Audits-Pillar of any system

Audit, Lean Management, PDCA

Audits-Pillar of any system
Audits are the Action Undertaken for Deviation Identification To Sustain

Audits are very important part of any PDCA cycle. To proceed further, lets explain PDCA cycle.

Plan, Do, Check, Act:- These are very important step of any type activity/project to be successful. Project may be related to engineering, management, social etc.

Rightly said, “To cut a tree, 80% of time should be used for sharpening the axe & remaining 20% to hit at the trunk.” Indeed, Planning plays very important part for any activity.

Implementing as per planning is equally important. Once, the system is in place,  Check as per desired specification is important to find the gaps. Corrective action should be taken for filling the gaps.

Audits are an important tools for “check” step of the PDCA cycle. There are different types of audits. Few of them are as given below:

Routine Checks: These are the audits taken at scheduled intervals for monitoring the performance of an established systems. These can be internal & external.

Internal audits are for monitoring own performance with established rules & procedures.

External audits are to map our performance with national & international standards.

Pre startup checks: These type of audits are taken up before commissioning of any project to find out gaps that may result in loss after start up of the equipment/machine etc.

The Audits can also be categorized as :

First party: These are done by internal resources. These may be done by same department or by cross functional teams. Person from shop floor, middle management, upper management, leadership level can be engaged depending on importance & criticality of system.

Second Party: The team can be formed from different location of same company. This brings learning of different sites together.

Third Party: Consultants can be hired to get best knowledge available in market.

Audits helps in finding fault at right time & acting immediately, so that further consequences can be avoided.

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Have a look on some beautiful posters of Decision tree and Root Cause analysis that can be added to your workplace are available for buying at our Breval store

7 waste in an industry

7 waste in an industry

7 waste in an industry

7 waste in an industry is very well explained in the poster above. The main need is to have a vision for identifying these wastes & take corrective actions on immediate basis.

Our industries are paralysed with these types of wastes. We are loosing on very important resources. Time is one of those resource. Once wasted, it never returns.

As demand for energy is increasing, efficiency has become major concern. many of the sectors are still working with 50 % efficiency, which by any standard is a lagging indicator.

Many times, it needs external eyes to identify wastes in our system. Lets invest little to gain more in future. Understand, resources are scare. Efficiency is going to be the key of success in this century.

If we have to beat out competitors, we have to do things differently. Let’s be the part of the change, Let’s bring change, identify all wastes in our organisation. Work towards eliminating them.

5S is a starting & very important tool for  bringing change in work culture, for moving towards efficiency & zero defect.

Remember TIM WOOD is not allowed in our ecosystem.

You would also like to have a beautiful poster for studing wastage at your work place which is available for buying online at our Breval store.
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Case Study – Frequent maintenance in Stack Analyser (Banish MUDA)

Case Study – Frequent maintenance in Stack Analyser (Banish MUDA)

This is a beautiful case study resembling positive approach of the team towards finding solution.

A stack analyser was having very high frequency of maintenance. Being mounted in stack of incineration plant, the probe was exposed to dust & acidic gases, which were the main cause of probe failure.  Main Issues with the Analyser is:

  • High Frequency of Cell and heater failure.
  • Frequent chocking of cell assembly.
  • High time required for cleaning and cell replacement.
  • High cost of maintenance

The team took up the challenge to come out of the issue. The study done was a good example of usage of various reliability tools like RCA, Fishbone diagram, Brainstorming, etc. ,there is another angle to it, ie. Lean Management. The main objective of the study was to reduce the quantity of jobs performed on the analyser.

The team has recently gone through “7 Wastes-Mr. TIMWOOD “. They decided to identify the wastes in the activities on the analyser. All the activities were identified & written.

Each activity was studied and type wastes were identified.

Case Study- Frequent maintenance in Stack Analyser (Banish MUDA)

Analysis of the identified waste is as under:

  1. Transportation of probe to the repair location: Can the probe be repaired at the installed location?
  2. Motion of the workmen for steaming, hammering & temporarily electrical connections: Why Steaming, Hammering is required? Why temporarily connections are required?
  3. Defect during leak checking: What is the procedure for ensuring correct assembly?
  4. Inventory: How to reduce inventory required supporting the frequent maintenance?
  5. Waiting: Why can’t the warm up done at location?
  6. Over Processing: Why calibration & response check is required two times?

The next step was to find answer to these questions. The maximum time was consumed by removal of Cell & seal assembly. RCA tool, Why Why analysis was used to drill down to accumulation of the acidic dust at the cell as the root cause. A ceramic diffuser was prepared with OEM, to put in place of mesh, which is more capable of filtering dust. This small change after value engineering has resulted in substantial improvement in terms of time, cost, inventory, maintenance frequency, reliability & availability of the instrument.

Continuous Improvement

Cost of Modification: Rs. 25000

  • Total time of job was reduced from 8.8 hours to 4.3 hours.
  • No. of jobs reduced from 10/year to 4/year.
  • Material cost reduced from Rs. 1.8 Lakh to Zero.

Continuous Improvement

Experience of industries has been concentrated in different quality, Reliability & Lean tools. Correct knowledge & implementation of these tools is necessary for best results.

Check other case studies on Vanilla Ice Cream and Flight 5390 failure.
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Case Study- Frequent maintenance in Stack Analyser (Lean Tools)

Wastes in Lean Management-Mr. TIM WOODS

  • MUDA
    MUDA
  • LEAN WASTE
    TIMWOOD
  • 7 WASTES
    PEOPLE,QUANTITY,QUALITY
  • TIM WOOD
    THE 8TH WASTE

WASTES IN LEAN MANAGEMENT-Mr. TIM WOODS

Lean Management categories waste in seven areas. All 7 types of wastes are further categorised as:

  1. People
  2. Quantity
  3. Quality

The People waste comprises of

  • Over Processing
  • Waiting
  • Motion

The Quantity waste comprises of

  • Inventory
  • Transportation
  • Over Production

The Quality waste comprises of

  • Defects

Eliminating wastes is very important part of lean Management.

Kick out Mr. TIM WOODS from your organisations.

Virtual Stream Mapping is tool that help in identifying the type of wastes  in any system. VSM also tells which waste to remove & how to remove. VSM is basically derived from customer requirements. The flow is traced back to inputs, thereby studying whole value chain. Virtual stream mapping is very important in growth of any organisation.

If you want

  • Improve your section.
  • Eliminate wastes
  • Improve efficiency
  • Save time & Money
  • Improve Production
  • Improve Quality
  • Be Best in class.

Put a beautiful poster designed to identify waste Poster on MUDA at your work place.
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Cost of Inventory

  • Cost Of Inventory
    Cost of Inventory

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