Defects lead to a rework operation or a destruction of the units produced; consequently to a waste of products and time. Causes of this waste are unclear customer specifications, incapable processes, lack of process control, unskilled personnel, and incapable suppliers. Quality is doing the right thing right the first time. It is about prevention and planning, not correction and inspection. Bad quality or defects do not only result in customer dissatisfaction and damage to company image, but also in wastes due to additional costs and time to recall, rework, repair, and replace the defective items.
The 7 principles are as follows; a) Eliminate Waste b) Build Integrity In c) Create Knowledge d) Delay Commitment e) Deliver Fast f) Respect People g) Optimize the Whole i) Eliminate Waste Anything you do that does not add value from the customer perspective is waste. The seven wastes of software development are: ® Partially
These negative impacts has led to different crisis and even damage the company’ brand and reputation in the marketing environment. Over the years there has been different disadvantages of turnover, the following are some negative impacts (disadvantages) of turnover on organizations,Neil Kokemuller (n.d). High cost High turnover has always been more expensive to an organization as the company will have to undergo costs of recruiting and replacing the employees who left and also the company will experience the cost of training the new employees since they are not familiar with the working environment. These cost are the disadvantages of turnover on organizations around the world such as Wight Hotels (WH), Neil Kokemuller (n.d). Low morale When there is high turnover in the company the morale of the remaining employees is likely to be low which leads to other disadvantages such as poor performance.
1. INTRODUCTION The practical management problem faced by managers at Medal Paints is that there has been an increase in equipment breakdown due to lack of maintenance on the equipment. The company was faced with a challenge of maximising production outputs and minimise cost. When minimising costs very often company s look at the cost of maintenance and Medal Paints also decided to minimise costs by cutting down on maintenance costs. The company purposely allows the equipment to function until a breakdown occurs, at this point responsive maintenance will then be performed on the equipment.
Lean manufacturing Lean manufacturing is the way to get rid of Muda, Muri, and Mura (wastes) and improve efficiency in manufacturing environment. Less waste, human effort, manufacturing space, investment in tool, inventory, and engineering time to develop a new product are traditional mass production of products using less of everything to be compared. Lean manufacturing provide the customer a defect-free product or service when they need it and in the quantity that they need, a system that focuses of eliminating waste and creating value for the customer. So why using lean manufacturing in production system? Becoming lean means increased cash flow (by freeing up inventory and short lead times, increased long-term profitability ( by improving
7). Cynicism entails the lack of passion and enthusiasm for one’s work. Cynicism is a product of exhaustion in the sense that a worker gets detached from their work as a result of being overly exhausted. Other than excessive workload, other causes of burn out in health care are inadequate resources, and mediocre pay (Campbell, 2013, Pg. 27).
2. Poor Maintenance Improper maintenance is the number one reason why machines fail. Unfortunately, most companies don’t take this issue seriously. It pays to have the moving parts of a machine greased properly and done on a timely basis. Sometimes companies will skip lubrication routines or miss some grease locations on a new industrial device since they did not go through the entire maintenance manual of the machine.
Without efficient management, it becomes difficult for information to feed up and down the chain of command. Staffs feel less empowered. Presently, the company has various front-end and back-end systems running separately. It results in a clash between different processes that ensure that the company is running easily. Inventory management is suffering due to lack of accurate data from sales.
Preventive and corrective maintenance is done based on the criticality of that equipment. The production processes and products are designed in such a way to achieve a fault-free production and increase the quality and reliability of the products. The employees are trained on the basic methods of preventive quality assurance and in each production area there are additional employees who have in-depth knowledge about early stage error prevention. Kostal uses poka-yoke mechanism, it is a mechanism used in lean manufacturing processes to help the equipment operators avoid mistakes. The aim of this mechanism is to get rid of product defects by preventing, correcting or drawing attention to human errors as they occur.
Recalibrating machinery causes downtime in production and the waste of a technician's time, which can be better spent working on other aspects of operations while abnormally high amounts of overtime show that operations in the company are inefficient. So, it is crucial for manager to look up for this situation if