premkumar thirunavukkarasu

A3 Problem Solving:
It’s a practice started in Toyota later adapted in lean methodology.
There is a huge difference between the movies before the 1930 and after, yes your guess is rights its about the sound.
The same logic applies when we discuss about the problem in shop floor with or without a Print / Soft copy document which describes the Problem status.
 

 
To bridge the gap, A3 Problem solving tool in place.
 

 
A Typical A3 Problem solving tool standard, looks as above.
(The Yellow text box comments indicates “HOW TO”)
 
The sequence of A3 tool as follows:
1)      Theme or Brief about the problem (one or two line)
2)      Current (initial condition) in a quantified way
3)      Target, in specific
4)      List of action with Plan vs Actual
5)      Peformance indicators for visualing the progress
6)      Closure with Signature
This is is not a one time document, its to be used whenever required. It serves in following situation, during the problem solving for discussion, communicate to the team and then for learning (reference) for future.
An unique nature in this tool, there is no specific time line to complete the standard.
Based on the severity of the problem, shall differ.
Although the A3 is typically on one page in size, there can be additional pages for backup documenting.
A better processs to start, ask the project leader for a proposal using A3 without formatted layout and fine tune it with format for a noble A3.
Also A3 (297mm x 420mm) tool, shall customize it to suit the requirement for solving any problem.
 
Apart from the format & how to use it, further will discuss about how its helps for building a continuous improvement culture.
The composite essence for building any continuous improvement culture are:
i)                    Simple in use
ii)                   Communication
iii)                 Innovation / Kaizen
All the above three components are well harmonized with A3.
A3 – for usage its very simple, when compared to other tools
A3 – Its ease to communicate a single A3 sheet, continuous improvement is a complicated “THE MINDSET” able to disrupt because of its minimal size when compared to other tools.
A3 – Any innovation / kaizen able to fit in A3, may need a detailed back up its apart but when considering a quick, simple to prepare and ease to communicate A3 is well ahead.
 

JIT – Just in Time is a part of Toyota Production System, yes its originated in Japan.
In an overall it looks like more focusing on Inventory Management, but in practical the approach will make other issues visible and also towards solving the same.
Any approach or a concept needs a foundation, same way JIT also requires following Pre requisites to make it efficient.
 
 
 
Pre requisites:
1)     Awareness about JIT
2)     5S
3)     Flow Manufacturing
4)     Levelling
5)     Standardized Operations
 
In another view all above are Primary Prerequisites and to support the primary prerequisites, secondary prerequisites are as follows:
 
1)     Visual Management
2)     Optimized Man power
3)     Multiskilled Operator
4)     Kanban System
5)     SMED / Quick Changeover
6)     Zero Defect / Quality Awareness
7)     Human Autonomation / JIDOKA
8)     Maintenance – PM & AM
9)     Safety / Zero Risk
For ease understanding, summarized as below:
 

 

 

 
 
In Brief, take care all the anomalies related to "reducing the phase of process flow and also the reverse flow".
 

JIT – Just in Time is a part of Toyota Production System, yes its originated in Japan.
In an overall it looks like more focusing on Inventory Management, but in practical the approach will make other issues visible and also towards solving the same.
Any approach or a concept needs a foundation, same way JIT also requires following Pre requisites to make it efficient.
 
 
 
Pre requisites:
1)     Awareness about JIT
2)     5S
3)     Flow Manufacturing
4)     Levelling
5)     Standardized Operations
 
In another view all above are Primary Prerequisites and to support the primary prerequisites, secondary prerequisites are as follows:
 
1)     Visual Management
2)     Optimized Man power
3)     Multiskilled Operator
4)     Kanban System
5)     SMED / Quick Changeover
6)     Zero Defect / Quality Awareness
7)     Human Autonomation / JIDOKA
8)     Maintenance – PM & AM
9)     Safety / Zero Risk
For ease understanding, summarized as below:
 

 

 

 
 
In Brief, take care all the anomalies related to "reducing the phase of process flow and also the reverse flow".
 

To before getting in to the methods of how the objectives realized in Economies of scale Vs Customization, first will understand the concept Economies of scale & Customization…
Economies of scale:
Economies of scale are cost advantages of an organization experienced when production is efficient, as costs can be spread over a larger amount of goods.
Imagine only one car is produced in a car manufacturing plant with full resources, whether profit able to realize by the organization?
Exactly you are right, there will be no profit in the above case.
The profit will be realised only when mass quantity done in a car manufacturing plant.
Thus Economies of scale will be realised when product quantity exceeds to meet the profit.
The other key aspect of Economies of scale as follows:
-      Higher production levels
-      Business size is very related to the Economies of scale
-      There are both internal & external factors related to Economies of scale
 
Following are the main reasons for Economies of scale why leads to lower per-unit costs.
i)             Specialization of labour and more integrated technology boost production volumes.
ii)            Lower per-unit costs can come from bulk orders from suppliers / market / customer base or lower cost of capital.
iii)          Spreading internal function costs across mass units produced and its leads to reduce costs.
Let’s move to the other part of the bridge, “Customization” …
In brief, Customization is defined as to make or alter to individual or personal specifications.
The background of customization starts from the early stages of human history; customization is the another symbol of pride & sophistication.
There is always space (now in the competitive market with more) for customized product in the market and leads to growth of the business.
The key aspect of customization are:
-      Continuous business
-      Comparatively satisfied customer
-      Comparatively quite individualistic manufacturing process
 
Now it’s time to conclude, how we can realize the objective of both Economies of scale vs Customization?
Ø    Flexibility in Manufacturing:
Recently a leading car manufacturer converted their line conveyor method to flexible line to meet the supply immediately according to the changes in market requirement, by adapting a flexible manufacturing system able to meet the Economies of scale & Customization.
 
Ø    The other approaches (of course still evolving) in manufacturing which meets the both sides are Micro manufacturing, hyper-local manufacturing and additive manufacturing.
 
Ø    Mass customization is the another method to meet the objective of Economies of scale & Customization, it is the process of delivering market goods and services that are modified to satisfy a specific customer's needs. This is a marketing and manufacturing technique that combines the flexibility and personalization of custom-made products resulting in low unit costs because of mass production.
 
Ø    Further take the advantage of Artificial intelligence & Machine Learning analyse the market and understand the behaviour of market strive the business approach towards the same.
 
Ø    Other suggested solution is Minimum Viable Product approach, at the early stage of launch of product keep it in minimum performing (basic requirements of mass customer) then customize based on the individual requirements.
 
Ø    Finally, ensure the Me-Factor customize the things that will add a difference to your customer in other way know what matters to your customer and the deal breakers.

Apart from all the above approaches, further add two more real life views for thought process.
Once Henry Ford indicated “Your customer doesn’t know what he required so don’t ask your customer what he wants, instead of car may his view will need a cart to add more horse for increasing the speed of travel to complete the required distance”
Steve Jobs, introduced the iPhone at a stage where there is an unexpected market by combining three machines camera, MP3 Player and a personal computer.  In simple, a visionary thinking from customer point of view.