Improvement of Lean methodology with FMEA - POMS

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Management goals and policy Lean thinking plan Training Scheduling Teaming up Project definition Value determination Setting the borders Sketching value stream Considering customer point of view Design of present condition Design of desirable condition What must be changed Must be changed into what Muda identificati on Planning for Muda elimination How must be changed Yield Problem solving Establishing the streams Pull processing Continuous improvement and perfection Feedback Figure 3: lean manufacturing process 4. Comparing lean manufacturing and FMEA Considering the specifications and characteristics of FMEA and Lean manufacturing (lean thinking), these two techniques has been compared and the results are in table 1.
Table 1: comparing lean thinking and FMEA No Lean FMEA 1 History 1950's – Toyota Co. Aerospace industry – 1950's 2 3 4 5 Aim methodology Focus on theory Establishing value stream – eliminating Muda's and waste – maximizing value stream – flexibility in operations Semi structured VVFPP – identifying waste resources and then eliminating them Muda identification and elimination – costumer value stream – job standardization – waste identification and elimination Waste elimination Decrease in costs – increase in reliability – costumer satisfaction – increase in market share Failure mode and effects analysis Identifying potential failure modes and their effects Failure prevention 6 7 8 9 10 11 12 Operational area Key success factors Tools and key techniques What are the benefits? Hypothesis Concept of value Required infrastructure Production system – quality – human resources – repair and maintenance – engineering Planning – contribution of senior management – team work – Lean principles training - less setup and installation time – less production cycle – less waste – less breakdown – layout optimization – continuous improvement ( Kaizen )- 5S – pull systems – cellular manufacturing – persistent test – statistical tools ( poka yoke ) – visual management Savings due to less Muda – less wastes and less doing over Eliminating wastes will lead to better operation – lots of small changes is better than a few big analysis Principles for improving the process / Muda and waste resources removal Senior management support / standardization of operations / communication system / team work / problem solving process ( Process – design – system – service ) – system – sub system - Team work – team skill – exact implementation of suggestions Tree diagram – quality engineering – risk priority number – market studies – QFD techniques - test More safety – faster introduction to market – improvement of organization image – less deficiency costs – controllability - propagation of team work culture in company If less resources are dedicated to FMEA ,cost is reduced – if the defects aren’t comprehended , costumer satisfaction will be less Principles for improving the equipment accuracy ( faultless equipment ) Training / customers and interested parties communication system / team members specialized skills
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Improvement of Lean methodology with FMEA - POMS

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