The tools of continuous improvement

Quality no matter the system, relies on the dynamic PDCA cycle:
The first step entails Planning followed by Doing then Checking control which leads to a decision for Action, with the choice of a new objective, strategy, etc...

A new phase is then planned and the cycle continues.

SMED is a method which seeks to systematically reduce the changing time between series with a quantified objective.
Single Minute Exchange of Die = A change of tools in under 10 minutes.
Single Minute means that the time needed for a change, counted in minutes should consist of one digit.

There are four steps for achieving SMED:
1. Suppress useless operations, convert IS operations into ES
2. Simplify fittings and tightening
3. Work together
4. Eliminate tests and adjustments. Reduction of "Machine Idle" tasks.

HOSHIN management has three objectives:
- Direct measures to focus all the company staff in direction of the same key objectives
- Orientation of all functions and tasks (daily work or work which co-ordinates efforts and resources)
- It aims to adapt quickly the company activities and objectives to rapid changes within the company and the environment

This is based on the principle that all losses mean potential gains. So eliminating losses means gain. There is no real improvement in productivity or quality unless there is the elimination of waste.
Seven types of waste:
1 - Waste from overproduction
2 - Waste from waiting times
3 - Waste attributable to transport
4 - Waste attributable to useless stock
5 - Waste in manufacturing processes
6 - Useless movements
7 - Waste due to faulty parts

This entails the precise dimensioning and control of stock and production based on real and forecast consumption.

At each step of the process, as soon as the customer consumes the products, production is launched for the exact quantity corresponding with that very consumption so as to replace the stock and maintain it at the chosen level.
Follow-up is ensured with badges which correspond to the quantities produced, implemented on visual tables.

La méthode QRQC (Quick Reponse Quality Control) est une démarche qualité visant la résolution rapide (3 jours maxi) des problèmes de non-qualité. Elle est destinée à combler les temps de latence entre l’identification d’un problème et son traitement par les systèmes de management de la qualité classiques, ainsi qu’à réduire le coût des actions correctives, en insistant sur une solution simple et immédiate.
La démarche s’appuie sur la philosophie japonaise du San-gen-shugi (« les trois réels ») :
Gen-jutsu : la réalité (collecter et examiner des données réelles et par une synthèse périodique)
Gen-ba : le lieu réel (aller dans l’atelier ou les bureaux discuter avec le personnel)
Gen-butsu : les choses réelles (examiner les pièces ou les produits défectueux)
Il ne s’agit pas d’un outil, mais d’un état d’esprit « terrain » et « proximité » : le personnel de production résout lui-même rapidement et quotidiennement les problèmes de non-qualité.

A large number of accidents could be avoided with an effective prevention policy, respect for rules and personnel awareness. Nine basic rules may protect your team:
1 - Display all information regarding safety
2 - Get each person involved in formulating and applying the safety rules
3 - Set up a "near accident" and "minor incident" book in which observations and experiences may be entered
4 - Take every opportunity to remind staff
5 - Be doubly vigilant with temporary staff who are particularly exposed
6 - Notify management by communicating all the necessary information
7 - Promote the role of the safety manager
8 - Set the example
9 - Create a climate of trust which will facilitate exchanges (listen, convince, avoid sanctions...)

The institution of environmental management enables companies to minimise the impact of their activities on the environment, prevent incidents and establish an action plan to improve their environmental performance.
Why sort waste?
- In accordance with legislation (law of 15 July 1975, decree 94-609 of 13 July 1994)
- To fight against wastage in the professional environment
- To create the image of an environmentally-friendly company living up to its citizen responsibilities
- Recycle your waste.