We wish all of you a merry christmas and a happy new year and hope that we can welcome some of you in June 2012 in Frankfurt!

Check this video.

After you create chart you can save it as image to you computer or share it on web. Download this software from
QTcharts free quality management tools

The Business Complexity Accelerator at Toyota

There was an interesting article in the Knowledge@Wharton newsletter today. Wharton management professor John Paul MacDuffie interviewed Toyota expert, author and Tokyo University Professor Takahiro Fujimoto. The piece is called Under the Hood of Toyota’s Recall: ‘A Tremendous Expansion of Complexity’ and raises the by now familiar questions of complexity of modern automobile systems design, attitudes at Toyota towards its recent quality problems, and what this means for both Toyota and its competitors. To sum up the article with an automotive metaphor, Toyota needs to take its foot off of the business complexity accelerator.

Fujimoto said, “I was surprised to see that Toyota was the first to be caught in this trap of what we may call

complexity problems.” What has puzzled Toyota watchers is how Toyota, proven to be so great at solving problems for so many years, seems to have stumbled in a big way during this recent acceleration-related recall. Why?

Toyota failed to see this problem in the right way, at least in the beginning.

Failing to grasp a problem clearly, quantitatively and without prejudice is the first step in problem solving. Was this a case that the problem solving approach was flawed, or was it that the problem solving process is still sound but that Toyota did not follow their own process?

The danger is that people tend to connect the two problems. “This happened and that happened, so there must be causal relations between the two.” But this is not the case. There appears to be no connections between the design problems and the Toyota production system or Toyota Way.

He clearly says that the recent quality issue at Toyota is not connected to their way of working within the production operations, i.e. the Toyota Production System or even more broadly their philosophy, the Toyota Way. He suggests that that the complexity of new systems within the design simply got out of hand, and when they did, Toyota was unable to respond properly. While the processes within TPS are sound, the mindsets and behaviors of people may have shifted in an unhealthy way towards overconfidence, even arrogance. Fujimoto said:

Read more text http://www.gembapantarei.com

Road vehicles – Pedestrian protection ISO 11096:2011

The number of pedestrian leg injuries caused by dangerous car design should be reduced thanks to an ISO International Standard defining a new crash test method.

According to the World Health Organization, road traffic accidents kill more than one million people a year, injuring another thirty-eight million (five million of them seriously). The death toll on the world’s roadways makes driving the number one cause of death and injury for people aged 15 to 44.

ISO 11096:2011, Road vehicles – Pedestrian protection – Impact test method for pedestrian thigh, leg and knee, sets out a test method to assess the protection of an adult pedestrian by simulating the leg-impact conditions sustained during the car-to-pedestrian crash.

The goal is two-fold – to:

- Provide information on pedestrian safety to consumers
– Induce manufacturers to develop vehicles with excellent pedestrian protection.

Sukhbir Bilkhu, Chair of the ISO subcommittee that developed the standard, commented: “The pedestrian impact test simulates accidents in which a pedestrian is hit by an oncoming vehicle. These accidents represent about 15 % of fatal crashes. Thanks to ISO 11096, we will make substantial progress in improving vehicle structure, and in so doing, reducing pedestrian lower-limb injuries.”

Read more text http://www.iso.org

Christopher J. Scolese

After 30 years of missions, NASA is ending its Space Shuttle programme. Why was this decision taken, and what’s next for NASA ?

Christopher J. Scolese : The Space Shuttle has been around for 30 years and it has proven itself to be a remarkable machine that has accomplished some absolutely fantastic missions and tasks. The Hubble Space Telescope and astronomy would not be where they are today without the Space Shuttle and all the work NASA carried out with our international partners. Without the Shuttle, today’s International Space Station (ISS) could not have been built to serve all
15 partner countries. Our work on the ISS truly serves the whole world as more and more countries have come to

use it. Now NASA is ready to embark on the
next phase of space exploration. This will be the utilization of the ISS now that it has been built, and we have all started to understand how to exploit it. NASA is in a position to carry out necessary research in order to fully utilize the ISS and prepare, once again, to send humans beyond low-Earth orbit with the technologies of today. This was

the reason for moving on from the Space Shuttle to build upon the great legacy of that machine. Of course, like anything else, the space industry has changed over the past 30 to 40 years.

In 1970, roughly, when the Space Shuttle was conceived, there were really only two countries in the world that were sending people into space : the USA and the Soviet Union. Both  countries are very different today ; the world is very different. I like to joke with young engineers and say, “ Think about it : the power of your handheld cellular phone today is probably
greater than that of the computers that sent Apollo astronauts to the moon in the 1970s ”. So, clearly technology, the environment and globalization have changed the way we all look at the world. This is all factored into our plans for the future.

Space exploration and discovery are associated with innovation. Can standards act as a vehicle for disseminating innovation ? Are there particular areas in which ISO standards can help the industry move forward ?

Christopher J. Scolese :

Of course people think that standards and innovation do not go together and that they inhibit what you can do. And that is wrong. In my mind, there are two types of standards. First, there are systems specifications– standards that tell the user the right way to do things, regardless of the technology used. To give you some examples from my background as an electrical engineer :

Read more text http://www.iso.org

The Illustrated Toyota Production System, Vol. 2

We are pleased to bring to you The Illustrated Toyota Production System, Volume 2. This is a book that sheds light on lean manufacturing practices and in particular the Industrial Engineering underpinnings of TPS. Building on the overview of philosophy, principles and systems provided in Volume 1, the second half gives 60 practical lessons on kaizen and industrial engineering approaches and their use.

To celebrate the publishing of this book in English, we are offering a 2-for-1 sale through the month of June. Click on the banner above or visit www.gemba-shop.com and enter the coupon code TPSGEMBA upon checkout.

Each book is about 130 pages, half of which are illustrations of various principles and tools.

Volume 2 contains 60 lessons made up of one page of text and one supporting illustration, such as the one below from “Lesson 38: Education and Training Help People See Waste“.

The book is organized into four sections as shown below:

Section 1. What Is Kaizen?

1. Kaizen Is Built on Respect for People
2. A Key to Toyota’s Outstanding Success
3. Sharing Information through Visualization
4. Creating a Common Understanding of Work through Visual Management
5. Examples of Visual Management
6. Knowledge Is Not Sufficient–Creativity Is Needed
7. We Know Defects Are Waste–Why Can’t We Kaizen Them Away?
8. Understand Time-Tested and Proven Problem Solving Techniques
9. Kaizen Must Be Workplace-Centered
10. Understand the True Nature of Defects
11. How to Find the Root Causes of Defects in the Workplace
12. Getting Rid of the Waste of Inspection
13. Causes of Careless Mistakes & the Pokayoke Concept
14. Three Approaches to Pokayoke
15. How to Cope with Unplanned Minor Stops of Equipment
16. How Can We Learn to See Waste?
17. What to Do When You Cannot Find Topics for Kaizen

Read more text http://www.gembapantarei.com

Future of Quality

Change is persistant, what an old but never outdated wisdom. But what does that mean to our organizational environment? What does that mean concerning the job outline of a Quality Systems Manager? We will give you to both questions some answers. Mr. Paul Borawski, Chief Executive Officer, American Society for Quality, will provide you with useful information about the future of quality. He will invite you to lead. To take action. To prepare yourself and your organizations to benefit by anticipating and preparing for the future.

Mr. Benedikt Sommerhoff, Senior Consultant, German Society for Quality, is going to outline the change of the

occupational image of a Quality Systems Manager and will invite you to look into the future.

Closing Ceremony and Announcement of the 56th EOQ Congress

The quality infrastructure

Introduction

UK businesses need to:

create and enter markets in a timely manner
meet customer requirements, including legislative requirements
manage risks, including risks to financial investment, product introductions, market exclusion, etc.

Underpinning these activities is the need to demonstrate conformance to standards (whether specified by

regulators, the market or the industry) in order to gain market access and gain market confidence in their products and services.



The ‘quality infrastructure’ supports these aims and comprises the physical facilities and the interrelated systems of organizations, structures and people that help organizations to implement quality practices and improve performance.

The principle parts of the infrastructure relate to:

regulation – government, regulators
standards – documentary, physical/ reference, other codified intellectual property
conformity assessment and accreditation
economic operators and their collective representatives
consumers

Overview

The UK quality infrastructure is concerned with the relationships between:

legal requirements contained in regulation and legislation
voluntary standards which define the quality of products and services and the methods of their production
industry practice and the actual solutions provided by business
the market, where the confidence and will to trade is promoted
the accreditation and conformity assessment regimes that provide the evidence and confidence

The UK quality infrastructure is principally made up of a number of separate bodies, each with separate remits but which impact the following:

Market access and international trade – facilitating the removal of technical barriers to trade, evolving common language and practices that promote trade and gaining access to overseas markets
Industrial policy – enabling the UK to take advantage of its strong science base and capacity for innovation to compete in global markets
Regulation – either supporting regulation where there are significant risks to health, safety or the environment, or through market self-regulation
Providing confidence, evidence, information and assurance to purchasers, suppliers and customers regarding the quality of products, services or their supply.
Promoting awareness of and providing training and assistance in quality tools, methods, practices and culture.

Read more text http://www.thecqi.org

Toyota

What do you get when you mix 1,000 engineers, four weeks of additional product development lead time and reduced reliance on outsourced engineering by 67%? In most product development departments this would get a decision maker quickly fired. Not so for Executive VP Takeshi Uchiyamada, a chief engineer at Toyota tasked with turning the tide on quality issues. Toyota is taking some expensive countermeasures to the root causes that their quality assurance process from the product design and testing standpoint seems to have been cut a bit too close to the bone over the past decade through cost reductions and development time reduction efforts.

According to the Wall Street Journal article Toyota Assigns 1,000 Engineers to Quality Drive :

Toyota Motor Corp. has assigned 1,000 engineers to help analyze quality problems and is extending time devoted



to testing new models by an average of four weeks in an effort to head off glitches before vehicles enter production

Toyota has so far spent about $4 billion to correct the problem of unintended acceleration in its vehicles, but this has been mostly containment and not root cause correction. The changes suggested in this article are aimed more at root causes, and will cost approximately $400 million if we take the cost of 1,000 engineers to be $150 million per year and estimate the cost of 4 weeks of lead time and the reduction in outsourcing to be another $250 million. Could this be a demonstration of the 10X rule of the cost of quality?

Toyota reportedly saved more than $11 billion in the early 2000s thanks to its CCC21 efforts, and some have linked these cost reductions in the design process as well as supply chain costs as contributors to today’s quality problems. Cost reduction should result from following and improving safe, high quality processes that deliver to customer’s expectations. When cost reduction programs put quality before the other KPIs there is a danger that the overall costs increase in the long-run.

Mr. Uchimayada said he would like to reduce the amount of outside engineers working on research and development, but the process will take time. The company must wait for contracts to expire before it can bring the work inside the company. A company executive said the target is 10% outside engineering contractors, down from 30% now.

Read more text http://www.gembapantarei.com