Lean Management is an integrated system of TQM, TPM and TPS
Lean Management is defined as a management philosophy which aims identifying and systematically elimination of all sources of waste at each stage of innovation chain and supply chain. Lean philosophy initially focused on manufacturing firms and later it was developed as an enterprise wide management philosophy. Lean philosophy is developed based on six principles. It is, Value , Value Stream, Flow, Pull, Quality at the source and perfection.
How you define waste ? “Any activity which absorbs resources but creates no value”
Toyota has identified seven type of waste in their manufacturing process and elimination of those waste helped them to challenge Just In Time(JIT). You can see Toyota seven waste in any type of business but the criticality is different. If you follow seven waste without proper understanding, it will become an another waste. Based on the above definition you can develop your own waste model and try to eliminate them. Your approach to be leaner and meaner. What is TQM ? TQM is an approach to improving the effectiveness and flexibility of business as a whole. It is essentially a way of organizing and involving the whole organization, every department, every activity, every single person at every level. TQM inculcate a culture where continuous improvement can sustain. Sustainability is defined as the ability of an organization to adapt to change in the business environment to capture contemporary best practices and to achieve and maintain superior competitive performance. For this we need to establish high performance culture in the organization and TQM does it well because TQM aims at bringing about a total cultural change in every facet of the organization. As per Dr.W.Edward Deming “80% of quality problems and caused by management, and 20% by workers” . So cross functional management involvement and taking the responsibility and accountability of quality in all management functions in the organization is mandatory to challenge zero defects and zero customer dissatisfaction. TQM concept break outdated organizational culture and lay a solid foundation for a Lean Enterprise. Quality is every bodies responsibility and it is defined by the customer. TQM set the direction and strategy to build a customer centric organization through harnessing every one`s commitment.
Main features of TQM organization are empowered cross functional teams and involvement of everybody at every level, Statistical method and analysis , Management Leadership and problem solving and continual improvement. Lean is all about people and how they use technology and tools . TQM concept clearly address this part and create a very good flat form for people to unleash their potential. Lean transformation is supported by cultural transformation. What is TPM ? TPM stands for Total Productive Maintenance & Management and it is defined as a programme that aims to create a culture and environment that constantly tries to maximize the effectiveness of the entire production system . TPM uses a hands –on shop floor approach to build a ‘ zero accident .zero defect and zero breakdown’ system designed to pre-empt losses of all types throughout the life cycle of the production system. When we challenge Just In Time we must make sure reliable equipment and process with multi skilled work force. TPM does it well and build the stability of the process and availability of equipment all the time. TPM further strengthen the foundation for Lean enterprise.
The 8 pillars of TPM covers all the functions of a manufacturing organization. It is Focused Improvement(Kobetsu Kaizen) , Autonomous Maintenance (Jishu - Hozen), Planned Maintenance (Keikaku – Hozen) , Eduction & Training , Early Management, Quality Maintenance (Hinshitsu – Hozen),TPM in administrative and supply chain department, Safety Health and environment . These pillars are mainly designed to challenge zero breakdown and zero defects which produced by the equipment. If anybody neglects their equipment and think of becoming a lean enterprise it is a nightmare. What is TPS ? TPS stands for Toyota Production System and it applies the “pull ” concept ( make only what has been sold or is needed) together with production leveling and mixed – flow, stockless production to minimize lead times and costs in order to produce a high variety of products inexpensively. But this requires an essential ingredient “TPM” since it can only be done successfully when breakdowns, minor stops, quality defects and rework have all been eliminated. TPS has become the world best production system due to its flexibility. They reduced the lead time drastically by eliminating seven type of losses ; Transportation, Inventory, Motion, Waiting, Over production, Over processing, Defect and rework. Toyota Production system was developed for Toyota Production System .So don`t striate away copy TPS and paste it to your production system. Try to copy Toyota way of thinking and customize TPS for your production process. Since TPS clearly reduces the lead time and maximize flexibility any organization can get the benefits of TPS in order to survive in a slow growth world economy. TPS program addresses Supply Chain Management issues and it is extended to supplier development stage. Sales and planning department plays a big role in production leveling that has become a key area of TPS.
The journey towards becoming a Lean enterprise is not easy and it is not a quick win. But it is realistic and a MUST DO task in Liberalized, Globalized and privatized business world for survival. Better understanding of TQM,TPM and TPS concepts and the ability to integrate all 3 ‘ T’s decides the success of your Lean journey. Implementing 3 Ts is not sequence it should be parallel. The lean road map with priorities can be decided after carrying out a detail diagnosis of your current way of doing business. The business need , the nature of the business , culture and competency level of the organization are few key parameters to understand the current situation. None of the organization can challenge Lean only with one concept. It should be the integrated system of TQM ,TPM and TPS. True lean strength comes over time and depth of experience.