tqm8
Post on 19-Jan-2016
5 Views
Preview:
DESCRIPTION
TRANSCRIPT
Total Quality Management
www.company.com
SESSION – 8
Quality Management Tools
TQM
www.company.com
Agenda
• Classic Quality Tools
• Management Tools (New Quality
Tools)
• Other tools
www.company.com
Classic Quality Tools
• There are 7 Classic Quality Tools, also known
as basic QC tools.
• Flowchart
• Check Sheet
• Cause-and-Effect Diagram
• Pareto Chart/Diagram
• Control charts
• Histograms
• Scatter Diagrams
www.company.com
Flowchart
• Graphical description of how work is done.
• Used to describe processes that are to be
improved.
• " Draw a flowchart for whatever you do. Until
you do, you do not know what you are doing,
you just have a job.” -- Dr. W. Edwards Deming.
1
www.company.com
Flowchart
• A flowchart may be used to:
• Document the as-is condition of a process.
• Reflect changes that are to be made to a process
• Design an entirely new process.
• Fulfill ISO 9001:2008 standard’s requirement to
identify and document the organization’s processes
and the sequence and interaction of these
processes.
www.company.com
Flowchart
• Some standard symbols:
Start or end
An activity
A decision point in the process.
A point at which the flowchart
connects with another process.
An off page connection
All records are identified
www.company.com
Flowchart
www.company.com
Sample Flowchart
www.company.com
Deployment Flowchart
www.company.com
Deployment Flowchart
www.company.com
Check Sheet
• Sometimes also called as “Tally sheet”.
• Tool for gathering information on root causes.
• Check sheets are used to collect data on the
frequency of occurrence of particular events
or defects
2
www.company.com
Check Sheet
• Purpose: Forms/Formats specially prepared
to enable data to be collected simply by check
marks
• Application: Used by inspectors during
checking of the process.
• Examples:
• Check sheet for defective items
• Check sheet for defect locations
www.company.com
Check Sheet – Example
www.company.com
Check Sheet – Example
www.company.com
Check Sheet – Example
www.company.com
Check List Vs Check Sheet
• Check List – guidelines, things to do, things to
check
• Check Sheet – Summary of check list,
recording observations of
check list.
www.company.com
Check List – Example
www.company.com
www.company.com
Scatter Diagram
• Purpose: To study and evaluate the
interrelationship between two characteristics
• Application: Commonly used to investigate
the effect of one characteristic on other. For
example, temperature effect on the strength
of metal, moisture effect on elongation, tec.
• Outputs:
• Positive correlation
• Negative correlation
• No correlation
3
www.company.com
Scatter Diagram
www.company.com
Scatter Diagram
www.company.com
Cause & Effect Diagram
• Also known as Fish Bone diagram and
Ishikawa Diagram.
• It is a tool for discovering all the possible
causes for a particular effect.
• The major purpose of this diagram is to act as
a first step in problem solving by creating a list
of possible causes.
• Carryout root cause analysis of the
causes/reasons through brain storming.
• Output: Identification of most contributing
causes.
4
www.company.com
Cause & Effect Diagram
• Constructing a Cause and Effect Diagram • First, clearly identify and define the problem or effect for
which the causes must be identified. Place the problem or effect at the right or the head of the diagram.
• Identify all the broad areas of the problem.
• Write in all the detailed possible causes in each of the broad areas.
• Each cause identified should be looked upon for further more specific causes.
• View the diagram and evaluate the main causes.
• Set goals and take action on the main causes.
• To construct the skeleton, guideline (not always):
• For manufacturing - the 4 M’s
man, method, machine, material
• For service applications
equipment, policies, procedures, people
www.company.com
Cause and Effect “Skeleton”
Quality
Problem
Materials
Equipment People
Procedures
www.company.com
Fishbone Diagram
Quality
Problem
Machines Measurement Human
Process Environment Materials
Faulty testing equipment
Incorrect specifications
Improper methods
Poor supervision
Lack of concentration
Inadequate training
Out of adjustment
Tooling problems
Old / worn
Defective from vendor
Not to specifications
Material-
handling problems Deficiencies
in product
design
Ineffective quality
management
Poor process
design
Inaccurate
temperature
control
Dust and
Dirt
www.company.com
Ishikawa Diagram
www.company.com
Pareto Chart/Diagram
• Identification of “vital few” and the “useful
many” (previously called as “trivial many”)
causes.
• Pareto charts are used to identify and
prioritize problems to be solved.
• They are actually histograms aided by the
80/20 rule adapted by Joseph Juran.
• Remember the 80/20 rule states that
approximately 80% of the problems are
created by approximately 20% of the causes.
5
www.company.com
Pareto Chart
www.company.com
Pareto Chart Benefits
Pareto analysis helps graphically display
results so the significant few problems
emerge from the general background.
It tells you what to work on first.
www.company.com
Histograms
• A histogram is a bar graph that shows
frequency data.
• Histograms provide the easiest way to
evaluate the distribution of data.
• It determines the spread or variation of a set
of data points in a graphical form.
6
www.company.com
Histograms
0
5
10
15
20
25F
req
uen
cy
Category
www.company.com
Histograms
www.company.com
Control Charts
• A method for monitoring a process for
preventing defects.
• Control charts are used to determine whether
a process will produce a product or service
with consistent measurable properties.
7
www.company.com
Control Charts
• Control charting is the most technically sophisticated tool of the 7 quality tools.
• It was developed in the 1920s by Dr. Walter A. Shewhart of the Bell Telephone Labs. Dr. Shewhart developed the control charts as a statistical approach to the study of manufacturing process variation.
• The purpose was to improve the process effectiveness and therefore reduce costs.
• These methods are based on continuous monitoring of the process variation.
www.company.com
Control Charts
• Steps Used in Developing Process Control Charts:
• Identify critical operations in the process where inspection might be needed.
• Identify critical product characteristics.
• Determine whether the critical product characteristic is a variable or an attribute.
• Select the appropriate process control chart.
• Establish the control limits and use the chart to monitor and improve.
• Update the limits.
www.company.com
Control Charts – Sample
18
12
6
3
9
15
21
24
27
2 4 6 8 10 12 14 16
Sample number
Num
ber
of
defe
cts
UCL = 23.35
LCL = 1.99
c = 12.67
www.company.com
Why use Control harts
• A Control chart is a device for describing in a precise manner what is meant by statistical control.
• It helps the process perform consistently and
predictably.
• It can minimise the variation in output.
• It can help to achieve lower product costs.
• It can help to increase effective capacity.
• It can help to meet customer expectations
www.company.com
Control Charts – Sample
www.company.com
Assignment
• Draw a flowchart for the complete process of
successful admission in the MEM Program at
NED University.
www.company.com
Exercise
• Handout – contains few sample exercises for
self practice.
• Chapter 18 (Revised 3rd edition) exercies:
• 1, 2, 3, 4, 5, 19, 20, 25, 26, 28, 29
• Control chart exercises
www.company.com
THE END
top related