Management System based on the ISO 9001:2008

International Quality Standards

By
Nisansala K.T.D
Index No: - HDBM-F-101030

A dissertation
Submitted in partial fulfillment
Of the requirement of the Quality Management module in the
Higher Diploma in
Business Management- 10.1 Batch

National Institute of Business Management,

Colombo 07
02nd August 2010
Acknowledgement

Without directions & correct guidance, the way to the triumph is impossible. But a
good teacher can direct naturally his students for the victory of their life. You are
one of the best teachers that I met in my life not only for your teaching but as a good
man living in the society.

Dear Sir, this little effort is acknowledged to you in order to respect your knowledge
& kindness.

Nisansala K.T.D
Index No: - HDBM-F-101030
Date: - 30th July 2010
Table of Content

Chapter Page
1. Management Philosophy 1-4
2. Manpower Hand Machine for Plastic Item Production 5-7
Current Management System
3. Analyzing the current management system 8-20

3.1 Process of the current management system by drafting a system 9

chart

3.2 Setting the quality standards to the current process 10

3.3 Resource allocation 11-13

3.4 Time standards settings 14

3.5 Schedule resources by establishing a GANTT Chart 15

3.6 Identifying the critical activities & the critical path 16-17

3.7 Identifying the floating time of each activity & balance 17

resources

3.8 Establishing a method for each activities 17-18

18
3.9 Crash programming
3.10 Develop a monitoring mechanism 18-20

4. Implementation process 21-22

4.1 Organizing process 21

4.2 Directing process 22
4.3 Coordinating process 22

5. Controlling Process 23-25

5.1 Checking process 23-24
5.2 Action process 24-25
 6. Improvement Programmes 26-28
6.1 Continual Improvement (KAIZEN) 26-27
6.2 Break trough innovation (KAKUSHIN) 27-28
7. The proposed Management System based on the ISO 29-36
9001:2008 International Quality Standard

7.1 The mapping of proposed management system according to the 29-31

ten questions in the ISO 9001: 2008 International quality standards.
7.2 Setting time standards of the Proposed Management System 32

7.3 The system chart for the proposed management system 33

7.4 the resource scheduling- the GANTT chart of the proposed 34

management system
7.5 The comparison between the Scheduling of time of the Current 35
management system and the proposed management system

7.6 The Integrated Productivity & Quality Management Chart for 36

the proposed management system based on ISO 9001:2008
International Quality Standards
8. Recommendations 37-41

8.1 Recommendations for effective implementation of proposed 37-38

management system
8.2 recommendations for implementing the improvement 39-41
programmes
 1

Management System based on the ISO 9001: 2008

International Quality Standards.

1. Management Philosophy

In the world we can see many religions, Science as well as Philosophies. The religions
based on the faith to the God. The science is got a different story that it is not having a
base. But a Philosophy is based on a premise. The premise is the basic foundation or the
building block of the philosophy that got the strength of holding the philosophy in a
stable manner.

So according to the premise of the management philosophy it includes the sustainable

development of the society, adhering to the local, national & international laws while
contribute to the business with the strong relationship with the stakeholders of the
company in a honest way.

The management philosophy includes ten areas which aims the development of the
business with sustainability. They are,

1) KAIZEN
2) Meaning of a Business
3) Enhance value addition relatively to achieve the goals in the goal hierarchy by
without violating the natural laws as well as the local, national & international
laws & regulations
4) Treat customers as kings
5) Treat employees as shareholders
6) Treat suppliers as business partners
7) Update & upgrade the machines & equipments & technology
8) Build the trust with the financial institutions
9) Contribute to harmonious & sustainable development of the society by paying
due taxes.
10) Aim for growth that is in harmony with the environment by seeking to minimize
the environmental impact of the business operations such as by working to
reduce the effects of products & operations on climate change & bio diversity.
 2

Explanation of the Management Philosophy and the way it

contributes to the wellbeing of the business.

1) KAIZEN

KAIZEN is the secret of the rapid development of the Japanese. The KAIZEN
emphasizes the continual improvement of a process.

The Definition of KAIZEN: -

KAIZEN means the improvement. More ever it means the continual improvement
in personnel life, social life & the working life. When applied to the work place
KAIZEN means continual improvement involving everyone managers & workers
alike.

So KAIZEN acknowledge that every company has problems & that problems are a set
back to the improvement of the company. It also got the potential to understand the value
of people by enhancing the value added activities relatively. KAIZEN involves with
finding problems and weaknesses of the process & try to make opportunities to prevent
the losses to the company & enhance the value addition

KAI means Duality or the change & the ZEN is the non separation. So change the
process for non separation leads the entire organization for the higher productivity which
means the continual improvement.

2) Meaning of a Business

There should be a meaning for everything that we are doing. Without a meaning any
work cannot be done that meaning is the driven for the activities. A business is doing in
order to earn profits. The investor invests in order to get a return from the investment
which commonly known as ROI premium or the return on investment premium. But the
businessmen have to hold a calculated risk in order to get a return on investment. So the
meaning of the business is to Balance the ROI premium & the Risk.

But the businessmen have to understand that never expect high return from low risk.
3) Enhance value addition relatively
 3

Enhancing value added pie relatively & continuously is the main goal of the goal
hierarchy. But the company has to achieve it without violating the natural principles as
well as the local, National & International laws & regulations. If the company does their
value addition in that way it will help the company to retain the existing stakeholders
with them.

4) Treat customers as kings

Customers are the heart of the process of an organization that without customers there
will be no requirements for the production and the processes of the companies will stop
automatically. By treating customers as kings by understanding their needs & wants the
company can survive in the business field by protecting the existing customers with them
& the organizations that treat customers as kings will be able to capture new markets with
new customers.

5) Treat employees as shareholders

Employees are the major contributors to an organization. Without the right employee
commitment there will be no quality products at all. Because all the employees are
involve in the companys production as well as quality procedure. By treating the
employees as shareholders the company will get products with the quality, right quantity
for the right cost.

6) Treat suppliers as business partners

Suppliers are the people who supply the raw materials as well as the essential services to
the business organizations. Without suppliers it is not possible to maintain a business in
order to reduce lead time & increase profits.

By treating the suppliers as business partners they will motivate to be connected with the
organization which the relationships of suppliers help organization to earn more profits
while preventing unnecessary losses to the company.

7) Update & upgrade the machines, equipment & the technology

 4

The organizations have to update & upgrade the machines as well as technology regularly
in order to have a better efficient production flow. By introducing new technology to the
production flow the companies will be able to do their operations in an efficient manner.

8) Build the trust with financial institutions

In order to have a continuous well maintained cash flow the organizations/businesses

have to build a strong trust with the financial facilitators such as banks. The
organizational responsibility is to pay the interests for loan term loans as well as the
others sums related to the financial loans from the financial institutes. The return of doing
like this is the increasing of trust with the financial institutes who will help when the
organizations face financial difficulties.

9) Contribute to harmonious & sustainable development of the society

by paying due taxes.

This is the way of proofing the corporate citizenship of the businesses by paying the due
taxes which will contribute a lot to the development of the society.

10) Aim for growth that is in harmony with the environment by seeking
to minimize the environmental impact of the business operations such as by
working to reduce the effects of products & operations on climate change &
bio diversity.

This is emphasizing the reduction of bad impact from the businesses to the environment.
If a business reduces their impact on the environment will help the entire society for the
sustainable development
 5

2. Manpower Hand Machine for Plastic Item Production

Current Management System: -

In this chapter it is all about the mapping of the current management system of the
Manpower Hand Machine for Plastic Item Production at my house. The mapping of the
current management system is based on a questionnaire which is described along with the
map.

Current Management System based on the ISO 9001:2008 International

Quality Management Standards.

1. Who are the internal customers?

The Pharmacies who are selling ayurwedic oils as well as the ayurwedic doctors

2. What are the requirements of the internal customers?

The 4R 1T concept of ISO 9001:2008- Right products (Plastic bottles) with

right quality (small type defects free), right quantity (according to the order) at the
right time (the due time or the ordered time) with the target cost.

3. What is the purpose of the intended system?

The 5R concept of ISO 9001:2008- Right products (Plastic bottles) with right
quality (small type defects free), right quantity (according to the order) at the right
time (the due time or the ordered time) with the right price.

4. What are the resources available for the intended system?

Men: - Father
Machine & Equipments: - The hand machine, heat controlling gadget, molds
Materials & Services: - Plastic pallets, Dies, tool kit, water basket
Methods: - The heat controlling methods, mould fittings, product finishing
Measurements: - the warniar caliper Measurements
 6

5. What is the system boundary?

The machine can be fixed small size moulds for producing small plastic bottles
with the radius of the bottle base not exceeding 0.88 cm.

6. What is the process to transform the resources (inputs) into to achieve the
objective (outcome) of the system?

Check the order & decide the related mold to be fixed to the machine & put the
mold at the relevant place.

Select the materials- the plastic pallets & make colour change using the dies
relevant to the order.

Turn the switch on the heat controller

Adjust the temperature of the heat controller according to the density of the
materials- the plastic pallets.

Apply died materials to the heated cylinder.

Push the handle of the machine connected with the heated cylinder & pour the
mould from the melted material.

Separate the product from the mold by adding water

The product as the outcome.

7. How to compare the desired results (objective) & the achieved results
(objectives) and identify the gap?

Every thing in this world made twice the physical creation and the mental creation.
So the desired level of the product will be the mental creation & the achieved results will
be the physical creation. The Quality, Quantity, Time & Cost standards has to be
established mentally and then must be compared with the current or the physical creation.
 7

Compare the desired & actual results

QQTC at the Mental QQTC at the physical
Creation Creation

QQTC Gap or the Stimulus

8. How to response to the resources to the resources to bridge the above gap for
having the desired results?

Have to take decisions based on the stimulus and it is a requirement to take the
right response right at the first time.

9. How to establish records to provide evidence of conformity to above

requirements?

Keep the notes on a separate paper which is kept near to the machine and record
the number of unit produced as well as the amount of material used.

10. How to audit the above steps to ensure the continual improvement?

There are four types of audits which are related to the ISO 9001:2008 International
Quality Standards.

1. Adequacy Audit for the documentation

2. Complains Audit
3. Surveillance Audit
4. Internal Audit

But currently the system is not having a proper auditing system.

3. Analyze the Current Management System

 8

In this chapter it is described about the,

Process of the current management system

Setting the quality standards to the current process

Resource allocation

Time standards settings

Schedule resources by establishing a GANTT Chart

Identifying the critical activities & the critical path

Identifying the floating time of each activity & balance resources

Crash programming

Establishing a method for each activities

Develop a monitoring mechanism

 9

Process of the current management system

M1 M2 M3 M1 M2 M3 M1 M2 M3
a d i a f ---- a --- g,h

Accord Switch Selec

ing to The on the Prepa t the Colore
prep heat
the red pallet d
Order ared controll Machi s and Pallets
order mol er & set a b k M1 M2 M3 M1 M2 M3
d ne
decide the
A a c,d k a d,e, j
tempera Apply
the ture colou
Mould accordin
rs The
& put g to the Apply Push Moul Separ bottl
standard Melt
on the Activity- B (1 min) Activity- C (10 min) colored ed
the d ate e
pallets handl with
machi pall the
the -
ne A (5 min)
Activity- to the ets e& bottle
prod Prod
heated pour uct (prod uct
cylinde the uct)
M1 M2 M3 r melte from
--- f,b --- d the
mat. moul
To the
Activity-E (0.5 min) Activity-F (0.5 min) Activity-G (1 min)
Let the Heated
machine Cylinder

to be
heated

Activity- D (10 min)

 10

3.2The quality standards for the current Management System

Quality standards for applying die to the pallets

Add one tea spoon (5g) for a 1 Kg of non colored pallets.

Quality standards for setting the temperature of the cylinder

The temperature level of the cylinder will be decided by checking the density type
of the pallets

Pallet type ( Density type) Standard temperature in 0C

VLDP- Very law density polythene 30-35
LDP- law density polythene 50-55
HDP- High density polythene 80-90
VHDP- Very High density polythene 130-150

Quality standards for removing the produced bottle from the mold.

Add water to the mold and separate the product by using the screw driver

Quality standards for ensuring the right measurement of the product.

Get random samples & check the right measurement by using a warniar caliper

The machine can make the small size of the plastic bottle and the measuring standards are
mentioned below.

Height of the bottle- 8cm

Radius of the bottom- 0.85cm
Radius of the top- 0.65cm

3.3 Resource Allocation - The Resource Pool

M1- Men
 11

Father (a)

1993

M2- Machine & Equipment

Cylinder (b) Hand Bar (c) Moulds (d)

Screw Driver (e) Heat controller (f)

M3- Materials & other services

Colorless Pallets (g) Colored Pallets (k) Dies (h)
 12

Order Book (i) Water Bucket (k)

Resource Allocation- According to the System Chart

Activity Resource Allocation

A) According to the order decide the M1- Father

mold & put on the machine M2- Mould
M3- Order Book
 13

B) Switch on the heat controller & set M1- Father

the temperature according to the M2- Heat controller
standards M3-

C) Select the pallets and M1- Father

Apply colours M2-
M3- colorless palates, Dies

D) Let the machine to be heated M1-

M2- Heat controller/ cylinder
M3-

E) Apply colored pallets to the heated M1- Father

cylinder M2- Cylinder
M3- Colored pallets

F) Push the handle & pour the melted M1- Father

mat. To the mold M2- Mould/Hand Bar
M3- Colored pallets

G) Separate the bottle (product) from M1- Father

the mold M2- Mould/screw driver
M3- Water Bucket

3.4Time Standards of Activities - According to the System

Chart

Activity Time ( Minutes)

A) According to the order decide the 5 Minutes

mould & put on the machine
 14

B) Switch on the heat controller & set 1 Minute

the temperature according to the
standards

C) Select the pallets and apply colors 10 minutes

D) Let the machine to be heated 10 Minutes

E) Apply colored pallets to the heated 0.5 Minutes

cylinder

F) Push the handle & pour the melted 0.5 Minutes

mat. To the mold

G) Separate the bottle (product) from 1 Minutes

the mould

The time related to the above mentioned activities are measured by using a stop
watch
 15

Resource Scheduling (Gantt chart) of the Proposed Management System The critical
Activities
Time in Minutes
Reso R S O U C E S C E D U L I N G
urce
Activity 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17

R
M1 a a
A M2 d d
M3 i i
M1 a
B M2 f
M3 --
-
M1 a a a a a a
C M2 --- --- --- --- --- ---
M3 g, g, g, g, g, g,
h h h h h h
M1
D M2 f, f, f, f, f, f,
b b b b b b
M3
M1 a
E M2 b
M3 k
M1 a
F M2 c
d
M3 k
M1 a
G M2 d
e
 16

M3 j
 16

3.6 The Critical Activities in the Process

The every activity in the process is crucial and I identified some critical activities which
got the potential to affect the entire process directly. The critical activities mentioned
follows;

Applying colors to the non colored material (pallets)

This is a critical activity that the right combination of colors (dies) has to be mixed in a
right quantity in order to get the right prepared material. If it is not done according to the
acceptable manner the quality of the product will reduce that the expected level of quality
cannot be seen in the final product. The wrong way of adding colors to the non colored
pallets will lead the entire batch for rejection which provides an unnecessary cost to the
organization.

Maintaining the required temperature level in the cylinder.

The temperature level of the cylinder will be decided by the density level of the material
used. The temperature levels for the different density levels are mentioned above & again
mentioned below for getting an easy understanding about the heating process of the
cylinder.

Pallet type ( Density type) Standard temperature in 0C

VLDP- Very law density polythene 30-35
LDP- law density polythene 50-55
HDP- High density polythene 80-90
VHDP- Very High density polythene 130-150

The cylinder heats because of the copper coil covered with Mica which will provide an
effective temperature level to the cylinder. The cylinder has to be kept for 10 to 15
minutes in order to stable with its temperature level & the time must not exceed a lot that
it will leads to waste more electrical energy and will cost unnecessary to the process.

Pushing the handle in order to pour the melted material in to the mould.

This activity is very critical that if it is not happen in a better way the process will deliver
a bad product without the right quality.
 17

The degree of pushing the handle in order to pour the melted material in to the mould is
with the experience of the machine operator.

Separate the bottle (product) from the mould

The mould has to be kept under the water for 20 to 25 seconds in order to reduce the
temperature & make the way easy to remove the bottle- the product from the mould. The
product will separate from the mould by using a screw driver & the operator must keep a
better patience in order to get the right quality product.

3.7 The floating Time of Activities

According to the Gantt chart the only activity which got a floating time is Activity D.
The activity is letting the machine to get heated for 10 minutes & the activity is parallel
to the other activities Deciding the mould & put on the machine & Selecting the
pallets & apply colors The floating time of the Activity D is 3 minutes (Pleases refer
the Gantt chart)

3.8 Methods for Activities in the Process

The current Management system is standardized that the system got many methods for
different activities in the process. The activities and the methods for performing the
relevant activities mentioned in the below table.

Activity in the process The Method for doing the activity

A. According to the order decide the mould Check the order Notes/ book
& put on the machine Select the mould fit for the
requirement of the order.
B. Select the pallets & apply colors Select pallets according to the
requirement of the order
Apply die by following the standards
 18

C. Switch on the heat controller & set the Turn the heat controller meter to the
temperature according to the standards required temperature & keep the
machine on for heating (follow
standards)
D. Let the machine to be heated Turn the heat controller meter to the
required temperature & keep the
machine on for heating (follow
standards)
E. Apply colored pallets to the heated Apply pallets which can bear to the
cylinder cylinder

F. Push the handle & pour the melted mat. Use experiences to decide the degree
To the mold to which the handle push

G. Separate the bottle (product) from the Keep the mold for 20-25 seconds
mould under the water & remove the product
by using a screw driver without
harming to the shape of the bottle.

3.9 Crash Programming

Please see the recommendation for the Crash programmes for the system in page 37-41

3.10 The Monitoring Mechanism of the Process

The monitoring mechanism is needed in order to take decision on the process by

checking the process in a better manner. In the monitoring mechanism it includes,

a) Setting QQTC (Quality, Quantity, Time, Cost) for each activity

b) Measure QQTC (Quality, Quantity, Time, Cost) for each activity

c) Identify the Gap

d) Choose the right response to bridge the Gap

 19

The monitoring mechanism for the current management system is shown in a table below
The Monitoring Mechanism of the Process

Activity Desired QQTC Actual QQTC

Quality Quantity Time Cost Quality Quantity Time Cost
A. According to the Right According 5 Initial Fixed Fixed the 7 Initial
order decide the mould to the minutes cost of the desired minutes cost of
mould & put on for right order the deseed level the
the machine order mould level mould
B. Select the pallets Right 5g of dies 10 Rs.15 Right 5g of 12 Rs.15
& apply colors color for 1 kg of minutes for dies color dies for 1 minutes for dies
requires. pallet & requires. kg of &
With the RS.210 With the pallet RS.210
order for order for
pallets pallets
C. Switch on the Standard - 1 - Standard - 1 -
heat controller & temper minute temper minute
set the for the for the
temperature materials materials
according to the
standards

D. Let the machine The coil - 10 - The coil - 10 -

to be heated of the minutes of the minutes
cylinder cylinder
has to be has to be
reddish redish
E. Apply colored Required 40-50g of 0.5 Rs11.25 Required 50-60g 0.5 Rs14
pallets to the color colored minutes per one color of minutes per one
heated cylinder levels materials putting levels colored putting
for 5 materials for 5
bottles bottles
F. Push the handle Push - 0.5 - Push - 0.5 -
& pour the until minutes until minutes
melted mat. To feels that feels that
the mold the the
mould mould
pour pour
with with
pallets pallets
G. Separate the Right 10g per a 1 Rs 2.25 Right 10g per a 1 Rs.2.8
bottle (product) shaped bottle minute per a shaped bottle minute per a
from the mould right small right small
weight size weight size
right Bottle right Bottle
colored colored
bottle bottle
 20

Please note: - The system chart as well as the Gantt chart

is mentioned in the Chapter No 07.
The Stimuli Vs the Response according to the Monitoring
Mechanism of the Process

Activity Stimuli for QQTC Response

Quality Quantity Time Cost Quality Quantity Time Cost
A. According to No No 2 minute No ------- --------- 5S -----
the order differenc differenc lose differenc -
decide the e between e e between
mould & put desired & between desired &
on the actual desired & actual
machine actual
B. Select the No No 2 No -------- --------- Develop -----
pallets & differenc differenc minutes differenc - Measur
apply colors e between e lose e between e
desired & between desired & equipmt
actual desired & actual
actual
C. Switch on the No No No No -------- ---------- ----------- ---
heat controller differenc differenc differenc differenc --
& set the e between e e between e between
temperature desired & between desired & desired &
according to actual desired & actual actual
the standards actual

D. Let the No No No No ------- ---------- --------- ----

machine to be differenc differenc differenc differenc
heated e between e e between e between
desired & between desired & desired &
actual desired & actual actual
actual
E. Apply colored No No No Rs 2.75 -------- --------- Develop
pallets to the differenc differenc differenc lose from Measur
heated e between e e between every e
cylinder desired & between desired & putting equipmt
actual desired & actual
actual
 21

F. Push the No No No No -------- ---------- ---------

handle & pour differenc differenc differenc differenc ---
the melted e between e e between e between
mat. To the desired & between desired & desired &
mold actual desired & actual actual
actual

G. Separate the No No No Rs0.55 -------- --------- ----

bottle differenc differenc differenc lose gap --
(product) from e between e e between for every
the mould desired & between desired & unit of
actual desired & actual outcome
actual

4. Implementation Process

4.1 Organizing Process: -

Organizing is the method of ensuring the availability of resources to achieve the planned
activities.

In the organizing process the management has to ensure that the resource availability for
every outcome produce by the process is available. After ensuring the relevant resources
for relevant activities the management has to assign / allocate resources for different and
relevant activities. The following examples will show you how the resource allocation did
at the management system of bottle making.

Controlling mould
Heat selection
 22

Hand Bar
Men
Mixed Father - pushing
pallets Men

In order to ensure the resource availability the management has to keep & maintain buffer
stocks as necessary.

4.2 Directing Process

Directing is the way of giving instructions & command to the assigned resources
including people especially. In this process father is the only human resource in the
process and he himself has to give commands & instructions of doing the assigned
activities in a right way.

Examples: -

The father gives instructions to himself to control he temperature according to the

density level of the plastic pallets.

The father gives instructions to himself to mix 5g of dies with 1Kg of pallets
according to the standards.

4.3 Coordinating Process

Coordinating is the way of linking the assigned work together in order to get a better
outcome. In the current management system there lot of activities which linked together
as you can see in the system chart.

Example: -
 23

Apply Push the Separate

colored handle & the bottle
pallets to pour the (product)
the heated melted from the
cylinder mat. To the mould
mold

The activity coordination

The Summary of the Implementation Process

Organizin Directing Coordinati

g Process Process ng
Process
The Father
resource commandin Linking all
pool & g & giving the
store instructions relevant
resources himself to activities
for the flow do the together in
of the work in a order to
production better way get an
effective
floor of

5. Controlling Process

The controlling process consisted with two aspects. They are,

Check
Action
 24

5.1 The Checking process

The checking process is the methodology of empowering assigned people to check the
progress of the activities and notice the weak points of the process. So according to the
current management system mentioned here the checking process involves with the
empowerment of employees to activate the above mentioned monitoring Mechanism.

The checking process succeed in this current management system that I realized the
stimulus in the process where there are gaps between the desired & actual QQTCs of the
each activity.

The Stimulus founded from the Checking Process of the current

management system.

2 Minutes lose from the actual results of putting the mould in to the machine by
realizing the order

2 Minutes lose from the actual results of dyeing pallets to the production

Rs 2.75 lose from every putting of applying the died materials to the cylinder

Rs 0.55 lose gap for every unit of outcome from the actual results

5.2 Action Taking Process

Based on the above mentioned stimulus the actions can be taken as short term or long
term decisions and actions generated trough the checkering process. The right action will
prevent unnecessary losses & save every aspect of resource to the company.

The Actions which can be taken for preventing the losses to the process

1. Actions which can be taken in order to prevent the time lose on putting the mould
in to the machine by realizing the order
 25

By maintaining a separate document for note downing orders as well as records the
employee can get a fast understanding about the nature of the order without wasting time.
Keeping all materials & equipments in a better way the employee can select the moulds
that he wants to precede the process. So the time for adjusting to the process will
decrease and both money as well as the time will save.

2. Actions which can be taken in order to prevent the time lose on dyeing pallets to
the production.

It is also the same action has to be taken that every material as well as equipment has to
be kept in a better order to find them quickly. By developing a measuring mechanism the
organization can save the resources (pallets and dies) which lead for saving lot of money
to the organization.

3. Actions which can be taken in order to prevent the Rs 2.75 lose from every
putting of applying the died materials to the cylinder.

Use a suitable mechanism in order to pour the colored material to the cylinder without
leaking to the outside. It will save the additional Rs 2.75 lose from every putting of
applying the died materials to the cylinder. (Please see recommendations for more
details)

4. Rs 0.55 lose gap for every unit of outcome from the actual results

This happens as the unnecessary cost incurred at the beginning of the materials
preparation. By managing the way of mixing the materials with dies as well as pouring
the materials to the cylinder by using a measurement mechanism are the strategies that
help to overcome this situation.
 26

6 Improvement Programmes KAIZEN

6.1 The Identification of Value Added, Non Value Added & Waste of the
Process.

As I mentioned earlier KAIZEN is the way of continually improvement of a persons

personal life, social life as well as working life. When applied to the process it is saying
the continual development of the process with increasing Value added activities and
reducing the non Value Added Activities & eliminate Waste.

Let see the VA Activities, NVA Activities and Waste of the Current Management system.

The Value Added Activities of the Process

Mixing dies with pallets is a value added activity in the process. People or the
customers are willing to pay the outlook of the bottle. So the colors give a better
outlook to the products.

The shape of the product is another aspect that the customer is willing to pay.
They need a better perfect finish as well as the shape of the product. So the
customer will pay to the activity where separate the bottle from the mould which
is a value added activity.

The Non Value Added Activities of the Process

 27

There are lots of non value added activities in the process such as,

Deciding the mould & putting in the machine

Turn on the heat controller
Let the machine to be heated
Push the hand bar to pour the material with the mould
Adding materials to the heated cylinder
But the issue is in this short process reducing non value added activities is not a
good thing at all.

Waste of the Process

Adding more coloring to the pallets

It is a huge waste that adding more dies to the pallets by not following a measuring
mechanism. It will cause the process to a loss situation as the prices of dies are very high.

Over application of colored pallets to the cylinder

At the desired system the weight of colored pallets for five bottles is 50g but the actual
scenario is 60g. This is a waste of 10g approximately from every putting and for 100
units of production the waste is 200g. the monitory worth is approximately 44.2 /= per
100 units.

The rejects / Defective products

The system is not 100% perfect that there are failures products produce from the process.

6.2 The Break through Improvement KAKUSHIN- the

Innovations of the Process lead for KAIZEN

I discovered that the cylinder get heated because of the copper coil which is wrapped
around the Mica coated cylinder. There is a positive relationship between the numbers of
rounds of the copper coil & the time of heating the cylinder.
 28

I did the experiment with my father by increasing the numbers of rounds of the copper
coil around the cylinder. The results are the reduction of time of heating which save the
time as well as the cost related to the electricity of the process.

I also discovered that the startup of the machine takes lots of electrical energy which is
used to heat the cylinder again & again. By maintaining a continuous production for a
particular long period of time will help the process to save the time as well as the energy
of the system.

Mica Mechanism to keep

temperature

The copper coil

Electricity Connection
 29

7 The proposed Management System based on the ISO

9001:2008 International Quality Standard

In this chapter it is describing the proposed management system develop according to the
ISO 9001:2008 International Quality Standard. The objective of developing a proposed
management system is to overcome the weakness happened in the current management
system.

The proposed management system mapped based on the ten questions given in the
assignment & that ten questions related to the ISO 9001:2008 International Quality
Standard. After mapping the proposed management system according to the ten questions
the system is mapped by using an integrated productivity & quality management chart
(IPQC).

7.1 The mapping of proposed management system according to the ten

questions in the ISO 9001: 2008 International quality standards.

1. Who are the internal customers?

My father, who is the only employee for the entire process

2. What are the requirements of the internal customers?

The 4R 1T concept of ISO 9001:2008- Right products (Plastic bottles) with

right quality (small type defects free, expected shaped), right quantity (according
to the order) at the right time (the due time or the ordered time) with the target
cost.
 30

3. What is the purpose of the intended system?

The 5R concept of ISO 9001:2008- Right products (Plastic bottles) with right
quality (small type defects free, expected shaped), right quantity (according to the
order) at the right time (the due time or the ordered time) with the right price.

4 What are the resources available for the intended system?

Men: - Father
Machine & Equipments: - The hand machine, heat controlling gadget, molds,
measuring equipment for dies and pallets
Materials & Services: - Plastic pallets, Dies, tool kit
Methods: - The heat controlling methods, mould fittings, product finishing
Measurements: - the warniar caliper Measurements

5 What is the system boundary?

The machine can be fixed small size moulds for producing small plastic bottles
with the radius of the bottle base not exceeding 0.88 cm.

6 What is the process to transform the resources (inputs) into to achieve the
objective (outcome) of the system?

Check the order & decide the related mold to be fixed to the machine & put the
mold at the relevant place.

Select the materials- the plastic pallets & make colour change using the dies
relevant to the order.

Turn the switch on the heat controller

Adjust the temperature of the heat controller according to the density of the
materials- the plastic pallets.
 31

Apply died materials to the heated cylinder.

Push the handle of the machine connected with the heated cylinder & pour the
mould from the melted material.

Separate the product from the mold by adding water

The product as the outcome.

7 How to compare the desired results (objective) & the achieved results
(objectives) and identify the gap?

Keeping a separate note book for keep records as well as special scenarios of day today
activities of the process & compare the actual results with the things that has been noted
down as evidence.

8 How to response to the resources to the resources to bridge the above gap for
having the desired results?

Have to take decisions based on the stimulus and it is a requirement to take the
right response right at the first time. Check the actual outcome with the mental
creation noted in the note book and select the right response to betaken as an
action

9 How to establish records to provide evidence of conformity to above

requirements?

Maintaining a note book for keeping the day to day special scenarios as well
production details & new product designs.
Maintain a record book to record all accounts related to past monetary
transactions & the record book will help the system to take decisions as well as to
realize the strengths, weakness and opportunities of the process.
Maintaining an order book to record orders separately.

10 How to audit the above steps to ensure the continual improvement?

By maintaining systems owned auditing system which audit the above mentioned steps
every month which ensure the system is in the right track.
 32

7.2 Setting time standards of the Proposed Management

System

Activity Time ( Minutes)

A) According to the order decide the 2 Minutes

mould & put on the machine

B) Switch on the heat controller & set 1 Minute

the temperature according to the
standards

C) Select the pallets and apply colors 6 minutes

D) Let the machine to be heated 6 Minutes

E) Apply colored pallets to the heated 0.5 Minutes

cylinder
 33

F) Push the handle & pour the melted 0.5 Minutes

mat. To the mold

G) Separate the bottle (product) from 1 Minutes

the mould
 33

7.3 The system chart for the Proposed Management System

M1 M2 M3 M1 M2 M3 M1 M2 M3
a d i a f ---- a --- g,h

Accord Switch Selec

ing to The on the Prepa t the Colore
prep heat
the red pallet d
Order ared controll Machi s and Pallets
order mou er & set a b k M1 M2 M3 M1 M2 M3
ld ne
decide the
A a c,d k a d,e, j
tempera Apply
the ture colou
Mould accordin
rs The
& put g to the Apply Push Separ bottl
Melt Moul
on the Activity- B (1 min) Activity- C (6 min) colored ed
the d ate e
machi pallets pall handl with
the
the -
ne to the ets e& produ bottle Prod
Activity- A (2 min) heated pour ct (prod uct
cylinde the uct)
r melte from
M1 M2 M3 d the
--- f,b --- mat. moul
To the
Activity-E (0.5 min) Activity-F (0.5 min) Activity-G (1 min)
Let the Heated
machine Cylinder

to be
Activity- D (6 min)
heated

Resource Scheduling (Gantt chart) of the Proposed Management System The critical Activities
 34

Time in Minutes
Reso R S O U C E S C E D U L I N G
urce
Activity 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17

R
M1 a a
A M2 d d
M3 i i
M1 a
B M2 f
M3 --
-
M1 a a a a a a
C M2 --- --- --- --- --- ---
M3 g, g, g, g, g, g,
h h h h h h
M1
D M2 f, f, f, f, f, f,
b b b b b b
M3
M1 a
E M2 b
M3 k
M1 a
F M2 c
d
M3 k
M1 a
G M2 d
e
M3 j
 35

7.5 The comparison between the Scheduling of time of the

Current management system and the proposed management
system

Activity Time (Minutes) The saving of time

Proposed mgt Current and other aspects by
system mgt system converting the system
into the proposed mgt
system
A) According to the order 2 Minutes 5 Minutes 3 minutes saving leads
decide the mould & put to an efficient start.
on the machine

B) Switch on the heat 1 Minute 1 Minute --------------------------

controller & set the
temperature according to
the standards

C) Select the pallets and 6 minutes 10 minutes 4 minutes saving leads

apply colors to the higher level of
saving the pallets& the
dies as the using of
measuring mechanism
D) Let the machine to be 6 Minutes 10 Minutes Saving 40% of
heated electricity to be used in
order to heat the
cylinder
E) Apply colored pallets to 0.5 Minutes 0.5 Minutes ---------------------
the heated cylinder

F) Push the handle & pour 0.5 Minutes 0.5 Minutes ---------------------
the melted mat. To the
mold

G) Separate the bottle 1 Minutes 1 Minutes -----------------------

(product) from the mould
 36

7.6 The Integrated Productivity & Quality Management Chart

for the proposed management system based on ISO 9001:2008
International Quality Standards

The continual Improvement of the Quality Management System

C C
Management
U Responsibility U

S Identify the stimulus S

trough note book & record
T book select the right T

O O

M Resource Measurement M
Management Analysis &
E improvement E
M1- Father / M2-Heat
R cont, screw driver, bar Measure pallets, R
/ M3- Pallets,dies, dies / improve the
heating system

Product Realization
Requirem Produc
Consum
ent Realize the order from the t
ption
order book and prepare The
the system for that
required product
 37

8. Recommendations
I. Recommendations for effective implementation of proposed management system
II. Recommendations for implementing the improvement programmes

Recommendations for effective implementation of proposed

management system

1. Keep an order book in order to get the information about the order in a quick
time. The system has to maintain a record book to record all the notes & accounts
related to the process in order to take quick correct decisions

2. Keep all the moulds, Materials as well as tools in a one place and in an order in
order to find them in less time.

3. Develop a measuring mechanism to measure pallets & dies in order to reduce the
waste involves with the overusing of them.
 38

4. Cover the cylinder with more copper coils as well as Mica in order to get an
effective Temperature level of the cylinder by using less amount of energy.

5. Prepare large quantity of colored pallets at a once sufficient for an order.

By doing this the process can save more time as well as more electricity on wasting time
and power for preparing materials for the production in regular intervals.

6. Increasing the processing time which leads to decrease the startup cost as well as
time of the process.

By conducting operations for long hours the startup cost as well as the startup time can be
prevented and this strategy will save more to the organization.

7. Develop and maintain a note book for keeping sudden decisions as well as sudden
ideas for the improvement of the system.

8. Audit the system by using the system owned audit system in order to check the
system & get actions on the improvements as well as changes.
 39

Recommendations for implementing the improvement

programmes

The Improvement Programmes involves the 5S Programme & the KAIZEN +

KAKUSHIN programme.

Recommendations for implementing the 5S Programme

1. Identifying & Separate the necessary & unnecessary items of the system and
allocate specific places for different items

Orders as well as records are in a separate place

Keep documentary support items such as pen, calculator,

rubber seal and the bill book at one place

Dies & mixing materials in a separate place

Tools situated in a separate place for clear identifying

 40

Moulds at a one place for easy selecting

Keep the plastic pallets near to the machine

2. Cleaning and inspection the workplace every time that motivate the person who
involve in the process as well as the strategy is leading for the production of right
quality product at the right time with the right quality to be offered at the right
price to the customers.

The cleaned, zero dust floor leads for right quality

 41

Recommendations for implementing the KAIZEN + KAKUSHIN

Programme

THINK BEYOND THE LIMITS AS WE SOLVED THE NINE DOT PROBLE

1. Do experiments parallel to the process & innovate useful concepts to be absorbed

to the process which leads the process for its improvement.

The innovation based on the cylinder is the best eample in the process for ensuring
the continual improvemnet

2. Keep the process going on while doing small jumps the KAIZEN + KAKUSHI
approach.

The results of a better management system is Right Quality Products

42