Problem Solving: Plan-Do-Check-Act

Description:

This tool provides guidelines for using the Plan-Do-Check-Act approach and the steps to engage in the process.

How it can be used:

Effective problem-solving requires planning, testing, reviewing and refining a solution. The Plan-Do Check-Act (PDCA) cycle is a tool that provides a structured process to approach problem solving. Follow the steps below when you need a problem-solving approach that requires a methodical yet iterative process. Just as a circle has no end, the PDCA cycle should be repeated again and again for continuous improvement.

Benefits of using PDCA:

• To identify new solutions and improvements to processes that are frequently repeated

• To explore potential solutions to problems and make improvements using a controlled approach before selecting one for full implementation

• To avoid wasting resources due to full implementation of an ineffective solution When to use PDCA:

• As a model for continuous improvement

• When developing a new or improved design of a process, product or service

• When defining a repetitive work process

• When planning data collection to verify and prioritize issues The four phases in the Plan Do-Check-Act Cycle are:

1. Plan:

• Identify the problem

• Analyze the problem

• Map the process that is at the root of the problem

• Gather information required to identify a solution

2. Do:

• Generate several possible solutions

• Select the best potential solution

• Test a potential solution using a small-scale approach such as a pilot project or test trial

*Note that the ‘Do’ phase refers to ‘Try’ or ‘Test’. Implementation happens in the ‘Act’ phase.

3. Check:

• Measure the effectiveness of the pilot project or trial

• Identify what was learned

• Analyze whether and how it could be improved

• Depending on how successful the pilot project or trial was, the number of areas for improvement, and the scope of the initiative, consider repeating the ‘Do’ and ‘Check’ phases incorporating the additional improvements

• Once you confirm that the costs of repeating the ‘Do-Check’ sub-cycle further would outweigh any additional benefits, move onto the ‘Act’ phase

4. Act:

• Implement the improved solution

• Continue measuring to ensure the solution is working

• Loop back to the ‘Plan’ phase and seek further areas for improvement

Some examples of the types of activities during each phase are:

Lean Manufacturing - Definition - Concepts - Examples

 

What is Lean Manufacturing?

→ It is all about optimizing processes and eliminating waste and we will become more efficient.

→ This is a Japanese concept and in this concept, we have to find waste in our process and cut it out and the process will become lean.

→ It is a systematic approach to identifying and eliminating waste through continuous improvement in our process.

→ It is a methodology that focuses on minimizing waste within production systems and simultaneously it maximizes productivity.

→ This kind of production of goods using less of everything as compared to traditional mass production like less waste, less human effort, less manufacturing space, less investment in tools, less inventory, less engineering time to develop a new product, etc.

History:

History of Lean Manufacturing 

Goals of Lean Production:

→ Cost Reduction

→ Creating Conditions for Improving Product Quality

→ Quality First Time Through

→ Customer Satisfaction

→ Building In Quality at Each Stage

→ The Added Value of Repairs

→ Motivate all workers towards continuous improvement

→ Streamline or smooth operation flow etc....

8 Wastes of Lean:

[1] Transportation:

→ Transportation is the movement of goods from one location to another in the case of production or it also refers to information flow in case of service.

→ In manufacturing, unnecessary transportation during product assembly is a waste.

→ In easy language, we can say that performing different tasks in different locations.

→ For example, we are producing child parts in China and shipping them to India to assemble.

→ This process doesn’t add value to the end product, it doesn’t change the end result and it adds more cost.

→ If we take an example of Toyota, Tata, Ford’s manufacturing setup, many of their

suppliers are near their production plants.

[2] Inventory:

→ If our finished goods are not moving as per the forecast then it is called inventory waste.

→ Inventory has is a physical cost while the overproduction is assumed waste based on the forecast.

[3] Motion:

→ It is the unnecessary movement of people, machines, or items that do not add value in the final product and it decreases productivity.

→ Motion waste is usually caused by not following the 5S Methodology.

→ Some examples are employees looking for materials or equipment, poorly designed workspaces, SOP not defined for the process of operation, etc.

[4] Waiting:

→ Waiting is any type of delays in information flow or material flow which leads to decrease efficiency and increases the manufacturing or operation cost.

→ Some examples of delay are machine failure, the truck is not available for delivery, the semi-finish part is not available for assembly, the child part is not available, inspection pending, etc.

[5] Over Production:

→ If we produce products in bulk based on the forecast so we have to maintain more inventory and for the storage of finished goods we have to pay for space.

→ However, forecasts are commonly imperfect or it changes based on the market condition which leads to too much inventory and which is not good for the organization.

[6] Over Processing:

→ Over Processing refers to additional work in a process that isn’t required.

→ It costs us in the form of the time of our employees, materials used and wear & tear of equipment,

 → It also makes your production less efficient.

[7] Defects:

→ Defects are the most dangerous things for the organization.

→ It is the most visible type of waste and it is also referred to as not meeting customer's specification so it is scrap.

→ We have to bear the cost of the defects and scraps and it impacts our profitability.

→ In some cases, the organization has to bear rework or repair costs in case of defect.

[8] Skills sets (non-utilized talent):

→ If we are not using our employees to their full potential, talents or skills then it is a loss for us.

→ We can have a big effect on our organization's bottom line.

→ Examples of skill-set waste are Poor teamwork, minimal training, bad communication, and unnecessary administrative tasks.

Key Points:

→ Teamwork: Team Formation, people are used to doing the work

→ Observe: Analyses the current situation

→ Ideas: The team develops ideas by brainstorming - Ideas related to eliminate the waste.

→ Communication: By any mode of communication, the team is informed about the goals, any changes, the progress of the project, etc.

→ Culture: Create a continuous improvement culture surround the workplace.

Lean Manufacturing Principles

→ Five Fundamental Principles are mentioned below:

1. Identify Value

2. Map Value Stream

3. Create Flow

4. Establish Pull

5. Seek Performance

[1] Identify Value:

→ The manufacturer is the only person who creates value in product or service but it is defined by the customer.

→ In other words, the organization needs to understand the value that is defined by the customer in their products and services and they are willing to pay.

→ As a manufacturer or service provider, we have to focus on eliminating waste and optimize the cost of our product or service so that we can easily meet the customer's required price and we can have a business.

[2] Map Value Stream (VSM Study):

→ Value Stream Mapping is related to analyze and improve the flow of information in the case of the service provider and it refers to the flow of material in case of a manufacturer of a product.

→ In this method, we have to identify the wastes related to material or information flow and eliminate it from the system.

→ The VSM Study includes the product's entire lifecycle, from raw materials to disposal of the final product.

→ As an organization, we have to analyze each stage of the process and identify all non-value added activities and eliminate them from the system.

[3] Create Flow:

→ By eliminating wastes and non-value added activity we can improve our lead time for our material or information flow so we can get smooth process flow.

→ Lean Production depends on preventing interruptions in the production process.

[4] Establish Pull:

→ Establish pull means if we have a new order in the pipeline then and then we have to produce the products. This is a pull system instead of a push system.

→ With a push system, we manufacture the products based on the forecast and we have to maintain more inventory and we have to bear more cost for that.

→ However, forecasts are commonly imperfect, which leads to too much inventory and which is not good for the organization.

[5] Seek Perfection:

→ By following the above practices we can get the improved performance of our organization.

→ It also helps us to eliminate wastes from our value stream.

Benefits of Lean Manufacturing:

→ Improve Quality and Visual Management

→ Increase efficiency and easy to manage any process

→ Manpower and space Optimization

→ Continuous improvement

→ Problem Elimination and on-time delivery

→ Safer Work Environment

→ Improved employee morale

→ Empowerment of employees

Lean Manufacturing Examples:

→ Some of the very common examples of lean manufacturing are cut the waste in all processes, identify the optimum solution for the transportation of products or any information, follow the efficient process, try to do the first time through, eliminate 8 wastes from the system and process.

Lean Manufacturing Tools

Very commonly used tools are listed below..

⇢ 5S Methodology

⇢ Kaizen (Continuous Improvement)

⇢ PDCA Problem Solving

⇢ Jidoka

⇢ Single piece flow (One Piece Flow)

⇢ Poka-yoke (error-proofing)

⇢ Pull System/Kanban (Just In Time - JIT)

⇢ Heijunka (leveling or balancing)

⇢ Takt Time

⇢ Andon

⇢ Hoshin Kanri

⇢ Overall Equipment Effectiveness (OEE)

⇢ Cellular Manufacturing

⇢ Total Productive Maintenance (TPM)

⇢ Total Quality Management (TQM)

⇢ SMART Goals

⇢ Key Process Indicators (KPIs)

⇢ Single-Minute Exchange of Die (SMED)

⇢ 5 Whys | Why Why Analysis

⇢ Quality At Source

⇢ Process Standardization

⇢ Six Big Losses Analysis

⇢ Bottleneck Analysis

⇢ Gemba

⇢ VSM Study

Different Types of Garments Samples

 

Introduction:

Sampling is one of the most important processes in garments industry which has a vital role in attracting the buyers. Normally buyers are placed an order after satisfying with the quality of samples. As its importance on garments industry, today I will discuss about the different kinds of sample used for completing an order.

 

Types of Samples Required for Completing a Garments Order:

There are mainly eight types of sample needed for completing a garment order. Those ares-

1.    Proto sample,

2.    Fit sample,

3.    Size set sample,

4.    Counter sample,

5.    Salesman sample (SMS),

6.    Pre-production sample (PPS),

7.    Top over production sample (TOP),

8.    Shipment sample.

All the above garments samples are discussed in the below:

1. Proto sample:

It is the very first sample given into the buyer. It is prepared according to the buyer’s specification. It is a trial sample prepared on product development department. Buyer wants to see here that how its look likes after applying new design on it. Any types of fabric and color can be used here. For this types of sample 2-3pcs garments should be made where 1pc for manufacturer and rest of those are sent to the buyer for correction.

2. Fit sample: 

After approving proto sample

After approving proto sample, fit sample should be made by following buyer provided measurement sheet. It can be made by using similar fabric, nearer GSM and any color. In Fit sample, stitching and measurement must be 100% accurate. Here fabrication and color can be changed but no compromise on stitching and measurement. 2-3 garments are used in fit sample where 1pc kept by the manufacturer and rest of those are sent to the buyer.

3. Size set sample:

After approving fit sample, based on the patterns of approved sample, all the other sizes samples should be graded here and make pattern for different sizes. After that, make 2-3pcs sample for each size of that order. Manufacturer keep 1pc sample for himself and send 1pc or 2pc samples to the buyer for cutting approval. Here, it should be noted that, without the size set sample approval, cutting should not be started.

4. Counter sample:

This type of sample is based on the comments received from the buyer. For this sample, 2-3pcs garments are required.

5. Salesman sample (SMS):

Salesman sample is used by sales team of buyer to enhance the sales of any garment. Buyer sends the sample by salesman in the market to receive market feedback from the customers. It is done approximately 200-500pcs depending on the customers and season. The main objects of SMS sample are to check market, feedback, Buyer’s design etc.

6. Pre-production sample (PPS):

P.P sample should be made in actual production line by maintaining all actual of an order specification. It is the main stage of a garments order where any sample may be approved or rejected. If the sample will approve then can go for the rest of the process of that order. But if rejected then there will be the revision of previous processes. PPC (Planning production and control) department is also involved in this stage. Ones PPC department is involved then there’s no way for accepting of any style change. It is the very critical stage than other’s stage. Extra care must be needed here to confirm an order correctly.

7. Top of production sample (TOP):

During running an order in production line, a few samples sent to the buyer or buyers Q, C as TOP sample. TOP sample has a great importance in achieving certification of whole order. If TOP sample failed to approve its required quality then whole order will be resumed.

8. Shipment sample:

Shipment sample is needed after completing final inspection, when goods are ready for the shipment. It is a sample that reflects what buyers will receive down to Q.C, folding, tagging, bagging, labeling and final packaging included.