Some useful methodologies and tools

Error-proofing (“Poka-yoke”)

  • Aims to avoid human (and other) errors

Quality Improvement Teams

  • Small teams (usually Inter-functional)
  • Aim is to solve specific problems; then disband

Theory of Constraints

  • Looks at causes of “bottlenecks” that can result in productivity losses

Quality Control Circles

  • Ongoing small teams (usually at operational level)
  • Can be used for problem-solving or process improvement activities

Improvement Methodologies

  • Systematic Problem Solving (“QC Story”)
  • Developed by JUSE (Japan Union of Scientists and Engineers)
  • Problem-solving effort unfolds as a story from discovery of the problem to the search for a solution and planning for the future.
  • Sometimes referred to as “7D” or “8D” methodology (Auto industry)
  • Small-step continual improvement (“Kaizen”)
  • Breakthrough Improvement (“Process Reengineering”)
  • Innovation – New ISO standard under development (ISO 50501)

Suggestions Plans

  • Can be motivational and provide ideas for improvement (if properly managed and resourced)

Benchmarking

  • Helps identify “best-in-class” performance
  • Can be useful to look outside the organization’s own business sector

Just-in-time Inventories (“KANBAN”)

  • Helps reduce work in progress
  • Reduces working capital and improves cash-flow