. Manufacturing cells and Interdisciplinary Workforce c. Philosophy of TQC (Total Quality Control)

JIT Production

JIT production is a production scheduling system components or products on time, quality, and in accordance with the required amount by the next production stage or in accordance with customer demand. JIT production can reduce the time and cost of production by: 1. Reduce or eliminate work in process in each workstation (work station) or the stages of product processing (the concept of zero inventory). 2. Reducing or eliminating “Lead Time” (waiting time) of production (the concept of zero wait time). 3. Continuously pushing hard to reduce machine setup costs at each stage of processing products (workstation). 4. Emphasis on the simplification of processing the product so that activities are not value-added production can be eliminated.

JIT Purchasing

Purchase JIT scheduling system is the procurement of goods in a way such that it can be done immediately to meet demand delivery or use. Purchase JIT can reduce time and costs associated with purchasing activities by: 1. Reducing the number of suppliers so that companies can reduce the resources expended in negotiations with pamasoknya. 2. Reducing or eliminating the time and cost negotiations with suppliers. 3. Having a buyer or customer with an established purchasing program. 4. Eliminate or reduce activities and costs that are not value added. 5. Reduce time and cost for quality inspection programs.

Understanding the JIT

In broad terms, JIT is a philosophy that focuses on timely activities required by other internal segments within an organization. JIT has four main aspects as follows: 1. All the activities are not value-added to the product or service should be eliminated. Value-added activities that do not unnecessarily increase the cost of such supplies as much as possible to zero. 2. Commitment to constantly improve the quality higher. So that the damaged and defective products as far as possible to zero, does not require the time and cost to rework defective products, and buyer satisfaction can be increased. 3. Always strived continuous improvement (Continuous Improvement) in improving the efficiency of activities. 4. Emphasis on streamlining the activities and improve the understanding of the value-added activities.

Kanban systems for JIT

In Japanese manufacturing systems of the kanban system is a very popular term in the adjustment process and maintain the production of Just-In-Time. Kanban system is an information system that harmoniously controlling the production of products needed in the required amount at the time it takes in every process plant and also between companies. This is known as the timely production (Just-In-Time = JIT). At Toyota kanban system is seen as a sub system of the Toyota production system as a whole. In other words, the kanban system is not the same as the Toyota production system, although many people mistakenly refer to this latter kanban system.

Six Sigma as a tool and system management

In the study of Six Sigma, there are several qualifications that are often referred to as a White Belt, Yellow Belt, Green Belt, Black Belt and Master Black Belt. Each has its own level of expertise required, simply getting into the direction of Master Black Belt, of course, requires more skill and experience are more complex. Six Sigma is not just quality improvement, but it could become an integrated management system that has an impact on various aspects, including the discipline of leadership development. That said, a qualified operator should-he was a white-yellow belt or a belt, a team leader or supervisor ideally a green belt that is capable of organizing improvement team, preferably in a managerial level it is a black belt in charge of organizing the improvement team and set a performance improvement program in the area of responsibility. When we refer to the level of Master Black Belt, this capability must be owned by a business unit head is capable of delivering a large impac

The Quality Control Circle Tools

The method presented the results of improvement should be carried out effectively and systematically. Submission must be understood by everyone and comprehensive. Results are accurate and systematically obtained from the appropriate data collection, appropriate methods, use of assistive devices, use of software for data analysis as appropriate. Several tools and methods of presenting the results of improvement for the QCC Tools; 1. Process flow chart 2. Check sheet 3. brainstorming 4. Pareto diagram 5. histogram 6. Run Chart 7. decision Matrix 8. Cause and effect diagram 9. radar Chart

Grasp the Present Situation

Mastery of the situation will be very important research project. For that a project must involve people who are In-Charge and working in the relevant section. Person In charge who really understand the process flow, and the problem of raw materials, machinery and the type of damage that often occurs and the process of repair, defective products produced along with the frequent and so forth. Therefore, when there are problems can be directly aware of the problem point and picture completion. Six sigma team must really have a solid skill for each job that needed improvement in research. The first one should be someone who really mastered the situation particularly on the process / section that will be the project. And the best person is the PIC (Person In-charge).

Plan The Schedule

Schedule of improvement Project Preparation of planning for improvement such as Six Sigma projects must be done carefully. An urgent project should be promptly dealt with a systematic and scheduled according to need. However, otherwise it will not abandon the rules of research and improvement has been learned, which must still treat the improvement project with a systematic and proper procedures. The test product should be fixed step by step in accordance with standard operating system. Schedule to be prepared for example, determining the theme, identifying problems, setting goals, designing the project, meetings are conducted regularly and intensively, the test method in the field, determination of results and presentation of results and standardization.

Theme Selection

There are so many problems that exist in manufacturing plants, both in the category of critical issues and simple which only requires repairs that are not too significant. Six sigma project priorities is to solve problems in the company, the most urgent and have a great impact for the company. Selection of a theme for six sigma project will also affect the success or failure of a Six Sigma project to make improvements at the plant. Therefore be sought emergency issues with the highest priority.

Plan-Do-Check-Action | PDCA Concept

The concept applied in the improvement cycle such as Shewhart; s cycles (PDCA Concept) is a simple step, but if carried out in accordance with existing procedures will have a huge effect on improvement. Plan-Do-Check-Action returned to the Plan-Do-Check-Action and so on. Stages PDCA Concept if would like further elaborated the following explanation: PLAN: Planning an improvement project which will be composed of the following activities:

Shewhart's Cycles

Every improvement requires a systematic method to solve a problem. The steps taken in the repair is an ongoing process to achieve near-perfect production quality. Shewhart’s Cycles, one of the measures designed to ease resolve quality problems. The method used in the form of cycles in order to be sustainable into the next cycles. PDCA concept which later developed into a standardized problem solving as well as increased productivity and quality.

In the Autonomous Defective Control System

As stated earlier, the two pillars that support the Toyota production system is JIT and Autonomation. To achieve JIT perfect, 100 percent defect-free unit must flow into the following process, and this flow must be rhythmic without Interruption. Therefore, quality control must live together with the JIT operations throughout the Kanban system.Autonomation means making a mechanism to prevent the defective goods were produced en masse in the machine or product line. Autonomation word does not mean automation, but it is checked in the autonomous existence of abnormal things in a process. Autonomous machine is a machine that given the automatic stop device. In Toyota factories, nearly all the machines are autonomous so that the mass production of defective goods can be prevented and damage to the machine automatically checked.Mechanisms to prevent product defects by placing a variety of inspection tools in a variety of equipment and instruments is called foolproof. (“Bakayoke” or “Pokayoke

The Goals of Toyota Production System

The basic intent of the Toyota production system is to increase profits by reducing costs through the elimination of all waste such as inventory or labor that is too much.To achieve cost reductions, production must be quickly and flexibly adjust to changes in market demand without excess time on useless. Such ideas were achieved with the concept of JIT: produce the goods required, the amount required, and when necessary. At Toyota, the Kanban system has been developed as a way to post production for a month and managing JIT. To implement the Kanban system, is required smoothing production by leveling the number and variety of spare parts by taking the last line of the raft. This reduction in time required for production orders, for a variety of spare parts should be produced quickly every day. This can be achieved with small lot size production or one-piece production and transport of one-piece. Production of a small lot can be achieved by shortening the time of preparation, and produc


Toyota production system to integrate and achieve different goals (ie controlling the quantity, quality assurance, and respect for humanity) while pursuing the ultimate goal of reducing costs. Repair activity is a fundamental element of the Toyota production system; is what makes the Toyota production system really can work. Each employee mempuyai opportunity to give advice and propose improvements through a small group called Quality Control. The process of giving such suggestions enable improvements in control by adjusting the number of routine operations to changes in cycle time, improvements in quality assurance to prevent the recurrence of work disability and the machine breaks, and in honor of humanity by allowing each worker to participate in the production process.

Layout Process for Shortening the Time Orders

Note the design or layout of the process in a factory. In the past, in this factory every machine out of five of the booth lathes, milling machines, and driller placed side by side: one machine is held by a worker, for example one only holds one turner lathe. According to the Toyota production system ,The engine layout would be reformed to expedite the flow of production.Therefore, every worker will hold three types of machines. For example, one worker will hold a lathe, a milling machine, and a drilling machine at the same time. This system is called double-handling process (multi-process holding). In other words, single-function workers, a concept that was applicable at the Toyota factory, now a dual-function workers.

Shortening the Preparation Time

One of the most difficult process in the current production is about preparation. In a pressing process, for example, common sense to determine that cost reduction can be obtained by continuously using one type of mold, thereby allowing the largest lot size and reduce the cost of preparation. However, in a state where the last process has been smooth production and reduce the dosage between the pons and the next line of the body, as a process preceding the pressing need to prepare quickly and frequently. This means changing the type of mold for the press in accordance with various types of products repeatedly ole taken the next process.

Self Adjusting to Product Variations with Multipurpose Machine

When considering the fabrication machinery or equipment actually, to conflict between product variety and production. If we do not produce many kinds of products, special equipment for mass production for example is usually a powerful weapon to reduce costs. However, at the Toyota there are various types of cars that are distinguished in various combinations based on type, tires, options, colors and others. For example, three or four thousand types of corona, actually produced. To carry out production lancar with various types of similar products, needed a useful machines or flexible. By adding certain instruments and tools on these machines, Toyota has set a production process to accommodate the general usability.

Production According to Market Demand

Production launch is the most important requirement for production with Kanban and to minimize the idle time in terms of manpower, equipment and goods in process. smoothing production is the cornerstone of the Toyota production system. As previously mentioned, every process goes into the process earlier to take the necessary goods at the time required in the necessary quantities. With that kind of production arrangement, if the next process to take spare parts are fluctuating in terms of time or number, then the previous process have to prepare supplies, equipment, and labor amount needed to adjust to peak variation of the amount requested.

Toyota Production system : Determine Daily Production Order

For example there is a production line is expected to produce 10,000 cars type A in 10 working days, 8 hours each, within a month. 10,000 cars type A consists of the 5,000 cars, 2,500 hardtop, and 2,500 wagons. If these values are divided by 20 working days, obtained 250 sedan, 125 hardtop, and 125 wagons per day. This is pelancaran production in terms of average daily amount of each type of cars manufactured, so is great for people wanting to change their cars for a new one, since getting rid of a car is not that difficult with services as Scrap My Car Montreal online. In a turn (shift) operations during the eight-hour (480 minutes), have produced 500 units. Therefore, the unit cycle time, or mean time needed to produce one vehicle of any kind, is 0.96 minutes (480/500) or about 57.5 seconds. The right mix or production sequence can be determined by comparing the actual cycle time to produce a particular model of car type A. For example, the maximum time to produce a sedan type A is

TPS principle: Self Adjust to a Changing Number of Production Change

Let us consider the adjustment of production by using Kanban. Suppose a machine fabrication process should produce 100 engines per day. The next process, with Kanban-making, asking for five machines per one lot. Lot-lot was then drawn 20 times per day, in order to reach exactly 100 the number of machines produced each day. With a production plan like this, if there is a need to reduce all of the production process by 10 percent as the adjustment procedure, the final process in this example should take the machine 18 times per day. Then, because the machine only produces 90 units a day, the time left for the 10 units will be saved by stopping production of this process. On the other hand, if there is a need to increase total production by 10 percent, the final process should take the machine 22 times per day with Kanban it.Then the previous process must produce 110 units, an additional 10 units could be covered through overtime.

Information via the Kanban : Toyota Production System

These cards are in circulation in Toyota factories, between Toyota and other companies that work with him. And in the factories of companies that work together is. In this way, Kanban can convey information about the number of shots and the amount of production to achieve JIT production. Flow of 2 Kanban For example we make the products A, B and C in a raft line. Spare parts needed to manufacture these products are a and b are produced by the previous engine line. Spare parts a and b are stored behind this line and Kanban production orders from this line attached to him.

JIT Implementation: JIT in the Process of Assembling Auto Parts

One example of JIT in the auto parts assembly process is to see to type sub-assembly is required from the previous process to achieve product line at the time required and the amount needed. If JIT is achieved throughout the company, the stocks that do not have the factory will be removed altogether. So that no material or warehouse inventory needed. Warehouse inventory costs will be reduced and capital turnover ratio will increase. However, it is very difficult to achieve JIT in all processes for a product like a car when used arrangement of central planning (push system), which determines the production schedule and distribute to all processes simultaneously Because of it, the Toyota system, we need to see the production flow in reverse, in other words, people of a certain process to go into the process earlier to take the necessary units in the required amount in the required amount of time required. Previous process was only manufacture enough units to replace units that have been

Standardization of Mechanisms to Control the New Process and Hold the Gains

Design product to be produced to some extent will affect the production activities. Moreover, the design was made at the time of production is still going to produce long products. With the new product design that will certainly cause changes in manufacturing management system for example: 1. Setting machine The machine that normally re-used should be setup to be the size, speed and so forth depending on the design of modified products More and more design modifications of course the more the machine settings to be done. Even the possibility of adding machine tool production if the new design does not allow work by the old engine.

Unnecessary Capital Investment

Inappropriate initial planning will lead to wastage in the production process, but with the Nuwire Investor you can invest your money in a safe way. Therefore, the design must be able to predict market manufacturing and processes that have the potential to change. Moreover, its relationship with the investment that is not necessary. This needs to be avoided remember to get optimum benefit should use the optimal investment as well. Get the benefits of trading education . Some investments that should be eliminated, namely: 1. Construction of warehouses to store stocks Extra 2. The addition of extra labor to transport supplies to a new warehouse 3. Purchases of goods for each machine tool conveyances 4. The addition of employee stock controllers to handle the new warehouse 5. Addition Operator to repair the damaged stocks 6. The making process for managing requirements and the number of stocks indifferent types, making a smart investment is using the forex trading strategy pdf , most pe

Target of Toyota Production System is Eliminating Waste.

The main consideration for the Toyota production system is a reduction in costs by eliminating waste altogether. There are four types of waste in manufacturing production operations. 1. Source of production a day too many 2. Excessive production 3. Preparations are too many 4. Unnecessary capital investment First, the waste in the manufacturing workplace is primarily the production of too many resources, that is labor that is too many, too many facilities and preparations are too much. If these elements are present in greater numbers than are needed, whether people, equipment, materials, or products, they will only add cost and do not add value. For example, labor is too much resulting in excessive personnel costs, facility costs too much cause excessive shrinkage, and the dosage was too much resulted in excessive interest. In addition, production of too many resources to create secondary waste – overproduction, which is seen as a waste of the worst kind at Toyota. Excessive production

Quality Improvement Concept: Establishing Specific Improvement Project

This article is still something to do with Juran’s Quality Trilogy, which is about Quality Improvement. Making Improvement can not be carried out directly and make immediate changes that big. As well as improving quality by reducing dust particles attached to the product. Improvement projects that have campaigned is about 5s management, ranging from awareness training 5s, Seiso suppression activities by controlling dust at the area desk each and standardization to ensure continuity. Problems in the company are many and complex, so many improvement projects that must be tilled. But improvement is good improvement more specific and refers to the scale of priorities:

Juran's Quality Trilogy: Providing the Needs for Improvement

In Juran’s Quality Trilogy, is the second point is the quality improvement. Improvement is an important activity in manufacturing. For that we need the support of all parties. The Company will not be able to compete if it does not make improvement. To get the best product quality can not be achieved by means of instant, but the improvement done in stages. The things most important improvement is the participation of all components of the company. Improvement projects should be supported fully. It should also be done by the ranks of top management. Top management has the power to decide everything about the company’s policy will be crucial, especially in the provision needs improvement

Quality Planning: New Design of Product Must Be Transferred to Operator

Important work that involves all components of the company. The realization of new design is meant to happen Transferred process with all those involved with the plan and training approximately them. The new design will require a great energy in order to conduct training to all operators in the factory. Training not just for the operators, but a manager should also understand about the product specifications. Operators in charge of transporting the product / material should also understand how to treat the product in accordance with operating standards and find out critical control point, which often causes defective.

Capable of Making the Product Under Actual Operating Conditions

Creating a quality product design should stick to the efficiency and effectiveness of manufacturing. Lean manufacturing focuses on the savings in all production lines must remain the reference. Indeed the general product quality must be built with raw materials, machinery and processes are also expensive. But that does not mean having to add production machinery if there are changes in product design or any new product. Trends and design changes may often occur in the course of making products that meet the standards of customer demand. However, the appropriate design expertise with production machinery that exists is the main priority in order to obtain maximum benefits.

Toyota Production System: The System of “Kanban”

In this system, the type and number of units required is written on a card similar to a label called “Kanban”, sent by workers from one process to another worker in theprevious process. As a result, many processes in the plant will be interconnected. Withinterrelated processes in this plant allows better control in terms of the number needed for various products. In the Toyota production system, kanban system supported the following things: – efforts to streamline production – Standardization of work – Reduced setup time – Activities improvement – The design of machine layout – autonomation

Determine the Customer's Needs

To achieve the quality that meets customer needs, a manufacturing company should be able to determine the products that really fit with the needs of consumers. Along with the development of demand and customer requirements then there are things to note are: 1. Development of goods and services to meet those needs There are two items that should receive attention of goods and services. Development of goods in terms of design, reliability, low price is the main priority to be able to compete in the business world in the world. Goods that can not follow the development of time is left on its own. Trends in new goods will be the main priority in designing a product. Through rigorous research stage and will systematically produced product up to date and the product that is able to predict market demand.

Determined Our Customers as a First Step Quality Planning

This is the first in implementing quality management planning as suggested by Juran is to determine our customers. Market segmentation must be accurate so that all the products we produce. Identify the customer is very important to eliminate the activity, work that should not be necessary. Incorrect identification will result in waste production, and many require additional fees. Quality Planning does not only focus on how to design a product with high quality. But must also consider the effectiveness of production and could reduce waste inproduction. Research design invalid would complicate the production which can lead to waste.

Strategic Management and Technical Management

Still talking about quality management of Juran, that he third line with quality management functions of Quality in product planning, quality in production processes and quality control in some improvement in every line of the company, Juran also distinguish two types of quality, namely a. Strategic Quality, which is managing the quality management level. All of wisdom-related products company, employees, the use of funds to ensure the quality of a strategic nature. The system involves a company that company officials will determine the direction of the company itself. Quality control will not work properly if there is nosupport system that encourages improvement in corporate activity. Regulations andt his strategic system plays an important role to improve quality.

Quality Improvement

Quality improvement is the third step in the Juran trilogy. If all systems in manufacturing is already well under a coordinated and well controlled, then the next step is quality improvement. Quality improvement must necessarily be done by the company, because the market demand is always changing. If not able to follow the market will be increasingly left behind. We cannot rely on the product that we think is perfect last year because it has been through the stages of design and good process control. But the product should be able to compensate for the existing development trends in the community. Quality is not an end. Each time quality standards will change in terms of design and usability. Quality should continue to be developed towards a better and better. Quality products and has built a reputation in the eyes of consumers with a very long time. Time required to make improvement. Although any small improvements made, it must be done because it is a process of becoming perfect qual

Quality Control to Ensure Only quality Products are Delivered to the Customer

Juran trilogy still learning about them to deliver a quality product must be in strict quality control. Control is done starting material flow from suppliers, production processes and treatment of the finished goods and shipment of goods to the customer. All must be checked and carried in a strict and regular control on the basis of good management. Material coming from the material supplier should be able to ensure a truly qualified. Quality materials have been through some process of supplier selection, material characteristics of the survey, a review of factory construction. Once selected and confirmed the material and suppliers of the most important thing is to control every material is ordered. If any problems occur when the supply of materials must be done quick and organized action. Example there are out of spec material received from suppliers, it should immediately complain to a supplier because if it will not cause a lot abnormality in the production process. With Scantech In

Quality Planning as the Foundation for Achieving High-Quality Product

To design a product requires a long time to do research. Research was conducted to obtain products that do have high sales; customer can be accepted and supported by the resources that allow making the product. Planning a mature will make the company the confidence to market their product designs, competitive, and the iconic company that will produce many benefits for the company. But on the contrary, if the research product is not able to follow the market trend is reversed. Product will be rejected by society, low quality and of course the loss will be suffered by the company.

Six Sigma Provide a Way to Measure Variability

Product market trends and customer desires to obtain the best product is always changing and unpredictable. To answer the challenge that was then carried out improvement activities, called Six Sigma. Six Sigma is a way to Identify, measure, and analyze product variety to meet standards and customer requirements. When a company refers to the six sigma to solve quality problems in manufacturing, then they will use the method DMAIC (Define, Measure, Analysis, Improvement and Control) as a step improvement. Design For Six Sigma (DFSS) is more than just a defined methodological approach, but an attempt to design the product or re-design existing products, to become more sensitive and able to follow the development of products and manufacturing variability

Quality Control Management Functions Kown as the Juran Trilogy *

Joseph M. Juran is the father of quality after Deming trilogy with the concept put forward in quality and translate theory into 3 quality control management functions, known as the Juran Trilogy. The third management function in question is the Quality Planning, Quality Control, and Quality Improvement. • Quality planning , a process that identifies the customer and the process that will deliver products and services with the right characteristics and then transfer this knowledge throughout the company’s accomplice in order to satisfy customers. This is done to maintain keloyalan customers by providing all their needs, develop products or services in accordance with the wishes of customers, and developing processes for the production of goods and services more efficiently.

Total Quality Management : Deming’s 14 points *

1. Create purpose towards improvement of product and services in the long run. 2. Shoddy materials,poor workmanship, defective products and lax service must become unacceptable. 3. Cease dependence on mass inspection. Instead, process must be improved. 4. Buy material only if the supplier has a quality process rather than on the basis of price alone. 5. Waste must be reduced and quality improvement in every activity (Procurement, engineering, maintenance, sales, distribution, accounting, payroll, customer service and manufacturing)

The Basic Concept of Design For Six Sigma is DMADV or DMADOV

Unlike Six Sigma, the the foundatio of Six Sigma is DMAIC that consists of Define, Measure, Analyze, Improve and Control, Design For Six Sigma has its own guidelines in its execution method that is DMADV (Define, Measure, Analyze, Design and Verify) or DMADOV (Define, Measure, Analyze, Design, Optimize and Verify). Step of Design For Six Sigma implementation is not universal, such as Six Sigma itself. If Six Sigma DMAIC phases valid and recognized by all companies that use this system, but the stages of DFSS (Design For Six Sigma) each company has its own means and methods. Training companies define DFSS training different from each other according to the needs and conditions of existing products company.

Design for Six Sigma (DFSS) Set up Quality with a Focus on Product Design

Planning product that will be made by a company must refer to the concept of lean manufacturing as a whole. Product design is not just a futuristic design and sophisticated, smart but the design to suit customer demand. In addition, the design taking into account the existing processes. A structured and systematic research of the market demand is one key to the success of a company that will launch a new product. However, it should be a concern that the company should deliver a quality product. Design For Six Sigma is a systematic and proactive methods are still prioritizing customer requirements that keep referring to aspects of the development of production processes under control, optimized to obtain a quality product.

Indirect Cost of Poor Quality (COPQ) Reached 15-25% of Sales

There is a bigger problem in poor quality, that is a huge cost burden and require special identification to solve it. Because of this problem not tangible. Iceberg below the water surface was more complex and highly detrimental to the company if not managed properly. Among the company’s cost burden is Expediting Costs, Lost of customer loyalty,Long cycle time, engineering change, Late Delivery, Excess Inventory.

Six Sigma Training : Direct Cost of Poor Quality Iceberg

Direct and Indirect Cost of Poor Quality Problems in the company will gradually mounting like an iceberg if it does not get serious treatment. Problem after problem will freeze into a single large company problem. The real problem could be easily identified and can take action quickly, but the iceberg contains more problems that are not visible and have a high finance. As shown in the picture. Ice Mountain is a huge stumbling block, turned out to save the ice did not seem even bigger problems. Real problems, for example. Scraps: do not reject the remaining waste product in accordance with the specifications, by naked eye can be calculated economic value. Not only that raw materials that do not qualify for the production or defects due to poor handling will be turned into scrap to be discarded. Reworks: error procedure, setting errors and error inspection engine will be forced to rework processes that do not fit standard product (rework), but in certain product rework cannot be done. If

Six Sigma Training: Cost of Poor Quality (COPQ) Iceberg That Must be Solved

Poor quality is always experienced by almost all companies all the time. Maybe for the new company, realized or not will always get it. They may wonder, whereas the procedure had passed all stages of the process perfectly. But why still the product remains in accordance with the specifications of the expected quality. Manufacturing is a very complex activity that involves thousands of variables that influence it. Starting from the materials from suppliers, storage systems, production processes, delivery and so forth. But for the new company should be gradual. Problem solved one by one seriously and continuously. Kaizen (Improvement continously) should be used as the working culture in the company. Obviously it requires a serious handling and coordination of the management. You look at the image below:

"Six Sigma Has Spread like Wildfire Across the Company" : Jack Welch

One of the rapid development of six sigma led by Jack Welch who is the CEO of General Electric. He’s not half-hearted invest for the development of his company by doing a six sigma project. His hard work has yielded remarkable results. Development initiatives his company a role model for global companies. Projects handled and conducted training has resulted in millions of dollars in profits for his company.

Six Sigma Training: Some Factors Influencing the Success of Six Sigma

Six Sigma will work with a brilliant achievement if supported by the resources and the role of various components of the company. Six Sigma is a big project that could save millions of dollars if properly executed. Like the CEO of General Electric Jack Welch: invested More Than U.S. $ 500 million in Six Sigma Initiatives Increase 40% on operating margin and $ 5 billion in savings Tied in 40% of top executive bonuses to Their Six Sigma record (in the book “Jack Welch and The GE Way “by Robert Slater.) Basically, six sigma is influenced by things as follows: