Use Shingo Maps to Drive Continuous Improvement in ISO 9001:2015
William A. Levinson, P.E., FASQ, CFPIM is the principal of Levinson Productivity Systems, P.C. He is an ASQ Certified Quality Engineer, Quality Auditor, Quality Manager, Reliability Engineer, and Six Sigma Black Belt, and the author of several books on quality, productivity, and management.
This webinar will show how to expand Shingo maps from individual project applications into evolving, data-driven process documentation for an ISO 9001:2015 or related quality management system. Shingo maps support ISO 9001's process orientation, and also identify opportunities to reduce or eliminate wastes of time, material, and energy (muda). The latter applications support ISO 14001 and ISO 50001 as well as ISO 9001.
Shingo process maps were developed originally to support improvement projects, but their very nature of being process maps supports ISO 9001:2015's process-oriented approach. Shingo maps, however, add data collection to process maps to identify wastes of time, materials, and even energy (muda) to support continual improvement. This makes them ideal synergistic additions to any ISO 9001 (or similar) quality management system.
- Know the original role of Shingo maps in process improvement projects, and how their data-driven nature exposes wastes that can be removed by lean and/or Six Sigma projects. Shingo maps can expose wastes of time, material, and even energy.
- No material or energy waste can hide from what chemical engineers call a material and energy balance. Process inputs must equal process outputs in quantity and kind, and any output that is not a saleable product is waste. Avoidance of material and energy waste reduces costs and supports ISO 14001 and ISO 50001.
- Shingo maps support the Plan, Do, Check, Act (PDCA) continual improvement cycle.
- Construct Shingo maps to assess a process' effective use of cycle time. Classify operations as Transformation (value-adding), Setup/Handling, Inspection, Transportation, or Delay. Only transformation of the product (Masaaki Imai's value-adding "Bang!") adds value for the customer. (Gaa, Peter. 2015. Creating and Using a Shingo Style Process Map. Waring TX: Rikai Publishing, is a highly recommended reference.)
- Calculate process cycle time efficiency, and recognize the negative impact of variation in processing and material transfer times on inventory and cycle time. The latter issue is described in Eliyahu Goldratt's The Goal.
- Use the Shingo map to document a process in an ISO 9001 or related quality management systems, and to show interfaces and handoffs between processes. These interfaces and handoffs are often hiding places for wasted cycle time, generally in the form of waiting or transport
Who Should Attend
Manufacturing and quality professionals, and people involved in the ISO 9001:2015 transition