Toyota Production System & Lean Hub

Credits: Sergio D'Amico, CSSBB The cost of ignoring employee skills? Massive. Here’s how to unlock hidden potential in your team. Non-utilized talent is the biggest waste in Lean. Ignoring skills and ideas costs you more than you think. Here’s how to fix it: 1/ Ask for Ideas → Host brainstorming sessions → Listen without interrupting → Try what they suggest 2/ Train Often → Teach new skills → Certify and upskill teams → Share knowledge freely 3/ Delegate Tasks → Trust your team’s abilities → Assign real challenges → Stop micromanaging 4/ Spot Strengths → Watch your team closely → Match tasks to skills → Promote their growth 5/ Celebrate Creativity → Reward innovation → Highlight great ideas → Appreciate openly 6/ Rotate Roles → Prevent boredom → Build versatile teams → Discover hidden talents 7/ Fix Barriers → Remove strict rules → Simplify approvals → Empower decision-making 8/ Track Progress → Measure engagement → Get employee feedback → Improve yearly Unused talent is lost potential. Start using it today. Share ♻️ to help others unlock hidden talent and follow Sergio D’Amico for more insights on continuous improvement and organizational excellence.

Credits: Govind Tiwari,PhD 𝟒 𝐓𝐲𝐩𝐞𝐬 𝐨𝐟 𝐐𝐮𝐚𝐥𝐢𝐭𝐲 𝐌𝐚𝐧𝐚𝐠𝐞𝐦𝐞𝐧𝐭: 𝐓𝐐𝐌, 𝐐𝐌𝐒, 𝐒𝐢𝐱 𝐒𝐢𝐠𝐦𝐚 & 𝐐𝐅𝐃 🚀 Quality management is essential for customer satisfaction, efficiency, and defect reduction and choosing the right Quality Management framework is key. Let's break down four major quality management approaches, their tools, and real-world applications. ❶Hierarchy of Quality Management Frameworks Quality improvement follows a structured hierarchy: 🔹 Total Quality Management (TQM) – A culture-driven, company-wide commitment to continuous improvement. 🔹 Quality Management System (QMS) – A standardized system (e.g., ISO 9001) ensuring policies, procedures, and compliance. 🔹 Six Sigma – A data-driven methodology focused on reducing process variability and defects. 🔹 Quality Function Deployment (QFD) – A customer-centric tool that translates needs into technical requirements. ❷Essential Tools for Each Framework ➤TQM Tools: ✔ PDCA Cycle – Plan, Do, Check, Act for continuous improvement. ✔ 5S Methodology – Organizing and optimizing the workplace. ✔ Fishbone Diagram – Identifying root causes of problems. ✔ Pareto Analysis – 80/20 rule for prioritizing key issues. ✔ Benchmarking – Learning from best practices to enhance performance. ➤Quality Management Tools : ✔ Seven Basic Quality Tools (7QC): Cause-and-effect diagram, check sheets, control charts, histograms, Pareto charts, scatter diagrams, and flowcharts. ✔ ISO 9001 Framework – Standard for quality management and regulatory compliance. ✔ Benchmarking – Comparing with industry best practices. ✔ Cost of Quality (CoQ) – Measuring prevention, appraisal, and failure costs. ➤Six Sigma Tools: 📊 DMAIC Framework – Define, Measure, Analyze, Improve, Control. 📈 Statistical Process Control (SPC) – Control charts for monitoring variations. 🔍 Failure Mode and Effects Analysis (FMEA) – Risk assessment for potential failures. 🔬 Design of Experiments (DOE) – Controlled testing for optimization. 🔗 Cause-and-Effect Matrix – Prioritizing process improvements. ➤QFD Tools: 🗣 House of Quality (HoQ) – Mapping customer needs to technical specifications. 📊 Affinity Diagrams – Grouping and structuring ideas for problem-solving. 📈 Kano Model – Categorizing customer needs into basic, performance, and delight factors. 🔍 Voice of the Customer (VOC) – Gathering direct customer feedback. ❸Applications of These Quality Management Approaches: ✅ TQM in Manufacturing ✅ QMS in Healthcare, Oil and Gas ✅ Six Sigma in Aviation, Manufacturing ✅ QFD in Product Development 📢 Which quality management approach have you found most effective? Let's discuss! 🔍

Credits: Jeff Winter When a data scientist looks at a pump, they see a dataset. When a maintenance technician looks at a dataset, they see gibberish. And therein lies the problem. 😮 𝐖𝐡𝐚𝐭 𝐢𝐬 𝐏𝐫𝐞𝐝𝐢𝐜𝐭𝐢𝐯𝐞 𝐌𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞? Predictive maintenance refers to the use of data analysis tools and techniques to detect anomalies in equipment and predict potential failures before they occur. This approach leverages data from sensors and machines to anticipate maintenance needs, thereby preventing costly downtime and extending the lifespan of machinery. The power of predictive maintenance lies in its ability to ensure operational efficiency and save substantial costs in the long run. By preventing unexpected equipment failures, companies can reduce downtime, enhance safety, and optimize spare parts handling, making operations smoother and more cost-effective. 𝐓𝐡𝐞 𝐂𝐡𝐚𝐥𝐥𝐞𝐧𝐠𝐞: 𝐓𝐰𝐨 𝐖𝐨𝐫𝐥𝐝𝐬 𝐂𝐨𝐥𝐥𝐢𝐝𝐢𝐧𝐠 However, integrating predictive maintenance into business operations isn't without its hurdles. One significant challenge is the cultural and knowledge gap between maintenance teams and AI experts. Maintenance professionals may lack a deep understanding of AI and data analytics, while AI specialists often do not possess firsthand knowledge of the intricate realities of day-to-day maintenance. This disparity can lead to miscommunication and inefficiencies in implementing predictive maintenance solutions. The companies that succeed in predictive maintenance are the ones that don’t just invest in technology—but also invest in breaking down silos between AI engineers and maintenance teams. 𝐀 𝐩𝐫𝐞𝐝𝐢𝐜𝐭𝐢𝐯𝐞 𝐦𝐨𝐝𝐞𝐥 𝐢𝐬 𝐨𝐧𝐥𝐲 𝐚𝐬 𝐠𝐨𝐨𝐝 𝐚𝐬 𝐭𝐡𝐞 𝐜𝐨𝐥𝐥𝐚𝐛𝐨𝐫𝐚𝐭𝐢𝐨𝐧 𝐛𝐞𝐡𝐢𝐧𝐝 𝐢𝐭. 𝐏𝐫𝐞𝐝𝐢𝐜𝐭𝐢𝐯𝐞 𝐌𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 𝐌𝐚𝐫𝐤𝐞𝐭 According to IoT Analytics, the predictive maintenance market is growing fast, hitting $𝟓.𝟓 𝐛𝐢𝐥𝐥𝐢𝐨𝐧 in 2022 and is expected to grow by 𝟏𝟕% annually until 2028. The market has evolved to include three main types of predictive maintenance: indirect failure prediction, anomaly detection, and remaining useful life (RUL). Most companies adopting predictive maintenance report a positive ROI, with 𝟗𝟓% seeing benefits and 𝟐𝟕% recouping costs within a year. Successful vendors often specialize in specific industries or assets, and software tools in this space share common features like data collection, analytics, and third-party integration. 𝐅𝐮𝐥𝐥 𝐚𝐫𝐭𝐢𝐜𝐥𝐞, 𝐡𝐢𝐠𝐡-𝐫𝐞𝐬𝐨𝐥𝐮𝐭𝐢𝐨𝐧 𝐢𝐦𝐚𝐠𝐞, 𝐚𝐧𝐝 𝐚𝐝𝐝𝐢𝐭𝐢𝐨𝐧𝐚𝐥 𝐫𝐞𝐬𝐨𝐮𝐫𝐜𝐞𝐬: https://lnkd.in/erQ5HTab ******************************************* • Visit www.jeffwinterinsights.com for access to all my content and to stay current on Industry 4.0 and other cool tech trends

Credits: Alper Ozel Unleashing the Power of TPM for Operational Excellence : Why you need to be more than "Lean" In the race for operational excellence, many organizations turn to Lean Manufacturing for waste reduction and efficiency. But WHAT IF there’s a more holistic and impactful approach : Welcome to Total Productive Managament (TPM) also known as World Class Operations Management (WCOM), a methodology that goes far beyond Lean to deliver sustainable excellence, centered and raising on the most valuable enterprise resource: Human. Why TPM/WCOM Stands Out : 1️⃣ Holistic Integration: Unlike Lean, which primarily focuses on waste elimination and process flow, TPM/WCM integrates equipment reliability,employee empowerment, and safety as foundational pillars. It ensures that machines, processes, and people all work harmoniously to achieve zero breakdowns, defects, and accidents. 2️⃣ Focus on Maintenance : TPM/WCM emphasizes proactive and predictive maintenance strategies (Planned Maintenance Pillar). This ensures equipment uptime and reliability—critical for industries where downtime can lead to significant losses. 3️⃣ Employee Engagement: While Lean fosters teamwork, TPM/WCM takes it further by empowering operators to take ownership of their machines (Autonomous Maintenance Pillar). This creates a culture of accountability and continuous improvement at every level. 4️⃣ Structured Loss Elimination: Focused Improvement Pillar in TPM systematically identifies and eliminates losses using tools like OEE (Overall Equipment Effectiveness) and Six Big Losses analysis. This structured approach delivers measurable results. 5️⃣ Quality at the Source: The Quality Maintenance Pillar ensures defects are prevented rather than detected later. By monitoring critical process parameters (Q Points),TPM/WCM achieves consistent product quality aligned with customer expectations. 6️⃣ Sustainability Beyond Waste: WCOM integrates innovative practices like Change Leadership, Performance Behavior, and the Shingo Model to create a culture of excellence that is sustainable over time. It’s not just about reducing waste—it’s about transforming the organization. Why you need to be more than Lean : In Accordance to great read "WCOM: World Class Operations Management - Why You Need More Than Lean"* and my ~30 years of experience in different Operational Excellence Philosophies, Methodologies and Tools, WCOM combines the best of Lean, Total Productive Maintenance/Management, and World Class Manufacturing while addressing human dynamics like leadership behavior and cultural transformation. Case studies from companies like The Bel,The Bemis, Saint-Gobain, L’Oréal, Milliken,Tetra Pak, Pirelli, Unilever, Honda, Mondelez, Owens Corning, Lindt, Toyota reveal how WCOM drives long-term success by integrating technical excellence with organizational development.

Credits: Sergio D'Amico, CSSBB Speed isn’t about deciding fast. It’s about executing flawlessly. Toyota’s 13th principle explains how. Slow decisions win. Fast execution wins bigger. Most teams rush to decide and stall in action. Toyota flips it. Here’s their secret to smart, swift execution: 1. TEAM INPUT → Gather all opinions → Encourage open talks → Value every voice 2. GROUP AGREEMENT → Seek shared approval → Build mutual trust → Unite on choices 3. DETAILED REVIEW → Study every option → Weigh pros and cons → Avoid quick fixes 4. SLOW DELIBERATION → Take time to discuss → Ask clarifying questions → Address concerns first 5. COLLECTIVE PLAN → Define clear steps → Assign team roles → Align on goals 6. CONSENSUS CHECK → Confirm full support → Resolve disagreements → Ensure no doubts 7. RAPID ACTION → Launch plans fast → Stick to timelines → Avoid delays 8. ALIGNED EXECUTION → Work as one team → Follow agreed steps → Stay coordinated 9. MONITOR RESULTS → Track progress closely → Adjust if needed → Celebrate successes 10. LEARNING LOOP → Review outcomes → Share lessons learned → Improve next time Decide slow. Execute fast. Win every time. Share ♻️ to help others and follow Sergio D’Amico for more insights on continuous improvement and organizational excellence.

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Credits: Sergio D'Amico, CSSBB Most businesses measure the wrong things. SQDCP helps you focus on what truly matters. SQDCP is your roadmap to operational success. 1️⃣ What is SQDCP? ++ Safety, Quality, Delivery, Cost, People ++ Balances operational priorities ++ Drives continuous improvement 2️⃣ Why Use It? ++ Aligns processes with business goals ++ Acts as a priority ladder: S → Q → D → C → P 3️⃣ Where is it Used? ++ Daily operational reviews ++ Monthly performance meetings ++ Strategic decision sessions 4️⃣ How to Apply It? ++ Use visuals. Make data easy to understand ++ Ask your team. Frontline insights drive improvement ++ Review often. Track progress and adjust 5️⃣ How It Works ++ Set clear goals ++ Track weekly progress ++ Adjust as needed 6️⃣ Common Mistakes ++ Ignoring people. They drive everything ++ Setting too many goals. Focus matters ++ Never updating metrics. Stale data, bad decisions 7️⃣ Why It Works ++ Clear Order. Focus on what matters first ++ No Overwhelm. Tackle the most urgent pillar first ++ Balanced Decisions. Avoid risky trade-offs (e.g., cutting costs at the expense of safety) 💡 Final Takeaway ++ SQDCP eliminates guesswork. It’s your cheat sheet for smarter, faster decisions. Share ♻️ to help your network and follow Sergio D’Amico for more insights on continuous improvement and organizational excellence.

Credits: Alper Ozel The Power of Q(uality) Points in Achieving Zero Defects : Are you in full control of your CPPs ? Quality Points, also known as Critical Process Parameters (CPPs) that directly impact product quality, are essential elements within TPM/Lean methodologies. These parameters represent the critical aspects of a production process that must be controlled to ensure consistent product quality. Understanding and effectively defining these parameters is crucial for organizations aiming to implement robust quality management systems. Understanding Q Points Q Points are fundamentally parameters that, when properly controlled, help achieving zero defects - a core objective of TPM and Lean. In TPM specifically, they form part of the Quality Maintenance Pillar, which focuses on establishing machine conditions that eliminate defects at their source. The concept of Q Points is directly related to Critical Process Parameters, which are attributes that require continous monitoring (SPC) to detect deviations in standardized production operations and product output quality. In TPM; Q Points are typically identified through specialized matrices and analysis methods that connect machine parameters, process settings, and potential defect modes. The QX Matrix (Quality X Matrix) serves as a critical tool in this process, focusing on machine and process parameters against potential defects. This matrix works as a connecting bridge between the QA Matrix (which identifies quality issues) and the QM Matrix (which establishes maintenance protocols to address quality concerns). The fundamental purpose of identifying Q Points is to establish a clear relationship between process parameters and product quality attributes. By understanding these relationships, organizations can implement targeted controls that prevent quality issues rather than detecting them after production. Next : How to Define and Follow Q Points (Critical Process Parameters)

Credits: Center for Lean Excellence Understanding FTT, Yield & Rolled-up FTT in Manufacturing 📌 FTT (First Time Through) measures the percentage of products that move through a process without rework or defects. 📌 Yield focuses on the percentage of products that are free from rejects, even if rework is needed. 📌 Rolled-up FTT calculates the cumulative impact of FTT across multiple processes, revealing the overall efficiency of an end-to-end system. 💡 Why does this matter? Even if individual processes show high FTT, the Rolled-up FTT often tells a different story. In the example above, each process has a relatively good FTT, but when combined, the overall efficiency drops to 65%. This means 35% of products require rework or get rejected, increasing cost and lead time. #FTT #Quality #Defectrate

Credits Lean Enterprise Institute