Download or read book Turning PDCA into a Routine for Learning written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2020-10-13 with total page 83 pages. Available in PDF, EPUB and Kindle. Book excerpt: Mistakenly, many people think plan-do-check-act (PDCA) is a continuous improvement cycle, even if they neglect the human part. PDCA does aim to improve the process, but if you have only improved the process without developing and teaching your people, you have put the process at risk of slipping back. People must be trained in the culture of continuous improvement so they can keep managing the process with the new method.

Download or read book Toyota Production System Concepts written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2023-12-10 with total page 27 pages. Available in PDF, EPUB and Kindle. Book excerpt: Changing how we manage people is important for making any business plan work. In his great book Toyota Kata (2009), Mike Rother talks about how Toyota changes the way its employees act and think by forming new habits and culture. Using the word "kata" to explain how Toyota solves problems instead of using the pharase "problem solving." Toyota's way helps create a better work environment by teaching people to become better leaders and make positive changes.

Download or read book Gemba Walks the Toyota Way The Place to Teach and Learn Management written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2020-10-12 with total page 70 pages. Available in PDF, EPUB and Kindle. Book excerpt: Gemba is a Japanese word meaning the actual place where value-creating work happens. Many leaders use gemba only for solving problems, visiting only when there is an issue. Others practice gemba walks on a daily basis to follow up and monitor the situation. However, Toyota believes that leaders truly develop through daily experiences at the gemba. In reality, gemba is a principle for managing, developing and improving people and processes. It is a valuable tool that helps lean practitioners learn the true facts so they can base management decisions on the actual situation.

Download or read book The Ultimate Guide to Successful Lean Transformation written by Mohammed Hamed Ahmed Soliman and published by personal-lean.org. This book was released on 2020-11-30 with total page 86 pages. Available in PDF, EPUB and Kindle. Book excerpt: Many businesses say that lean failed to meet their long-term objectives and that the improvements it brought about were only temporary. When businesses utilize lean as a toolkit, copying and pasting the methodologies without trying to adapt the employee culture, manage the improvement process, maintain the outcomes, and grow their leaders, 7 out of every 10 lean projects fail. The primary objective when the Toyota production method was developed was to eliminate wastes from the shop floor by utilizing some lean techniques and technologies. What wasn't made obvious was that Toyota would need to invest heavily in personnel development and training throughout a protracted leadership development process. An issue with management and leadership, as well as an incorrect understanding of human behavior and the necessary culture for success, is the failure to achieve and sustain improvement.

Download or read book A Complete Guide to Just in Time Production Inside Toyota s Mind written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2023-09-28 with total page 265 pages. Available in PDF, EPUB and Kindle. Book excerpt: Yes, people called it an inventory reduction program when they first heard of it. “Just in time” is one of the main pillars in the TPS. “Just in time” ideally means “one-piece flow.” Inventory is the greatest waste in the process, and it hides many problems, such as quality problems, breakdown times, waiting waste, and more. Let’s get back to history. Prior to the 1970 oil crisis, very few people in the world know what Toyota was up to. The fact that it emerged stronger than ever while many of its competitors were quite battered made people take notice. People went to Japan to find out how Toyota had done this. What people found was that Toyota was doing something called “just in time.” In the West, this was interpreted as an inventory reduction program. As a result, it became known as the “just-in-time inventory” program. Nobody really believed inventory could be taken out of the whole value stream. Therefore, “just in time” came to mean “go beat the heck out of your suppliers.” The big three auto companies (Ford, General Motors, and Chrysler) had lots of power over their suppliers, and they became pretty expert at this tactic—to their eventual detriment. James P. Womack came forward with Lean Thinking in 1996 and helped many to see the whole value chain. He showed how waste clogs the system and how continuous improvement was needed to link all parts of the chain to customer demand. He explained his findings in plain English, but once again people didn’t hear. Lean might be an element of the larger strategy, but it is most likely to be relegated to plant and manufacturing work. As a result, one company after another has tried lean and failed. Many people believe that just-in-time inventory equals zero inventory. The ideal situation is one-piece flow, which can only be achieved through the use of a manufacturing cell. The inventory buffer exists, but it is rarely used. The Andon system includes a buffer. There is a safeguard in place to protect your customer. There is a buffer to prevent the entire manufacturing line from being shut down to rectify a problem. There is a buffer in place to prevent the breakdown of a vital manufacturing process. Just-in-time production is a manufacturing system that produces and delivers only what is required, only when it is required, and only in the amount required. The Toyota Production System is built on two pillars: JIT and jidoka. JIT is based on heijunka and consists of three operating elements: the pull system, takt time, and continuous flow.

Download or read book Design Review Based on Failure Mode written by Mohammed Hamed Ahmed Soliman and published by personal-lean.org. This book was released on 2024-04-07 with total page 76 pages. Available in PDF, EPUB and Kindle. Book excerpt: Toyota doesn't just make high-quality products; they also have a process for making sure everything they do is high-quality. Next time you want to say Toyota isn't that great, think about how their way of doing things could help you make better quality products. Reliability is about having a product or service that can be trusted is really important for making customers happy. This means that the product will work the way the customer wants it to, and it will keep working well for a long time. Quality experts are basically saying that it is very important to focus on improving quality in all aspects of a business. They believe that businesses should prioritize quality in order to be successful. The more complicated the product is, the harder this task gets. Before World War II, the military, aerospace, and aircraft industries used the failure mode and effect analysis (FMEA) approach. Toyota then invented its production system after the war. FMEA has been around since the middle of the 20th century, especially in the aerospace and military industries. FMEA was made in the 1940s and used by the U.S The military works to find and fix problems in production before they happen. The method worked well, so NASA used it for different projects like Apollo and Voyager in the 1960s. Nowadays Six Sigma's project team use FMEA in the Analyze stage of DMAIC because extraordinary quality is not only designed into the product, it is designed into the development process itself. The DRBFM methodology was created by Tatsuhiko Yoshimura, who is an expert in quality and a professor at Kyushu University in Japan. Yoshimura understood that making changes without the right documents can cause design problems. He used the idea of preventing problems before they happen to come up with his own way of thinking called DRBFM.

Download or read book Machinery Oil Analysis Condition Monitoring A Practical Guide to Sampling and Analyzing Oil to Improve Equipment Reliability written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2020-09-27 with total page 75 pages. Available in PDF, EPUB and Kindle. Book excerpt: The laboratory examination of a lubricant's characteristics, suspended impurities, and wear debris is known as oil analysis (OA). OA is carried out as part of regular predictive maintenance to deliver precise and useful data on lubricant and machine condition. Trends can be found by following the findings of oil analysis samples over the course of a certain machine. These trends can help avoid expensive repairs. Tribology is the study of wear in machinery. Tribologists frequently perform or interpret results from oil analyses. Oil analysis is a long-term program that, where relevant, can eventually be more predictive than any of the other technologies. It can take years for a plant's oil program to reach this level of sophistication and effectiveness. This book includes what all practitioners need to know to build an oil analysis program for their machine inspection. This book includes three real case studies and numerous industrial examples to improve machine reliability and enhance the condition monitoring program.

Download or read book The Seven Deadly Wastes and How to Remove Them from Your Business written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2014-09-07 with total page 82 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book discusses the seven deadly wastes (muda) in the value stream process. It presents the cost of each waste, its effect on the process, and how it can be eliminated to increase profitability. Waste removal increases the profitability of any business. Processes are classified into value added and waste. The seven deadly wastes that could exist in any manufacturing process originated in Japan and are defined in the Toyota production system (TPS). The main goal became removing them. For each waste, there is a strategy to remove or eliminate it. What is less likely is that managers will know how any of these issues are affecting them and increasing costs. To remove each waste, you have to understand where it comes from, why it exists, and how it affects your business. In the economic recession, many companies are taking abstinence procedures to reduce costs. This might include layoff labors and reducing some wages. Actually, those actions might work for only a short period. Afterwards, the situation may return and in worse shape unless the company changes its way of doing things, including enacting a culture of continuous improvement. This puts us back to why the Toyota production system has been created.

Download or read book Takt Time A Guide to the Very Basic Lean Calculation written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2020-10-16 with total page 68 pages. Available in PDF, EPUB and Kindle. Book excerpt: Takt time is calculated as the amount of manufacturing time that is available divided by the volume of orders. In the 1930s, the German aviation industry employed Takt for the first time as a production management tool. The idea was widely used within Toyota in the 1950s, and by the late 1960s, it had been adopted by the majority of the Toyota supplier base. Every month, Toyota assesses the takt for a process, with a modifying review occurring every 10 days. Takt time is used to properly balance supply and demand. It gives a lean production system its beating heart.

Download or read book Kanban the Toyota Way An Inventory Buffering System to Eliminate Inventory written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2020-08-14 with total page 80 pages. Available in PDF, EPUB and Kindle. Book excerpt: Production kanban, which translates to "sign" or "signboard" in Japanese, instructs an upstream process on the kind and number of goods to produce for a downstream process. In a pull system, a kanban is a signalling tool that provides approval and instructions for the manufacture or withdrawal (conveyance) of products. The conveyance used by the downstream process is referred to as the "withdrawal." The assembly process and the client, the assembly process and the supplier process, and the supplier process and the vendor all benefit from kanban. The Toyota production system is founded on zero inventory, but because there are natural interruptions in flow as raw materials are transformed into completed goods and supplied to customers, some required inventory must be included. The Toyota kanban system is frequently the next best option when clean flow is impossible due to processes are too far apart or the cycle times to complete the operations vary greatly.

Download or read book Toyota Prodcution System Concepts written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on with total page 28 pages. Available in PDF, EPUB and Kindle. Book excerpt: Heijunka, which means "production smoothing or leveling" in Japanese, is a method that helps balance production in all areas and with suppliers over time. It aims to make Just-In-Time (JIT) production easier. Heijunka is an important part of Just-in-Time (JIT) production. It means finding and keeping a consistent level of production. The main purpose of using the Heijunka technique is to provide goods at a consistent pace, which allows other operationsto also run smoothly and predictably. This helps decrease wastes and the amount of inventory.

Download or read book Industrial Power Transformers written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2024-07-04 with total page 112 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book aims to explain the best ways to do work that is usually done to avoid issues with transformers. This book covers everything about choosing and storing transformers. It also talks about advanced methods for checking transformers using predictive maintenance or condition monitoring. It also includes a real example of using FMEA to make power transformers more reliable in a system or production process. The techniques in this book are not for making big changes to repair a transformer. However, many things are done as part of regular procedures. Maintenance and big transformer repair could be the same. We can do the tasks to take care of the transformer if it's not too broken. The advice in this book is similar to the suggestions that companies give for their products. If you need to know how to do something, the person in charge should check the instruction book from the company that made the product. Regularly check and fix small problems to keep transformers in good condition. Also follow special care instructions. Also, if the machine is set up and used the right way, it will keep working for a long time without any issues.

Download or read book Industrial Electric Motors written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2024-07-08 with total page 214 pages. Available in PDF, EPUB and Kindle. Book excerpt: Taking care of electrical equipment needs a lot of thinking ahead and checking regularly. You can only find problems early if you regularly check things. A careful team of workers can find machine problems by using their senses. They can smell burning insulation, feel excessive heat in bearings, hear strange sounds or vibrations, and see mechanical issues and sparks. Different methods can be used to check how electric motors are working. Taking care of equipment is not only about repairing it when it stops working. It's important to work hard to keep it running smoothly all the time. This means that even when the machines are working well, people who take care of them are still trying to make them better so they stay working well. This book wants to show the best ways to do work that is usually done to avoid problems with motors. This book has everything you need to know about putting in, using, and taking care of motors. It also discusses better ways to check motors using predictive maintenance or condition monitoring. It also shows how FMEA can be used to improve the reliability of electric motors in a system or production process. This book is for everyone, including technical, engineers, managers, leaders, and quality professionals.

Download or read book Manufacturing Wastes Stream Toyota Production System Lean Principles and Values written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2022-10-02 with total page 94 pages. Available in PDF, EPUB and Kindle. Book excerpt: In order to cut costs during the economic downturn, many businesses are implementing abstinence policies. This could mean laying off workers and cutting some wages. In fact, those actions might only work for a short time.Unless the company implements a culture of continuous improvement and alters its method of operation, the situation may recur and become even worse. This brings us back to the purpose for which the Toyota production system was developed. Waste is anything that uses resources but offers the customer nothing in return. Most activities are waste, or "muda," and can be divided into two categories. Although type one muda does not provide value, it is inescapable given the production assets and technologies available today. An illustration would be checking welds for safety, that type we also call necessary non value-added activity. Type two muda does not add value and can be quickly eliminated. An illustration is a process in a process village with disconnected phases that may be swiftly converted into a cell where unnecessary material moves and inventory are no longer necessary. A very small portion of all value-stream activities truly generate value as perceived by the client. The most effective way to boost business performance is to stop doing the numerous unnecessary things.

Download or read book Creating a One Piece Flow and Production Cell Just in time Production with Toyota s Single Piece Flow written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2022-12-01 with total page 116 pages. Available in PDF, EPUB and Kindle. Book excerpt: One-piece flow, also known as continuous flow, is considered the ultimate lean goal. It describes how items are efficiently moved from one stage of the process to the next by designing the workflow around the requirements of the product. To get from point A to point B is the objective. Any waste or halt in production is equivalent to the stones and dams that direct the flow of water. We examine our layouts, devices, procedures, rules, cultures, and knowledge while attempting to implement flow to see what might be causing these flow-blocking factors. Continuous flow aids in waste reduction. Because there is harmony and rhythm between each stage of the process, wastes are eliminated from the system. This enables each team member to provide value rather than produce waste. Processing waste is decreased because there is naturally less rework (or overprocessing), there is only as much work done as the customer is prepared to pay for, and there is only one accepted technique to complete the task (no bad processing).

Download or read book Toyota Standard Work The Foundation of Kaizen written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on 2021-03-13 with total page 75 pages. Available in PDF, EPUB and Kindle. Book excerpt: Having no standardization work process means no quality. Everyone will do this task differently. Tracking the source of errors is difficult without the work standard. When a leader perform gemba walk on shop floor to observe the situation, there is no benefit from the walk when there is no standard. In the classic old way of management, companies were and (many are still) following the Taylor’s principle, Taylor said that industrial engineers should be the only ones who initiate, create, modify, adapt and improve the process. And workers should follow what the industrial engineers are saying. Standard work is being used to measure employees performance. This is really a contrary to respect for people which is one of the main pillars in the Toyota production system and was the reason why Toyota is a high performance company. Toyota is strong by its people not by its process. Toyota Creates standard work to eliminate wastes, develop employees skills and develop high level of knowledge.

Download or read book A Failure Mode and Effect Analysis FMEA is a systematic method for identifying and preventing product and process problems before they occur FMEAs are focused on preventing defects enhancing safety and increasing customer satisfaction FMEAs are conducted in the product design or process development stages although conducting an FMEA on existing products and processes can also yield substantial benefits Six Sigma s project team use FMEA in the Analyze stage of DMAIC because extraordinary quality is not only designed into the product it is designed into the development process itself written by Mohammed Hamed Ahmed Soliman and published by Mohammed Hamed Ahmed Soliman. This book was released on with total page 75 pages. Available in PDF, EPUB and Kindle. Book excerpt: A Failure Mode and Effect Analysis FMEA is a systematic method for identifying and preventing product and process problems before they occur. FMEAs are focused on preventing defects, enhancing safety and increasing customer satisfaction. FMEAs are conducted in the product design or process development stages, although conducting an FMEA on existing products and processes can also yield substantial benefits. Six Sigma's project team use FMEA in the Analyze stage of DMAIC because extraordinary quality is not only designed into the product, it is designed into the development process itself.