Abstract

Solving problems quickly while controlling risk is the goal of process improvement through just-in-time or lean manufacturing methods. These methods are supported by the following principles. Improvement is ongoing. Approaches, techniques, and tools must be integrated into a systematic whole. Total quality control, just-in-time, and total productive maintenance concepts should be seen as overlapping elements. Involve those who do the work in the implementation of change. Do not set up barriers against new ideas. Instead of trying to do everything, aim at the most important problems. Be willing to accept 50 percent improvement in the early going, especially if some reasonable risk is traded off for rapid change. Keeping these principles in mind, the Rapid Improvement methodology uses a five-day, one-week workshop to allow process teams to implement quick improvements. Problem assessment and planning precede the workshop. The first couple of workshop days cover concepts like just-in-time systems, lean system methods, and developing a vision for process improvement. The rest of the workshop is spent in implementing change. Two case studies demonstrate the method for improvement of a component welding line and main chassis fabrication.