Simulation of Integrated Total Quality Management (TQM) with Lean Manufacturing (LM) Practices in Forming Process Using Delmia Quest

Abstract

Study on TQM in Malaysia is first reported in 1997 while LM in 2010. Since then, voluminous studies reported that TQM and LM can bring more benefits to a company but there is still lack of case study on company that has implemented both initiatives. Preliminary status of Integrating TQM and LM has been established from survey conducted on the highly practices LM in Malaysian automotive companies in 2011. The findings from the survey are used in order to evaluate the Integrated TQM and LM in a Malaysian Automotive Company. An Integrated Total Quality Management (TQM) with Lean Manufacturing (LM) is a system comprises TQM and LM principles. This system focuses in achieving total customer satisfaction by removing eight wastes available in any process in an organization. This paper presents the Integrated TQM and LM practices by a forming company. The integrated practices are an adaptation combination of four models award, ISO/TS16949 and lean manufacturing principles from Toyota Production System, SAEJ4000 and MAJAICO Lean Production System. A case study of the forming company in Selangor has been conducted and simulation of the process is done by Delmia Quest Software. It was found out that the company has been practicing TQM and LM separately. Other type of software can also be used to measure the level of TQM and LM implementation and can determine whether the model is adaptable for other industry and for all type of manufacturing process. This is the initial case study that combined 4 awards practices, ISO/TS16949, Toyota Production System, SAEJ4000 and MAJAICO Lean Production System (LPS).Lean Total Quality (GLTQ).