Applying the Lean Concept in Quality Management Systems

LUV-d-4UM

Quite Involved in Discussions
#1
Recently, I met with the Top Management of our organization. The meeting yielded a possible suggestion from her that I infuse the quality management system with some new life in the form of streamlining the management system so that the supply point will always be ready for ISO/TS and Customer Specific audits-OEM or non-OEM. How do I apply the LEAN principle in the management of these different quality systems. Your feedbacks are highly appreciated
 
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RoxaneB

Super Moderator
Super Moderator
#2
Re: Lean concept in Quality Management System

Recently, I met with the Top Management of our organization. The meeting yielded a possible suggestion from her that I infuse the quality management system with some new life in the form of streamlining the management system so that the supply point will always be ready for ISO/TS and Customer Specific audits-OEM or non-OEM. How do I apply the LEAN principle in the management of these different quality systems. Your feedbacks are highly appreciated
Why do you feel that the tools associated with Lean manufacturing are different than those used by quality management sytems?

If anything, I think there is a strong relationship between the two...especially when one replaces the word 'quality' with the word 'business'. Forget the idea of having a quality management system...and a safety management system...and an environmental management system. Have a Business Management System...a BMS that is the core of what your organization does for all things in all ways...it is your culture, your tools, your business "bible" on how you conduct business.

However, getting back to your actual question...as part of your QMS, have you developed process maps or work instructions outlining the activities that your organization does?

Are they effective? Are they efficient? How do you know? Do you have build-up of inventory along the manufacturing line? What about using Kaizen events as a means to demonstrate continual improvement? What about using 5S as a means to show preventive action or even a way to assist in controlling the production line?
 
#3
Re: Lean concept in Quality Management System

Recently, I met with the Top Management of our organization. The meeting yielded a possible suggestion from her that I infuse the quality management system with some new life in the form of streamlining the management system so that the supply point will always be ready for ISO/TS and Customer Specific audits-OEM or non-OEM. How do I apply the LEAN principle in the management of these different quality systems. Your feedbacks are highly appreciated
What a great opportunity! I've be positively excited at the chance to do this!

An obvious place (to me) to start this is taking a look at value stream mapping. If you look at what the process and procedures say compared to the actual practice, using the eyes of a Lean practitioner, you'll see that there's a huge difference! Also, taking examples of processing forms - like purchasing requisitions -if you apply one piece flow etc an look for little 'holding areas' for these forms, you'll often find that the process isn't clear, the form doesn't have all the info etc., so a small 'inventory' of WIP appears - all indicate a problem with the process!
 

Bev D

Heretical Statistician
Staff member
Super Moderator
#4
Re: Lean concept in Quality Management System

Think of the eight wastes. How can you reduce them?

There are 3 ways the QMS can 'be lean'.
  1. Reduce the non value add processes and steps within quality and the QMS processes. Reduce bureaucracy.
  2. Support lean initiatives within the organization. Actively participate and take suggestions from the org on how best to lean quality owned processes
  3. Actively promote lean within the organization through quality objectives and quality led initiatives and projects.

Mike Mickelwright has a decent book on leaning your QMS I strongly recommend it as a starting point for number 1.
 

LUV-d-4UM

Quite Involved in Discussions
#6
Re: Lean concept in Quality Management System

Thank you for supporting this light bulb. I will update you all with this project going forward.
 

LUV-d-4UM

Quite Involved in Discussions
#7
Re: Lean concept in Quality Management System

Thank you. I need all the resource I can gather before the proposal. I will call it TOTAL QUALITY MANAGEMENT SYSTEM-101.
 
S

Sturmkind

#8
Re: Lean concept in Quality Management System

AndyN had a great observation about WIP in paperwork. I did a process flow map of a relatively small gear manufacturing site beginning from first customer contact wanting product through shipment and, if the post-it note WIP was included, the part number alone was written out 41 times.

At the conclusion of a 3 month cross-functional effort, this was reduced to 12.

Best of luck with your effort!
 
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