7 tqm_quality circles & six sigma
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Total Quality Management
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Six Sigma Tools, Quality Circles
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Quality Circles
A smallgroup of employees from the sameworkarea, doing
similar type of work, who voluntarily meet regularly for
about an hour per week to identify, analyze and resolvework
related problems, not only to improve quality, productivity
but also to enrich the quality of work life of employees
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Quality CirclesFeatures
Members must be from the same work area
Should have 6 to 10 members
Membership is strictly voluntary
Originated from manufacturing employees but now spread toother areas like engineering, purchase, marketing, research,
maintenance etc.
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Quality Circles - Features
Permanent in nature, once a problem is solved, Circle takes up
another problem
May be held during or after working hours, Circles decide the
time and duration
Independent of management function, but supported and
blessed by management
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Objectives of Quality Circles
To involve the workforce in the improvement process
To promote teamwork and harmony (Agreement of opinions)
To increase employees morale and create an environment
where everyone is conscious about the need for improvement To stimulate people to think and use their creativity to make
continual improvement a habit
To improve communication and problem solving skills of
employees To implement TQM at the shop floor
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What Quality Circles are not?
Quality Circles do not change the existing organizational
structure
It is not a forum for grievances or a springboard for demands
It is not a means for the management to unload theirproblems
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Launching of Quality Circles
Select a few favorable areas in consultation with top
management
Declare through notices, circulars and posters that everyone
will have an opportunity for joining Quality Circles
All employees in the chosen area are invited for a
presentation session where the purpose of Quality Circles and
advantages of joining them are explained
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Launching of Quality Circles
Call the volunteers for a meeting and help them to elect a
leader and a deputy leader
Nominate trained facilitator to help the Quality Circle
formation
Train the Quality Circles leaders and members
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Operation of Quality Circles
Problem identification by members
Problem selection
Analysis of problem and discussion on alternatives
Arriving at best solution Presentation to management
Review of recommendation and approval by management
Implementation of solution
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Structure of Quality Circles
Top Management
Quality Council
Facilitator
Leader/ Deputy Leader
Members
Non - Members
A senior officer nominated by management who isresponsible for guiding and directing Quality Circlesin his area / department
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Quality Council
To set goals and objectives for Quality Circles activities
To establish and provide operational guidelines and direction
To provide resources for Quality Circle activities
To monitor and control functioning of Quality Circles
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Six Sigma
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Six Sigma
Measure of quality that strives for near perfection
A disciplined, data-driven methodology focused on
eliminating DEFECTS
Means a failure rate of 3.4 parts per million or 99.9997 %
perfect
Anything that falls outside of a customer's specifications
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Six Sigma
A management methodology
Customer focused
Data driven decisions
Breakthrough performance gains
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Six Sigma - DPMO
Defects per MillionOpportunities (DPMO) % Accuracy
One Sigma 691,500 30.85%Two Sigma 308,500 69.15%Three Sigma 66,810 93.32%Four Sigma 6,210 99.38%Five Sigma 233 99.977%Six Sigma 3.4 99.99966%
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Six Sigma Methodology - DMAIC
Define
Measure
AnalyzeImprove
Control
1. Identify goals of
improvement area
2. Develop team charter
1. Measure the
existing system
2. Establish valid
performance
standards
1. Establish process capability
2. Identify variation sources1. Screen potential causes
2. Find ways to eliminate the gap
3. Implement the new approach
1. Ensure that the result is
sustained
2. Share the lessons learnt
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Six Sigma Team
Executive
Leadership
ProjectChampions
Master
Black BeltsBlack Belts
GreenBelts
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Basic ImplementationA Roadmap
Understand and Define
Entire Value Streams
Deploy Key Business Objectives
- Measure and target
- Align and involve all employees
- Develop and motivate
Define, Measure, Analyze, Improve
Identify root causes, prioritize, eliminate waste,make things flow and pulled by customers
Control
-Sustain Improvement
-Drive Towards Perfection
Identify Customer Requirements
Vision (Strategic Business Plan)
Continuous Improvement (DMAIC)
Identify Customer Requirements