QRQC

Quick Response Quality Control

The QRQC can bee seen seen as a general management attitude to solve any kind of problem at the place where it occurs. Closely related to Gemba Walks. With QRQC the main focus relies on the so called “Three Reals”. The three reals aims to guide you firstly to think about the real place and real time (Gemba - or originally “gen-ba”), the real part (“gen-butsu”) and to have a focus on the reality (“gen-jitsu”)

Having a functioning QRQC systematic installed supports the greater target of smooth production by:

• Decrease of Cost for Quality

• Decrease of Scrap Rate

• Decrease Cost of Product

• Less line Stops

• Quick Response on customer Quality Claims

• Increasing the Quality Level in general

• Increasing the turnover of inventory

• Increase of throughput

As with all Lean or Operational Excellence activities you will need the support of coaches and management level. Implementing a standardized procedure on how to react on customer claims and internal failure rates needs C-Level support to promote and to walk the talk. The baseline of problem solving is and always will be the discipline to follow the complete structure and process of standardized problem solving.

Important as the problem solving itself, is in the end the transparency and promotion of solutions as well as clear communication and sharing of the gained knowledge through Shop Floor QRQC initiatives to be seen by the whole organization. Best way to do so is visualizing important information of the closed issues, such on Shop Floor Boards or at work stations themself.

MUDA

MUDA – Also see Timwood

In this article we want to talk about MUDA or the 7 kinds of waste known as TIMWOOD.

The seven kinds of waste have to be discovered and eliminated in daily operations. Therefore we will be looking at the 7 kinds of waste and learn how to use appropriate lean tools to reduce these non value-adding activities.

First of all use Gemba Walks to find out more about whats happening on the shop floor. Only through the on-site inspection you can see what is really going on. It is simply not possible to record the types of waste in the conference room at the green table. The CIP Kaizen action on site is always necessary to reduce waste.

When talking about production the ultimate goal is to increase value-creating activities in the complete organization and not to reduce them. Therefore non-value-adding activities are called MUDA - Japanese for wasteful.

Overview of the 7 kinds of waste and the lean approach to avoid these

The individual parts of muda are easily remembered with a simple mnemonic aid called TIMWOOD. TIMWOOD stands for the first letters of the several kinds of waste. Lets have a look at those and some hints what it means:

T = Transport

• Material flow

• Product-/Value-/Process orientation

• Just in Time material supply of workstations

• Pull steering of production with the Kanban principle

I = Inventory

• Just in Time or Just in Sequence material supply

• Pull steering of production with the Kanban principle

• Takt time

• Linking suppliers

• Reduction of batch sizes or production lots

• Implementation of One Piece Flow principle

 M = Motion

• 6 S principle   

• Standardization

• Fixed allocated spaces

• Shortest ways

 W = Waiting

• Multi machining

• Multi process handling

• Material flow in U-shaped manufacturing lines

• Implementation of SMED

• Installation of Andon Boards

 O = Overproduction     

• Leveling of manufacturing orders

• Mixed-Model-Production

• One-Piece-Flow

 O = Overprocessing/-engineering  

• Processes are not necessary

• Kaizen activities

• Quality circle

• Idea Management

• Reduction of complexity

• Reduction of components needed

• Reduction of unnecessary process steps

• Reduction of hand overs and quality loops

D = Defects

• Reduction of scrap rate or rework

• Internal customer supplier management

• Self-inspection

• Poka Yoke principle

• Automation

• Zero Defects principle

• Stop the line authority

• 5S activities as part of the standard work

• Visual Management and visual aids

S = Unutilized Staff

• Idea Mgt.

• Shop Floor Mgt.

• Lean Innovation

Each of the individual elements of the 7 kinds of waste often interact with each other. If you think about your organization as a system, it is necessary to classify not only one characteristics. An approach can only be derived when several classifications of waste have been analyzed.

The 3 MUDA expressions

With the individual process sections and activities and the corresponding 7 kinds of waste, they can be divided into the following activities:

Value Adding Activities 

Kanji Muda - Waste in terms of machinery and equipment

Hiragana Muda - Work that needs to be done in order to fulfill the task but not really add value

Katakana Muda - Everything not needed

All this combined is your total workflow

As seen in real life up to 75% of non-optimized processes are non-value-adding activities which means they are pure waste and eat up your resources. Therefore it always makes sense to eliminate each of the 7 kinds of waste in order to increase productivity. To get an idea see the following picture:

Katakana Muda (red - waste that can be eliminated immediately)

• Waiting

• Searching

• Filling

• Double work

• Stacking of components

Kanji Muda (gray and yellow - waste based on machines and equipment)

• Machinery movement without any function

• Oversized machines that can produce more than the required parts during the cycle time

Hiragan muda (green - work that is necessary for the provision of services under the current conditions; value-adding process steps)

• Return to starting position

• Cleaning

• Tightening

• Manual operation of machines

So how to recognize and eliminate the 7 kinds of waste?

Muda can always only be detected at the place of action. Therefore Gemba Walks are the best way to go on the search. But one thing has to be clear - it does not have to be always big projects to reduce waste. Continuous Improvement is key - recurring CIP or Kaizen activities are very supportive to develop an eye for the 7 kinds of waste. Training makes masters.

Second - it doesn’t has to be expensive. Most actions can be implemented at low cost. E.g. make a spaghetti plot to visualize and recognize obvious unnecessary movements.

Third - always have an eye on the value-adding activities. With a trained eye from GEMBA WALKS you will have improved awareness of waste already in the planing phase of new processes. Use those lessons learned and avoid waste in the beginning.

We don’t want to go into details but there are two other types of losses that can be witnessed in an organization. Mura meaning deviation and muri meaning overload (man, machine, material equally). If you want to read more about these, have a look here.  

Let us come to an end - even when it is hard, we could keep going on and on…

But some rules:

1. No excuses!

2. Be creative in first place - money always comes second

3. Never try to explain why something doesn't work, try how it works!

4. Adjustments kills your time and ambitions. Adjustment means to fight the symptoms not the root cause!

5. Do not worry about problems that do not yet exist.

Happy Improving!

GEMBA WALK

If you’re familiar with lean and you try to talk about it with others it is most of the time reduced on eliminating the 7 types of waste and people are feeling great when they know what TIMWOOD stands for. Don’t get me wrong it is great to have some knowledge and visibility out there but the downside is that it often leads to a quick end on taking action.

The key of lean is to fulfill the customer’s expectations and not reduce overproduction or WIP and all this by solving specific operational problems. The 7 kinds of waste are only the visible downside of weak or bad processes. They are only the symptoms but not the root cause.

This is always the tricky part in lean management. While it is mostly easy to identify waste it gets harder on seeing the root cause of waste in the process.

Lean is about learning to see!

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Read more in our reading picks here.

But let’s get to the Gemba Walk Trail

To get used to standardized problem solving in the first step is to go to the place of action. You can discuss problems as much as you want but when you don’t get yourself to see it, it is worthless. This is where the Gemba Walk comes in the game. Gemba is a Japanese Term (well surprise in the lean world) and stands for the place where it actually happens. This can be everywhere and everything in the process chain, starting from typing in customer orders over work stations on the shop floor where you actually add value on something to the fulfillment process in your outbound warehouse.

Key of Gemba is not to talk in wild theories or totally abstract about problems, but to have a look where it occurs and discuss them on site (looking at the process in the real world, get rid of unnecessary power points and excel sheets! Nobody cares anyway!) Too often we want to believe the statement of a “pro” and forget about it instead of going there and have a look ourselves to gain a better understanding of the problem and make up our own opinion. 

But above the pure problem solving it is about continuous improvement and the never ending journey of learning.

The question that might raise now is: What do I have to look for?

For this more rhetorical question are countless answers. Just google Gemba in the WWW and you will find plenty of sources and recommendations on where to start and what to look for. Some points that are always included are:

1. What is our standard? What should be and what is?

2. Can the person doing the job explain me the standard?

3. What is the person doing and what is he/she doing deviating from the standard to make it easier?

4. Why do have a deviation?

5. Do we need more material in the process?

6. Do we need less machinery in the process?

7. Can we do it with less resources?

8. Are there waiting times?

9. Do we have defective parts coming in or out the process?

10. Are we producing defective goods?

11. How can we identify defects?

12. Are all documents up to date?

13. What indicators are used/observed and how are they visualized?

14. And so on…

As you can see, there is a countless number of questions you can ask yourself and your employees during a Gemba Walk. Each of these questions is correct, important and have a right to be asked. But don’t even think about creating an audit checklist and ask always the same.

To bring it together

Stop thinking upfront what you want to achieve with a Gemba Walk, like improving a specified process, think about Gemba Walks in first place to gain a better understanding of the process flow and start from there making your way down to the root cause of problems in the process. As already mentioned this narrows it down to three simple questions:

1. What should happen?

2. What is happening?

3. Explain why!

Finally – use the chance during Gemba Walks and try to find improvements for visualization at the process. Even if you are not conducting a Gemba Walk – when you’re passing by and clearly see that something is wrong you have the chance to go straight in.

In the end it is all about time and we all know time is money.