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Challengers Group Members Name: Masroor Ali Soomro Zeeshan Ali Khan Ahmed Hussian Siddiqui Arslan Ahemd Sonia Kumari Sarika
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ChallengersGroup Members Name: Masroor Ali Soomro Zeeshan Ali Khan Ahmed Hussian Siddiqui Arslan Ahemd Sonia Kumari Sarika

Major Areas To be coveredJidoka Poka - Yoke Kaizen Event / Kaizen Blitz (sm) MUDA MURA MURI 5 Why? Heijunka 5S Sort, Simplify, Scrub, Standardize, Sustain

Key Concepts of Supply Chain Management

Automation with a human touch Practice of stopping a manual line or process when

something goes amiss Quality built-in to the process

Key Concepts of Supply Chain Management

Key Concepts of Supply Chain Management

Jidoka helps to detect a problem earlier and avoids the

spread of bad practices.

Jidoka results in high-quality products and makes

improvement in productivity.

Jidoka is sometimes called autonomation, meaning

automation with human intelligence .

Key Concepts of Supply Chain Management

When a machine breaks down or when defective parts

are produced). This auto-nomation (as it is also called) allows machines to run autonomously, as they will stop when a problem occurs. Ultimately, it is about transferring human (or better) intelligence to machines. Textile Industries KESC Bank Alarms/Fire Alarms Alerts

The phrase poka-yoke originates from the Japanese word:

Yokeru oka

= to avoid Poka-Yoke = inadvertent errors

It is a methodology that is used to strive toward zero defects by either preventing or automatically detecting defects.

Key Concepts of Supply Chain Management

Key Concepts of Supply Chain Management

Machine have limit switches connected to a warning

light that tell operators when parts are positioned improperly on the machine. Fast food restaurants use automated french-frying machine that be operated one way ; the French fries are prepackaged and automated to reduce the chance of human error. Electronics Industries Car Manufacturing Industries

Key Concepts of Supply Chain Management

Basically Poka yoke is same as the Six Sigma Concept :Bill Smith first formulated the particulars of the methodology at Motorola in 1986.

Six Sigma is a business management strategy originally developed by Motorola, USA in 1981. Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes. A six-sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defects per million).

Key Concepts of Supply Chain Management

Kaizen is the name given by the Japanese to

continuous improvement. Continuous improvement really means continuous incremental improvement. Kai = change Zen = good Kaizen means making changes for the better on a

continual, never-ending basis.

Kaizen refers to improvement of both processes and

people. In fact Kaizen philosophy aims at improving all aspects

of an organization all the time. Good is never good enough; kaizen is a never-ending

journey to excellence.Key Concepts of Supply Chain Management

Key Concepts of Supply Chain Management

Toyota production system known for kaizen, where all

line personnel are expected to their moving production line in case of any abnormality and, along with their supervisor, suggest an improvement to resolve the abnormality which may initiate a kaizen. Microsoft Google Wikipedia Rolls-Royce Ferrari Ford

Muda is a traditional Japanese term for an activity that

is wasteful and does not add value or is unproductive. Any element of processing or distribution that add no

value to the final product(services)-waste only adds cost time and (frustration).

Key Concepts of Supply Chain Management

Overproduction ; Printing paperwork (that might change) before it is needed. Processing an

order (that might change) before it is needed. Any processing that is done on a routine schedule - regardless of current demand.

Inventories ; purchasing or making things before they are needed (think office supplies,

literature...). Things waiting in an (electronic or physical) In Box. Unread email. Any form of batch processing (e.g. transactions, reports...)

Packaging

Key Concepts of Supply Chain Management

Mura is a traditional Japanese term for unevenness,

inconsistency in physical matter or human spiritual condition. Strive to reduce variation/fluctuation to a bare

minimum.

Key Concepts of Supply Chain Management

Key Concepts of Supply Chain Management

Mura in its simplest form means unevenness. For

example, Mura results when your operators are told to work like crazy early in the morning only to stand around and do nothing late in the day. Office Clerical Staff To work like donkeys first without forecasting demand and later become lazy (like Rabbit and Turtle) Mura is the unevenness or fluctuation of the schedule. Variability So, in the example Mura is looking at the imbalance in the assigned task.

Muri, made up of the ideograms representing

none + logic , literally means unreasonable, or overburden/overdoing. Muri is about being smooth, and doing things the

logical way.

Key Concepts of Supply Chain Management

Key Concepts of Supply Chain Management

Muri means to overburden equipment or operators.

For example, if your entertainment center is only meant to hold 200 pounds and you place your new 425 pound super duper HD Ready TV on it we have muri. We also have other issues like a very real safety

concern! Muri is the overburdening of your people or equipment. So, in the example muri is looking at demanding that a forklift carry X+ weight when it is rated to carry X weight.

Key Concepts of Supply Chain Management

The Five Whys is a question asking method used to

explore the cause/effect relationships underlying a particular problem. to determine a root cause of a defect or problem

Ultimately, the goal of applying the 5 Whys method is This technique explores deeper and deeper levels until

one gets to a level where proactive counter-measures can be applied.

Key Concepts of Supply Chain Management

A typical Example on www.wikipedia.org The car does not start. Why? - The battery is dead Why? - The alternator is not functioning Why? - The alternator belt has broken Why? - The alternator belt was well beyond its useful

service life and has never been replaced Why? - I have not been maintaining my car according to the recommended service schedule

Key Concepts of Supply Chain Management

Q1. Why is our client, Hinson Corp., unhappy? Ans: Because we did not deliver our services when we said we would. Q 2. Why were we unable to meet the agreed-upon timeline or schedule for delivery? Ans: The job took much longer than we thought it would. Q3. Why did it take so much longer? Ans: Because we underestimated the complexity of the job. Q4. Why did we underestimate the complexity of the job? Ans: Because we made a quick estimate of the time needed to complete it, and did not list the individual stages needed to complete the project. Q5. Why didn't we do this? Ans: Because we were running behind on other projects. We clearly need to review our time estimation and specification procedures.

Key Concepts of Supply Chain Management

Source: http://www.velaction.com/lean-information/wp-content/uploads/2009/02/5-whys-lean-manufacturing-example.jpg

Key Concepts of Supply Chain Management

Heijunka is a workaround for uneven demand. It is

the bridge between how customers order and how a Lean company operates.

The distribution of production volume and mix

evenly over time

Heijunka converts uneven Customer Pull into even

and predictable manufacturing process.

For example, weekly demand over a 3 week period

might be 200, 218, 197-fairly close. The Monday demand for those same three weeks could be 37, 61, 47-not quite as stable. And day-to-day demand might fluctuate even more wildly-Wednesdays might be the day that three of your biggest customers all place their orders (hey, not everyone is lean, right?).

Key Concepts of Supply Chain Management

Key Concepts of Supply Chain Management

Sort : All unneeded tolls, parts and supplies are removed from

the area.

Set in Order : A place for everything and everything is in its

place.

Shine :The area is cleaned as the work is performed. Standardize : Cleaning and identification methods are

consistently applied.

Sustain : 5s is a habit and is continually improved.

Source:http:// www.Strategosinc.com, Consultants , Engineers, Strategists

Key Concepts of Supply Chain Management