Shingo redefined the concept of quality production and efficiency in manufacturing. His exceptional contribution to the production of quality products has revolutionized the mechanism of manufacturing goods and manage human capital more efficiently. His principles were founded upon reducing the cost of production through reducing defects, improving the quality of production, reducing the timeframe of producing a product and finding more innovative techniques for manufacturing. Shingo’s theory aligns with the KAIZEN principles of production which emphasizes on making continuous improvements by having creative and robust involvement of every worker within an organization. His approach to production advocates for the achievement of an effective and result oriented manufacturing policies through the pursuit of the organization objectives, setting workable plans and implementing the laid out strategies. For instance, Shingo’s ideology on quality products is what has made Toyota Motor what it is today when he took charge of factory improvement and industrial engineering in 1955. His philosophy on quality management is based on the following concepts and theories i.e. just in time (JIT) production theory, Poka-yoke manufacturing design and the single minute exchange of dies (SMED).
Just in Time Concept
Reducing the timeframe of manufacturing a product can lead to efficiency in production. This theory was developed by Shingo and Taichii Ohno when he was the head of factory improvement and quality production at Toyota Motors (ref). The JIT concept is based on finding an effective and efficient way of eliminating waste through continuous improvement in manufacturing goods. This concept is also referred to as the Toyota Production System which is founded upon discarding production overload, eliminating inconsistencies during production and reducing waste. The JIT philosophical techniques emphasize the following elements during production i.e. improving product quality through zero defects, reducing lead time through reduction of setup times, having a specified amount of inventory at a given timeframe and optimizing queue lengths (ref). The most crucial and significant aspect of this concept is to optimize the cost of production in an effective manner. For instance, during his time at Toyota Motors Shingo revolutionized the production system by creating a more responsive production system by reducing waste which meant more products for more customers. Moreover, the JIT system has formed the backbone of quality products has been adopted by numerous manufacturing industries to increase their effectiveness in production.
Poka-yoke theory
Eliminating errors during production can increase the firm’s profit margin and competitive advantage. The Poka-yoke philosophy is based on eliminating defects by targeting production errors at its root cause hence having a continuous and efficient manufacturing system (ref). Shingo’s basic idea was to constitute achieving zero defects quality control mechanism through source inspection, eliminating the error and finding strategies to prevent such an error from reoccurring frequently. Errors have a huge impact on the quality of a product hence it’s essential that they are identified before they become a defect and inhibit the process of production. Shingo’s Poka-yoke ideology is founded on the following principles to having an effective and result oriented manufacturing system. First, monitoring the quality of a product should be achieved at the point source during the production process as opposed to correcting the error at a later stage. This is due to the fact that an error can impede the production process increases the cost of production and leads to the manufacture of substandard products. Secondly, giving quick feedback on the errors found during production. Shingo suggests that manufacturing industries should use machines to detect and eliminate defects as human beings are fallible and prone to make mistakes (ref). Besides, this concept of quality management encourages the elimination of production constraints through reducing employee orientation, discarding repetitive operations, immediate elimination of production errors and having a consistent improvement to the firm’s equipment (ref). Therefore, Poka-yoke philosophy advocates for quality production through the elimination of production defects.
Single Minute Exchange of Dies (SMED)
Shingo made an impactful contribution to the improvement of the SMED system of production. This concept helped companies reduce the cost of production by developing an effective mechanism that would enable them to quickly adjust their production system to new manufacturing designs. Moreover, just like the JIT concept of quality management the SMED theory helped industries to eliminate defects, improve their machine efficiency and record high production rate of quality products. The SMED philosophy is built upon the following tenets that drove Shingo’s concept of quality production i.e. reduce setup time when starting a production process and produce products in small batches hence maintain the product quality (ref). For instance, Shingo applied this policy when he was head of the production at Mitsubishi Heavy Industries where he was responsible for reducing the hull assembly time for the production of 65,000 tons of super-tankers from four to two months (ref). In addition, Shingo’s mentality was to use SMED to identify and isolate the time required for setup by varying and monitoring the internal and external time during production. His approach emphasizes improving the production process by having every employee meeting their deadlines within the specified timeframe of production. Hence, the SMED principle is founded on the pursuit of the organization objectives and the implementation of lasting solutions that have been adopted by global companies to increase their profit margin.
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