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MODERN CHAIRS A Total Quality Management/Kaizen – Failure By Jonathan Baker.

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MODERN CHAIRSA Total Quality Management/Kaizen – Failure

By Jonathan Baker.

INTRODUCTION

A Total Quality Management training video that a final year class at the University of Edinburgh made in the style of Charlie Chaplin's Modern Times. The intention was to teach teamwork, production line processes, process optimisation, defects, quality, and continual improvement 'Kaizen'.Click <https://youtu.be/L--Oyw6V8gI> or google “YouTube Modern Chairs”

NON TQM: 30 CHAIRS STACKED IN 120 SECONDS

Customer Specification: Create 6 Stacks of 5 Chairs per Stack

Simple Manufacturing Process: Chair Stacking; non-TQM method

6 People successfully move 30 chairs from one side of a room to another; the chairs are stacked already in piles of 5, and chairs can only be moved one at a time.

Each person grabs a chair and moves one across the room to create a pile of 5; no planning; no measurement of waste; no Total Quality Management (TQM)

Completed Pile: Left hand Stack has 6 chairs

Top Right: Start

Lower Right: Finish

APPLYING TQM PRINCIPLES STAGE: 1

Chain Gang Production Line Configuration, one person at the end stacking chairs into piles of 5 (Top Left)

One can see that Work In Process is waiting to be moved to the final stage of stacking (Top Middle) creating a waste or resources and time.

Completed Process (Top Right) 10 seconds faster, but still with defects in meeting the customer’s specification.

30 CHAIRS STACKED IN 110 SECONDS

RELATIONSHIP BETWEEN QUALITY AND CYCLE TIME

“Apparently”, as Cycle Time increases, Quality reduces

APPLYING TQM PRINCIPLES STAGE: 2

As the below formation takes place, the theme tune to ‘The Apprentice’ kicks in to suggest a revelation in using the Toyota Production System to eliminate waste, over processing, over production and waiting

OPTIMISATION – LEAN MANUFACTURING

30 CHAIRS STACKED IN 90 SECONDS!

IF YOU WATCHED THE ENTIRE VIDEO ON YOUTUBE; YOU WILL HAVE NOTICED THAT THEY HAVE ALREADY ENCOUNTERED DEFECTS AND IMPLEMENTED QUALITY CONTROL. DO YOU REMEMBER THE CUSTOMER SPECIFICATION?

CREATE 6 STACKS OF “5” CHAIRS PER STACK

CONTINUAL IMPROVEMENT

BUT COULD WE REDUCE A PROJECT BY 90% OR HIGHER?

Well there we have it!! From 120 seconds down to 65 seconds with the magic of TPS utilising TQM and the philosophies of Continual Improvement. An improvement of 45.83%

Is this enough to meet the Governments ambitions for Construction of a 50% reduction in duration of projects as outlined in the Construction 2025 Report?

Well; no…. But its pretty damn close right?

Watching this video though, it just doesn’t shock me, open my eyes to the power of TPS and Lean Thinking. Lets actually analyse the customer requirement and processes properly:

Simple Analysis of the figures show that if all people collecting a chair each, and then moving it to its final location achieves 30 chairs stacked in 120 seconds, we therefore have:

This is taken from the very first video.

A single cycle of moving a chair from point 1, and depositing at point 2 before returning to point 3 takes 4 seconds in total for 1 person.

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We have 6 people involved in the process.

Therefore if all 6 people followed the 1,2,3 cycle at the same time – we would have successfullymoved 6 chairs in 4 seconds.

We only have to repeat this process 5 times.

If each person knows and counts out 5 iterationsof this cycle and only deposits in their own areathen we also reduce the all too erroneous issues of6 chairs in some piles.

Lean Management can really be that easy andeffective. Poor consultants and educational sourcesleave many construction professionals with a foul tastewhen they hear the term ‘Lean’.

The only goal of Lean; is to DELIVER VALUE for the customer; in this instance, 6 stacks of 5 chairs is what the customer values, whilst eliminating waste and applying continual

improvement/lean principles. Eliminating all motion, and copying a production line which operates in a sequence of processes as closely as possible, is not the application of Lean or

the Toyota Production System (TPS); particularly when it means poorer performance and poorer quality.

20 SECONDS = REDUCTION BY 83.3%

The above improvements of 83.3% really don’t even apply any lean techniques. It is just a simple work/motion study of the original inefficient system and applying some common mathematical judgement.

Managing the Supply Chain (Where, how and what kind of chairs are originally stored, can they be changed?)

Delivering the Chairs on a wheeled pallet would mean that a stack of 5 chairs could be moved in 4 seconds. With 6 people the entire process could be delivered in:

Can any quality control or standardisation be applied to the chairs before being supplied?

4 seconds = 96.67% improvement

And that’s just 2 minutes of thinking laterally and innovatively, the same processes can and does apply in construction; even more so than manufacturing.

‘quod erat demonstrandum’

Decent Homes Programme: Current Contractor Improvement of 575% on Handovers within 4 weeks (2013)

Decent Homes Programme: 195% improvement over any week in the prior contractors 15 year contract (2013)

28 day refurbishment programme, reduced to 2 days saving £125,000 per day on critical path costs; that’s £3.25m [92.85%] (2014)

Q.E.D; Used to convey that a fact or situation demonstrates the truth of one’s theory or claim, especially to mark the conclusion of

formal proof. www.oxforddictionaries.com

Thank-you