"Total Quality Control is a thought revolution in management", Dr. Kaoru Ishikawa*

Process Improvement Japan News issue #2

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In This Issue:

1) Toyota Body managers discusses QC circles as the key to Japanese quality management.

2) Sango Co. Ltd. staff`s presentations An recap of some of the great presentations delivered on topics such as production management, kaizen, and cost reduction.

QC Circle - The key to Japanese quality management

Process Improvement Japan had the opportunity to sit down with members of Toyota Body to discuss views on the value and origins of QC circles and total participation. Our contacts choose to remain anonymous at this time.

Q. What are the origins of TQC & TQM in Japan? A. When Japan started its industrialization and production after World War Two, we lack sufficient management skills. Japan learned from overseas how to control management. We introduced Statistical Quality Control (SQC). *** The basic concept of SQC is to take average values, disparity vales.*** It was the start of Statistical Quality Managmenet. After awhile, it was evident that this was not enough. SQC had to be shared and pratcied company wide in order to be truly effective. Dr. Deming introduced the concept of P-D-C-A. (Plan Do Check Action) It became clear that the quality improvement process had to be company wide from the top to the gemba workers with total participation.

Q. How did QC circles start?

The QC circle became an important part. QC circle actually from the foundation of SQC. - it`s the key feature of japanese quality management The Priorities are:
1. Quality
2. Cost
3. Delivery
4. Safety
5. Morale
6. Environment

Key: All aspects of management should be improved. This is now called TQM.

There are two ways to implement improvement strategies: Top Down and Bottom Up

From the bottom comes creative suggestions. This is the key to effective kaizen.

Sango News

Sango`s Presentations

Employees at Sango Co. Ltd. a Toyota supplier of exhaust systems delivered informative presentations on a variety of key issues facing the manufacturing industry and specifically, Sango Co. Ltd. and its customers. Sango Co. Ltd. is a privately owned company with 6 International production bases and over 5000 employees.

Mr. Nishi (left photo) discussed the necessity for Kaizen at Nissan. Current methods had created some difficulty that needs to be rectified.

Mr. Suehiro delivered a very interesting talk on Kaizen in Simultaneous Engineering. They key to improvement he said was sharing problems and an increase in understanding and cooperation amongst co-workers.

Mr. Suzuki made an overview of the reduction in process defects for TIG welding. Before Kaizen, the defect rate was 5%. After Kaizen, the defect rate dropped to less than 1%.

Mr. Hayakawa gave an impressive presenation on the Value of 5s. "5s is not a target, it is a tool, " Mr. Hayakawa stated. " 5s is the foundation of our success."

Mr. Esaki discussed how weight reduction can lead to a 20% cost reduction.

Ms. Yamamura outlined a vision of Sango in 10 years - discussing their R&D projects.

Mr. Kamiya gave a very entertaining presentation on how the Hino muffler incorporates the same concepts as Lego and how we can achieve satisfaction in constructing both.

Mr. Nishino discussed Exhaust Heat recovery systems to improve mileage.

Mr. Takai presented on Digital Engineering Method for Stamping and the advantage of prediction techniques in accuracy analysis (decreased number of trials required)

Mr. Matsunaga discussed muffler construction and cost

Mr. Nitta - Discussed the future of the exhaust manifold and how the internal combustion engine may become unnecessary due to the Electronic Vehicle. Plant Communication Training Seminar 5s presenation was delivered by Mr. Tanigami and Mr. Sano

Production Process Flow by Mr. Nojima and Mr. Tanaka

Visual Control by Mr. Sakai and Mr Takeno

Motivation and Morale by Mr. Inoshita Mr. Hirota and Mr. Kudo

Sango Co. Ltd`s Yawatayama Plant - A model of high motivation and morale. Dr. Kaoru Ishikawa is one of the world`s foremost authorities on quality control. He has helped thousands of companies, including IBM, Bridgestone, and Komatsu, to turn out higher quality products at much lower costs. For more details on Dr. Kaoru Ishikawa, click here