Assignment Quality Essay

Submitted By ninnaaa
Words: 4663
Pages: 19

FACULTY OF ARTS, DESIGN & TECHNOLOGY

Programme:BEng Manufacturing and Production Engineering
Programme Code:J901
Module Code: 4ME512
Module Title: Quality and Reliability

ASSIGNMENT 1 & 2 – LEAN MANUFACTURING AND QUALITY TOOLS IMPLEMENTATION IN MOLD SOLUTIONS LIMITED

Submitted by: Ninna Mari Alves de Araujo
Student ID: 100312521

24 April 2014
Executive Summary Lean Manufacturing and Quality Tools are described and an implementation proposal is presented. The company of study is facing different problem and a consultant was recruited to overcome the issues It involves not only apply specific tools but also a cultural change.

Table of Content

Executive Summary 2
Table of Contents 3
List of Figures or illustrations 4
1. Introduction 5
2. Company Overview 6
3. Lean Manufacturing implementation 8
3.1 5Ss 8
3.2 Value Stream Map (VSM) 9
3.3 Single Minute Exchange of Die (SMED) 12
4. Quality tools and methods 13
4.1 PDCA 13
4.2 Seven basic quality tools 15
4.2.1 Ishikawa Diagram 16
4.2.2 Pareto Diagram 17
4.2.3 Control Chart 17
5. Analysis 18
6. Organizational Culture 20
7. Health and Safety practice 21
8. Conclusion 22
9. References 23
10. Bibliography 24
11. Appendices 25

List of Figures or illustration

Figure 1 - Overview of the problems the company is facing 6
Figure 2 - Comments and feedbacks from the workforce and their potential solution 6
Figure 3 - The seven wastes according to OHNO (1997) 8
Figure 4 - Before and after 5S implementation example [online] Available at: http://pt.kaizen.com/publicacoes/lean-innovation-news/file/kaizen-forum-nr-11/action/preview.html [Accessed: 23 Apr 2014] 9
Figure 5 - Example of VSM (current situation). ROTHER & SHOOK (1998) 10
Figure 6 - Typical process for Lean implementation (Rivera and Frank Chen, 2007) 11
Figure 7 - Implementation of the SMED methodology. Shingo (1985) 12
Figure 8 - PDCA explanation [online] Available at: http://www.cetcon.de/wps/fine/home/cetcon_en/focused_improvements/ [Accessed: 18 Apr 2014] 14
Figure 9 - Continuous quality improvement with PDCA [online] Available at: http://en.wikipedia.org/wiki/PDCA [Accessed: 18 Apr 2014] 14
Figure 10 - The 7 Basic Quality Tools 15
Figure 11 – Ishikawa Diagram to analyze the high scrap rate 16
Figure 12 – Pareto Diagram stratifying the causes of the problem 17
Figura 13 - Definition of Control Limits 18
Figure 14 - Key issue 1 and 2 18
Figure 15 - Key issue 3 19
Figure 16 - Key issue 4 19
Figure 17 - Key issue 5 and 6 19
Figure 18 - Key issue 7 19
Figure 19 - Key issue 8 19
Figure 20 - The 7 wastes of lean in detail [online] Available at: http://www.ibm.com/developerworks/bpm/bpmjournal/1308_col_schume/1308_schume.html [Accessed: 24 Apr 2014] 25
Figure 21 - Lean glossary to explain some expressions that were used in the analysis 25

1. Introduction
The pursuit for better management methods caused by the fierce competition in the business world induce companies to look for different tools to ensure a good internal organization, ethical relationships with their customers and partners, and superiority when compared with the competitors. This running for improvement can be called Quality Management and can be deeper explored through a good strategic planning, consolidated leaderships and procedures.
Quality, as a concept, evolved from fitness for standards to fitness to latent requirements (SHIBA et al, 1993). Naturally quality management has also evolved. It stopped to be primarily directed to the shop floor and began to involve all the process of the organisation.
According to the ISO 8402 definition, Quality is the totality of features of service or a product that bears its ability to meet implicit or explicit customer needs. The aim of a company is satisfy people needs: customers through the quality of the products, employees through personal development, shareholders over the company’s productivity and neighbours by social contribution.
This can be achieved practicing Total…