THE IMPACT OF WORLD-CLASS MANUFACTURING PRACTICES ON SMALL MANUFACTURERS - by
David K. Johnson

Continuous Improvement

Continuous improvement is the central concept behind many of the traditional quality improvement techniques. Dr. W. Edwards Deming proposed what is known as the Deming cycle, which advocates a structured methodology for continuous improvement.

This cycle includes four steps: Plan, Do, Check, and Act.
Too often manufacturing systems are managed “by the seat of someone’s pants”. Managers are often caught in the trap of doing and then “fighting fires” instead of using the Deming cycle to identify the causes of fires, and eliminating them at the source.

Quality Improvement Tools

Many tools are readily available to promote continuous improvement. Many of which are based on the use of statistics. Through the use of statistics, management is better able to gain an understanding of the system, and therefore make informed decisions in regard to improving the system. These tools include the use of poka yoke devices, control charts, Pareto diagrams, process capability analysis, cause and effect diagrams, continuous improvement teams, and other techniques, which are beyond the scope of this thesis.

Poka Yoke Devices (Mistake Proofing)

Poka yoke or mistake proofing is a method of designing parts and processes in ways that make desired results inevitable. An example of a simple poka yoke device might include the design of parts so that it is impossible to assemble them incorrectly because they only fit together the correct way. Compute cables, which only fit into the correct connections is another example of the use of poka yoke devices. The use of poka yoke devices is often a simple yet powerful solution to quality problems.

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Copyright © 2005. David K. Johnson. All Rights Reserved.