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Index » Business & Commerce » Business Administration

TQM Implementation Project Part 5a - The Improve Phase, How To Do It

T h i s T Q M a r t i c l e i s a c o n t i n u a t i o n o f t h e P a r t 4 a a r t i c l e , t h e I M P R O V E P H A S E . I n t h i s i s s u e , I w i l l s h a r e w i t h y o u h o w t o u s e C o n t r o l L o t a n d T e s t i n g a n d P i l o t t h e A c t i o n / S o l u t i o n i n c a r r y o u t t h i s T Q M p r o j e c t u s i n g t h e D . A . I . C . M e t h o d o l o g y a s d e s c r i b e d i n m y p r e v i o u s a r t i c l e . J u s t t o r e c a p , t o o l s u s e d i n t h e I M P R O V E P h a s e a r e l i s t e d b e l o w . I w i l l d e a l w i t h t o o l s t h a t a r e i n b o l d : B r a i n s t o r m i n g o f a c t i o n / s o l u t i o n | S e l e c t i o n G r i d | B e n c h m a r k i n g | C o s t - B e n e f i t A n a l y s i s | C o n t r o l l o t a n d t e s t i n g | P i l o t t h e a c t i o n / s o l u t i o n | F o r c e - F i e l d A n a l y s i s | P r e v e n t i o n P l a n n e r H o w t o u s e C o n t r o l L o t a n d T e s t i n g T h i s t o o l i s p a r t i c u l a r l y u s e f u l t o v e r i f y i f t h e c o r r e c t i v e a c t i o n / s o l u t i o n i s a b l e t o m e e t t h e t e a m ' s o b j e c t i v e . I t i s a l s o u s e d t o c o n f i r m c e r t a i n c o n t r o l p a r a m e t e r o f c h a n g e s i n p r o c e s s . I f t h e c o n t r o l l o t i s t o v e r i f y p r o c e s s c a p a b i l i t y , t h e n t h e p a r a m e t e r o f t h i s c o n t r o l l o t m u s t m e e t t h e d e s i r e p r o c e s s c a p a b i l i t y a s w e l l . L e t ’ s s e e h o w t o d o i t . I n a c o a t i n g l i n e , t h e t e a m h a s d e c i d e d t o c h a n g e t h e b e l t s p e e d o f a c o n v e y o r l i n e b u t n o t s u r e w h a t l e v e l o f s p e e d i s m o s t o p t i m i z e d t o o b t a i n t h e b e s t c o a t i n g t h i c k n e s s c o n t r o l . A c o n t r o l l o t i n t h i s c a s e w i l l b e r u n w i t h v a r i o u s s p e e d a d j u s t e d m a n u a l l y . A t e a c h s p e e d , t h e c o a t i n g t h i c k n e s s i s r e c o r d e d . A t t h e e n d o f t h e c o n t r o l l o t / t e s t i n g , a c o r r e l a t i o n i s d o n e t o v e r i f y w h i c h s p e e d y i e l d t h e m o s t o p t i m u m c o a t i n g t h i c k n e s s . A l l t h e s e t e s t i s d o n e i n a c o n t r o l l e d e n v i r o n m e n t . O n c e t h e c o n t r o l l o t i s s a t i s f i e d , r e c o r d t h e o p t i m i z e d b e l t s p e e d , t h e m t h e t e a m i s r e a d y f o r a l a r g e r l o t i n f u l l p r o d u c t i o n m o d e a n d s o m e c o n t r o l l e d e n v i r o n m e n t . P i l o t t h e s o l u t i o n P i l o t r u n i s a c o m m o n p r a c t i c e f o r a n e w p r o d u c t r e s t i n g . F o r t h i s D . A . I . C . M e t h o d o l o g y , w e u s e i t t o d o u b l e s u r e c h a n g e s t o t h e p r o d u c t i o n p a r a m e t e r s a r e w e l l i m p l e m e n t e d . T h e o b j e c t i v e i f t h i s t o o l i s t o i m p l e m e n t t h e o p t i m i z e d b e l t s p e e d d u r i n g f u l l p r o d u c t i o n r u n . H o w e v e r , t h e v o l u m e o f r u n i s m u c h l e s s e r a n d m o r e a t t e n t i o n i s g i v e n t o e n s u r e t h e n e w s p e e d i s c o m m u n i c a t e d a n d s e t f o r t h e p i l o t p r o d u c t i o n r u n . A s t h e p r o d u c t i o n l o t f o r t h e p i l o t r u n i s m o r e c o m p a r e d t o a c o n t r o l l o t , c a r e s h o u l d b e g i v e n t o e n s u r e a l l n e w b e l t s p e e d i s s e t a c c o r d i n g l y . D u e t o t h e f a c t t h a t t h i s i s l i k e a f u l l p r o d u c t i o n r u n , t e a m n e e d t o p u t e x t r a a t t e n t i o n t o a n y d r a s t i c c h a n g e s t o o t h e r p r o d u c t i o n p a r a m e t e r s . D u r i n g t h e p i l o t r u n , t e a m w o u l d r e c o r d t h e e f f e c t o f t h e p i l o t r u n i n t e r m s o f c o a t i n g t h i c k n e s s a n d o t h e r q u a l i t y s p e c i f i c a t i o n s . O n c e i t i s c o n f i r m e d , i t i s c o n s i d e r e d a s s u c c e s s f u l . I n s u m m a r y , t h i s I M P R O V E P H A S E C o n t r o l l o t a n d t e s t i n g a n d P i l o t t h e a c t i o n / s o l u t i o n w o u l d b e c r i t i c a l t o p r e v e n t a n y u n w a n t e d e l e m e n t o c c u r r e d w h e n a s o l u t i o n i s p u t i n p l a c e d f o r p r o d u c t i o n . T h i s i s t h e “ h a r d w a r e ” o f t h e s o l u t i o n . I n m o s t c a s e , i t c a n b e t e s t e d a n d a d j u s t e d u n t i l s a t i s f a c t o r y . H o w e v e r , t h i s a l o n e d o e s n o t g u a r a n t e e t h e s u c c e s s o f t h e i m p r o v e m e n t p r o j e c t . T h e h u m a n f a c t o r o r t h e " s o f t w a r e ” w i t h i n t h e p r o c e s s m u s t b e a d d r e s s e d i n o r d e r t o e n s u r e f u l l i m p l e m e n t a t i o n o f t h e p r o p o s e d s o l u t i o n . I n m y n e x t a r t i c l e , I w i l l s h a r e w i t h y o u h o w t h i s c a n b e a c c o m p l i s h e d w i t h t h e l a s t t w o t o o l s o f t h e I M P R O V E P H A S E i . e . F o r c e - F i e l d A n a l y s i s a n d P r e v e n t i o n P l a n n e r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - D i s c l a i m e r A l l r i g h t s r e s e r v e d . T h i s a r t i c l e i s w r i t t e n b y t h e a u t h o r b a s e d o n h i s p r a c t i c a l a p p l i c a t i o n e x p e r i e n c e . A l l d e f i n i t i o n s a n d i n t e r p r e t a t i o n o f t e r m i n o l o g y a r e h i s p o i n t o f v i e w a n d h a s i t h a s n o i n t e n t i o n t o c o n f l i c t w i t h e x p e r t s i n s i m i l a r t o p i c . T h e a u t h o r h o l d s n o r e s p o n s i b i l i t y f o r t h e u s e o f t h i s a r t i c l e i n a n y w a y . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - F r e e t o r e p r i n t o r r e - p u b l i s h A l l r i g h t s r e s e r v e d . Y o u a r e f r e e t o r e p r i n t o r r e - p u b l i s h t h i s a r t i c l e a s l o n g a s y o u i n c l u d e m y r e s o u r c e b o x a t t h e e n d o f t h i s a r t i c l e . P l e a s e e n s u r e t h a t t h e U R L i n t h e r e s o u r c e b o x r e m a i n i n t a c t a n d i t i s l i n k e d t o t h e a u t h o r ' s w e b s i t e . - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Author: LM Foong

Author Bio:

LM Foong

He holds a Master Degree in Business Administration majoring in Total Quality Management (TQM). He provides consulting services specializing in TQM Implementations, Malcolm Baldrige Framework and ISO 9001:2000 Quality Management System. He conducts interactive workshops and hand-holding sessions in Strategic Planning, Improvement Projects in Cost Reduction, Quality Improvement, Productivity Improvement, Cycle Time Reduction for transactional processes in Insurance and Banking Sectors As well as developing Market and Customer Database for a Marketing company.

To-date, he works in a local conglomorate in Malaysia. Being in the corporate office of a local conglomorate, he has exposed to entrepreneurial and financial aspect of the business. As an internal consultant and strategic partner for the last 6 years, his achievements include project managed Quality Initiatives with a property developer in Singapore and Insurance company in Malaysia. He also build Internal Improvement Capability for Strategy Execution, Cost Reduction Projects in several manufacturing companies. He has consulted and facilitated more than 20 improvement projects within the conglomorate.

He has over 35 years work and consulting experience in various industries like Processing, Manufacturing, Insurance, Banking, Education & Training and consulting with both local corporations and MNC.

He has worked for Ayer Hitam Tin Dredging, Kemaman Palm Oil Mill, Motorola, Applied Magnetics, OYL Group and held several positions like Sr. Facilities Engineer, Manager in Manufacturing, Business Planning, Quality Control and Business Unit Manager.

He welcome feedback from readers

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