Be Always Sure Inputs Create Success : 12 Lean Six Sigma Tools and Techniques to Reduce the Cost of Quality from the Coal Face Out book cover
1st Edition

Be Always Sure Inputs Create Success
12 Lean Six Sigma Tools and Techniques to Reduce the Cost of Quality from the Coal Face Out

  • Available for pre-order. Item will ship after November 30, 2020
ISBN 9780367444594
November 29, 2020 Forthcoming by Routledge
144 Pages

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Book Description

The BASICS Manual is designed to show personnel at all levels within a manufacturing operations environment that, with easy to understand continuous improvement tools, they can make a difference to operational performance where safety, quality, cost, delivery and people are paramount to business success. The tools and techniques throughout, based upon examples from the authors experience, demonstrate that no matter what industry they can bring the desired added value.

This book will help any manufacturing shop floor add value in terms of quality/cost and delivery performance. It will also show how using tools and techniques from the "coal face" out will improve process performance using simple data collection and measurement—not only on outputs, but just as importantly on "critical to quality inputs" such as process parameters and their windows—to deliver the desired output KPI. The power and confidence that this gives to local experts and processing teams enables them to make informed decisions, preventing drifts and non-conforming product: prevention being better than cure.

The result of these changes is tangible cultural impact to the shop floor, raising the level at which operating teams work and improving morale. B.A.S.I.C.S will enable staff at all levels to understand their performance measures and produce sustainable results. The book contains practical tools, methods and techniques that have been tried and tested by the author over a successful 30 year career as a contractor transforming performing processes and failing KPIs.

Table of Contents

Part 1 Cultural Development.

1. Policy Deployment.

2. Lean Productive Systems Road Map.

3. 5S Workplace Organisation.

4. TPM. Total Productive Maintenance.

5. Centers of Excellence. Safety. Quality. Cost. Delivery. People. SQCDP.

Part 2 Data Measurement Tools and Techniques.

6. Statisitical Process Control. SPC.

7. Overall Equipment Effectiveness (OEE)Link to Single Minute Exchange of Die. (SMED)

8. Process Parameter Monitoring.

9. Value Stream Mapping. (VSM) Current and Future State

Part 3 Root Cause Analysis.

10. 8D – 8 Disciplines / Practical Problem Solving (PPS)

11. Pareto Analysis. Cause and Effect. 5 Why.

12. 5F.Find It. Focus. Fast. Fix it. Feedback. .

Part 4 The Concept of People.

My Views on Continuous Improvement - A Philosophy.

Mom We Made It…

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Paul Cunningham is a Lean Six Sigma Black Belt and celebrated Improvement Contractor who has spent the past 15 years improving processes and failing Key Performance Indicators in varied industries inclusive of Automotive, Aerospace, Oil and Gas and Construction manufacturing, often transforming catastrophic loss into profit-making businesses. Paul's understanding that it is people together with processes that understand and fix problems and issues, not processes alone, have made him a go-to in the manufacturing industry when staff at all levels are needed to drive a transformation process of continuous improvement.