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Japanese Quality Tools - Coggle Diagram
Japanese Quality Tools
- Japanese Quality Concepts
- Activities not adding value, categorized as
- Type I: Non-value-added but seemingly essential.
- Type II: Non-value-added and can be eliminated immediately.
- Variation causing imbalance, leading to MURI and MUDA.
- Excessive stress on people, materials, or equipment.
- Inter-relationship of Concepts
- Imbalance (MURA) leads to overburden (MURI), causing waste (MUDA).
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5S Model
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Improved safety
foundation for continuous improvement
sense of ownership
reduction in waste
improved performance
TPS Management Practices
- Ensures production matches customer consumption.
- Avoids overproduction and underproduction.
- Helps gauge effort needed to meet demand.
- Fundamental to Toyota Production System.
- Ensures efficient work sequences.
- Repeated consistently to avoid waste and ensure safety.
- Includes Takt Time, Working Sequence, and Standard In-Process Stock.
- Work standards put into written forms: Capacity Sheet, Work Combination Sheet, Work Chart.
- Established on-site by those who follow it.
- Encourages continuous improvement by allowing adjustments.
- Jidoka (Automation with a Human Touch)
- Built-in judgment in machines.
- Stops production for quality issues, enabling problem visualization.
- Prevents defect passing, and allows quality building in the process.
- Employs principles: detect problems, stop, fix, and prevent recurrence.
- Empowers one operator to control multiple machines.
- Encourages mistake-proofing (Poka-Yoke).
- Philosophy for waste elimination and productivity improvement.
- Produces the right part, at the right time, in the needed amount.
- Built on Pull System, Continuous Flow Processing, and Takt time.
- Visual signaling system for needed activities.
- Supports JIT by indicating used parts for replenishment.
- Inspired by the supermarket stocking system for efficiency.
- Encourages balanced production and avoidance of excess parts.
- Heijunka (Production Leveling)
- Reduces waste by smoothing production fluctuations.
- Adopts flexible production to accommodate demand variability.
- Levels production by mixing models in small batches for efficiency.
- Quick changeovers for flexibility.
- Utilizes Heijunka box for visual production control, aiding in job queuing and scheduling.