Applying the Lean Quality Theory in the Modern Organizational Environment

Total Quality Management is a process that strives for complete satisfaction internally and externally. There are two popular methods used in today’s organizations, The Toyota Production System and the Six Sigma model. Toyota created its management system over the course of three decades. It is also known as lean manufacturing, which is in regards to limiting the amount of waste produced. This is not just physical waste but includes the management of time throughout the process, for example time waiting, conveyance,

Project Quality Management| -Cost Benefit Analysis -Cost of Quality -Control Charts -Benchmarking -Design of Experiments -Statistical Sampling -Flowcharting -Proprietary quality manage- ment methodologies -Additional quality planning tools (Brainstorming, Affinity Diagrams, Nominal Group Technique)| -Cost benefit: Looking at how much your quality activities will cost. -Benchmarking: means using the results of quality planning on other projects to set goals for your own. -Design of experiments: is the list of all the kinds of tests you are going to run on your product. -Total Quality Management (TQM): Everyone in the company is responsible for quality and is able to make a difference -Continuous Improvement (Kaizen): constant process improvement in the form of small changes -Just-In-Time(JIT) -ISO 9000: Companies document what they do and they do what they document

The implementation of lean operations is one the most popular ways to improve efficiency and productivity in operations. This strategy has afforded many businesses the opportunities to streamline processes that resulted in improved systems and efficiency. However, many businesses face obstacles with implementing lean practices for various reasons such as unclear directions, employees that are resistant to change, and poor planning. Businesses that encounter issues with lean implementation must identify performance metrics to improve operational strategies. This paper will examine the obstacles businesses experience with lean implementation.

The Lean Six Sigma looks for ways on how to eliminate defects. In healthcare, a defect can be the difference between life and death. The Lean Six Sigma is used to improve patient safety by eliminating life-threatening errors. Lean Six Sigma uses a five-step approach to process improvement called the Define-Measure-Analyze-Improve-Control (DMAIC). The DMAIC is an approach that is a data-driven quality strategy used to improve processes (ASQ, n.d.). The first phase, the define phase, is where the leaders would define the problem and begin to understand the needs of the customers. This is an important phase of the Lean Six Sigma because this is where the team would outline of their efforts for themselves and the leaders of the organization (goLEANSIXSIGMA.com,

Having in mind what Lean is not, and acknowledging that Lean is about eliminating waste and constant improvement, there are few core principles of the

Since the lean operation and the total quality management model are based on a highly technical approach, toolsets and qualitative analysis, hence sufficient training in leadership, functional and technical skill will be mandatory for the employees in every category, including the operation, functional and business area to ensure a successful operation and to communicate and maintain proper control in the process. The Company will follow the agile manufacturing practice which comprises a set of quality standards, practices and iterative testing process driven by the end user feedback method to deliver a high quality customizable product that fits the exact need for a specific market segment and keep constant focus to reduce production overheads and eliminate any unnecessary steps in the process engineering that could potentially increase the cost and the delivery timing (Schnaars,

Goal: Reduce product variance and the need for rework by implementing a company-wide quality control system that includes an element of Statistical Process Control. A secondary goal is to reduce waste by focusing on Lean

Six Sigma, Lean, and Kaizen are all strategies that hold their roots in business for the positive improvement of functions for particular entities. These strategies are unique in their global applicability and specific processes and yet similar with regard to the manner in which they are structured. They can be applied to improve processes for anything from large scale manufacturing to something as simple as gardening. The purpose of this paper is to introduce these individual strategies and then illustrate the similarities and differences among them.

Later on, many service industries have adopted the philosophy of Lean with the aim of improving their quality of service, processes, methods and resulting a better customer satisfaction. The study made revealed that although the Lean Manufacturing was designed and developed for the manufacturing industries initially, it is now proven that even the service industries could implement the Lean principles as well, and increasing the customer satisfaction.

Lean thinking is an organizational change method that is also implemented with the objective of increasing profit. Lean thinking originated in Japan, and is best exemplified by the Toyota Production System. Constraints placed on the Japanese manufacturing industry after the second world war lead Taiichi Ohno of Toyota to pioneer a new type of production system that was so different, and so much better, than mass production, as to warrant a new type manufacturing. Lean production is a method of organizing production using half the effort, space, inventory, and product development time compared with mass production. It also achieves fewer defects, and larger product variety. These improvements should result in increased sales, which is the key to re-deploying freed-up resources. Lean thinking codified and expanded upon the Toyota Production System to include non-manufacturing organizations, as well as product development efforts.

This essay is going to analyze a case study based on lean thinking principles and techniques. It is could divide in four significant parts. First, to outline the definitions of Lean manufacturing philosophy and applied the strategies to achieving, next create future state Value Stream Map, Furthermore justification Lean Six Sigma tools and techniques, which would appropriate, and critically discussed the key successful should his idea to the Evenort Company.

However, Chase et al (1998) identified lean themes as total visibility; respect for people; flexibility; continuous improvement (kaizen); synchronisation and balance; responsibility for the environment and a holistic approach. These two are similar as one must have respect for people while specifying value by putting their needs into consideration, the value stream needs to be identified and made to flow continuously and this can be achieved through synchronisation and balancing, the pull system depicts the flexibility approach and lastly both emphasize continuous improvement.

Total quality management focuses on several aspects such as Continuous improvement and the Customers to improve the quality of the products. Ford Company has in place a strong set of values, norms, and artifacts which it strongly enforces. The mission statement for the company is based on a simple phrase, “One Ford: One team, one plan, one goal.” The company vision is, “To become the world’s leading consumer company for automotive products and services.” (Haas-kotzegger, Schlegelmilch, & Ambos, 2013) Both these company philosophies give the company a good favor towards the consumers.

More and more companies have implemented quality management in their operations. According to isixsigma.com, many international organizations have implemented total quality management (TQM) such as Toyota Motor, Motorola, Ford Motor, and Philip semiconductor. TQM which is a strategy aimed at embedding awareness of quality in all organizational process (wikipedia) began in the 1950’s and it has become widely known in 1980’s. Also, Six Sigma was originated from Motorola in 1986. Its purpose is to “identify and remove the causes of defects and errors in manufacturing and business processes. It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the

Our company should make sure that manufacturers deliver products with the highest design specification, in order to be order-winner quality conformance, by delivering products with no defects (Hill and Hill, 2012). Furthermore, improvements in quality lead to a decrease in cost for the company. According to (Evans, 1997) higher quality products lead to a decrease in costs for the company through higher productivity: ‘improvements in quality leads to lower cost because of less re-work, fewer mistakes, fewer delays and snags’ (Evans 1997, P.55).