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Lean Quality Circle

The document describes Lean Quality Circles (LQC), a new concept originating in India that is based on traditional Quality Control Circles (QCC) but adapted for lean manufacturing. LQCs are smaller groups of 2-3 non-executive employees from the same or different functions, along with an executive mentor. They aim to continually improve processes by identifying and solving problems using tools like DMAIC methodology. LQCs are intended to address some limitations of traditional QCCs, such as lack of enthusiasm, inability to review problems quickly enough, and not achieving results in a short time frame.

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0% found this document useful (0 votes)
2K views19 pages

Lean Quality Circle

The document describes Lean Quality Circles (LQC), a new concept originating in India that is based on traditional Quality Control Circles (QCC) but adapted for lean manufacturing. LQCs are smaller groups of 2-3 non-executive employees from the same or different functions, along with an executive mentor. They aim to continually improve processes by identifying and solving problems using tools like DMAIC methodology. LQCs are intended to address some limitations of traditional QCCs, such as lack of enthusiasm, inability to review problems quickly enough, and not achieving results in a short time frame.

Uploaded by

sureshbaddha
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Lean Quality Circle (LQC)

By: RL MAURYA
FIE,MBA,BOE,CEA
DGM (BE)
NTPC-VSTPP
[email protected]
9425178087
Quality Control Circle (QCC)

QCC is popularly known as QC, the concept originated from Japan in 1962

Definition: QC is a small group in which people who work in the first


line work place, continually improve and maintain the quality of product,
services, job & so on.

Objective: Utilize quality control concept ,techniques and other


improvement tools, tap members creativity and promote self & mutual
development.

Aim: Develop member’s capability and achieve self actualization,


workplace management, improve customer satisfaction and contribute to
society.

Source: QCFI
Quality Control Circle (QCC)
QCC Problem solving methodology
1 • Identification of Problems
2 • Selection of Problems
3 • Definition of the problem
4 • Analysis of the problem
5 • Identification of causes
6 • Finding root causes
7 • Data Analysis
8 • Developing solutions
9 • Foreseeing probable resistance
10 • Trial Implementation
11 • Regular implementation
12 • Follow up & review
PDCA CYCLE
PDCA Vs QCC STEPS
1 • Identification of Problems
PLAN (1-3) 2 • Selection of Problems
3 • Definition of the problem
4 • Analysis of the problem
5 • Identification of causes
DO (4-8) 6 • Finding root causes
7 • Data Analysis
8 • Developing solutions
9 • Foreseeing probable resistance
CHECK (9-10)
10 • Trial Implementation
11 • Regular implementation
ACT (11-12) • Follow up & review
12
LEAN QUALITY CIRCLE
About LEAN …
Lean is about doing more in Less – time,
inventory, space, money etc.

Lean Manufacturing is adding value in


every process.

Lean is about speed and getting things


right the first time.

As a part of Toyota Product system.


Lean Quality Circle (LQC)
LQC (Lean Quality Circle): the concept is very new and originated in
India by QCFI.

Definition: No any formal or declared definition as in QCC. A small


group (Two to Three) of task performers of the same or cross functions
comprising of Non-Executives. Mentor (An executive) is part of the team.

Objective: Forming the competent team and solving the problems by


using appropriate problem solving tools & techniques with the tangible
and intangible benefit to the organisation.

Aim: Knowledge and skill development, continual improvement,


workplace management, improve customer satisfaction and contribute to
organisation & society.
LEAN QUALITY CIRCLE
About Lean Quality Circle…
Size can be 2 to 3 members
Cross functional
Problems directly related to department and organisational goals
Handle critical and major problem with higher knowledge

No fixed meetings but as per requirement


Meetings informal at workplace
Weekly progress report is reviewed
Facilitator will be guide
Leader will be the initiator of the project
LEAN QUALITY CIRCLE
Concept of LEAN QC
Small group of non executives from
problem area
Knowledgeable members with problem
solving skill

Who can by themselves select problem

Take help of immediate line executives

May co-opt members

Solve the problems using appropriate tools


LEAN QUALITY CIRCLE
Why? lean QC Over Conventional QCC

Lack of enthusiasm among top management

Shorten life cycle of the product

Difficulties in reviewing and monitoring

Reshuffling of the employees


Demand for results in shorter time

Lack of time and support by executives


LEAN QUALITY CIRCLE
Structure of LEAN QC
Top Management
Steering committee
Coordinating agency
Facilitator
Project Leader
Potential members
Members
LEAN QUALITY CIRCLE

LQC is based on DMAIC Methodology

• Developing business cases with


Define potential benefits

Measure • Measurement, data collection

Analysis • Analysis of experiments

Improve Recommendations & action

Control Sustain
LEAN QUALITY CIRCLE
QCC Steps Vs LQC Steps
1 • Identification of Problems
2 • Selection of Problems
3 • Definition of the problem
4 • Analysis of the problem
5 • Identification of causes
6 • Finding root causes
7 • Data Analysis
8 • Developing solutions
9 • Foreseeing probable resistance
10 • Trial Implementation
11 • Regular implementation
12 • Follow up & review
LEAN QUALITY CIRCLE
Methodology LQC Vs QCC
1. DEFINE – 3rd STEP

•Problem definition

•Current status

•How it affects the process

•Impact of it on waste

•Objective

•Set the Goals


LEAN QUALITY CIRCLE

2. Measure – 4th STEP


• Frequency of the problem
• Loss of material, man hours & cost etc
3. Analysis – 5th to 7th STEP
• Identify causes, Root cause and Data
Analysis
LEAN QUALITY CIRCLE

4. Improve – 8th to 11th STEP


• Develop solution, foresee resistance, trial
and implement

5. Control – 12th Step


•Follow up and review
LEAN QUALITY CIRCLE
category of wastes

• Refers to wasteful activity


MUDA

• Refers to wasteful design to


MURI reduce the strain

• Refers to wasteful
MURA implementation, over burden
LEAN QUALITY CIRCLE

Types of waste
Transportation
Inventory
Motion
Over processing
Defects & Rework
Under utilised Human potential
Over production
Waiting time
THANK YOU

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