total quality management - 7 new tools - final year ece - sri sairam institute of technology -...

7/30/2019 TOTAL QUALITY MANAGEMENT - 7 NEW TOOLS - FINAL YEAR ECE - SRI SAIRAM INSTITUTE OF TECHNOLOGY - Dr.K.BARANIDHARAN

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Dr.K.Baranidharan

Present by


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NEW SEVEN TOOLSOFQ C


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What are the

New Seven Q.C. ToolsAffinity DiagramsRelations Diagrams

Tree Diagrams

Matrix Diagrams

Arrow Diagrams

Process Decision Program Charts

Matrix Data Analysis


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History of the

New Seven Q.C. Tools Committee of J.U.S.E. - 1972

Aim was to develop more QCtechniques with design approach

Work in conjunction with original Basic

Seven Tools

New set of methods (N7) - 1977

Slide 1 0f 2


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History of the

New Seven Q.C. Tools Developed to organize verbal data

diagrammatically. Basic 7 tools effective for data analysis,

process control, and quality

improvement (numerical data) Used together increases TQM

effectiveness

Slide 2 0f 2


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What are the

Basic Seven Q.C. Tools? Flow ChartsRun Charts

Histograms

Pareto Diagrams

Cause and Effect Diagrams

Scatter Diagrams

Control Charts


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Relation Between New Seven

Q.C. Tools and Basic Seven

ToolsFACTS

Data

Numerical Data Verbal Data

Organize

The Seven New Tools

Information

The Basic Seven Tools

Generate Ideas

Formulate plans

Analytical approach

Define problem aftercollecting numerical data

Define problem beforecollecting numerical data

Source:Nayatani, Y., The Seven New QC Tools(Tokyo, Japan, 3A Corporation, 1984)


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Enhanced CapabilitiesGenerate ideas

Improve planning

Eliminate errors and omissions Explain problems intelligibly

Secure full cooperation

Persuade powerfully

Benefits of Incorporating

New Seven Q.C. Tools

Organize verbal data

Slide 1 0f 4


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Enhanced Keys to Organizational ReformClarify the desired situation

Prioritize tasks effectively

Proceed systematicallyAnticipate future events

Change proactively

Get things right the first time



Assess situations from various angles

Slide 2 0f 4


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Five Objectives of Organizational Reform

which will establish a Culture that:

Gives importance to planning

Stresses the importance of the process Prioritizes tasks

Encourages everyone to thinksystematically


New Seven Q.C. ToolsSlide 3 0f 4

Identifies problems


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Affinity DiagramsFor Pinpointing the Problem in a Chaotic

Situation and Generating Solution Strategies Gathers large amounts of intertwined

verbal data (ideas, opinions, issues)

Organizes the data into groups based

on natural relationship

Makes it feasible for further analysis

and to find a solution to the problem.

Slide 1 0f 7


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Affinity DiagramsAdvantages of Affinity Diagrams

Facilitates breakthrough thinking and

stimulate fresh ideas

Permits the problem to be pinned down

accurately

Ensures everyone clearly recognizes the

problem

Incorporates opinions of entire group

Slide 2 0f 7


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Affinity DiagramsAdvantages of Affinity Diagrams(cont.)

Fosters team spirit

Raises everyones level of awareness

Spurs to the group into action

Slide 3 0f 7

Topic

Affinity Statement

Data CardData Card

Data CardData Card

Affinity Statement

Data CardData Card

Data CardData Card

Affinity Statement

Data CardData Card

Data Card

Affinity Statement

Data CardData Card

Data CardData Card

Data Card Data Card


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Affinity DiagramsConstructing an Affinity Diagram

Group Method ApproachSlide 4 0f 7

Select a topicCollect verbal data by brainstorming

Discuss info collected until everyone

understands it thoroughlyWrite each item on separate data card

Spread out all cards on table


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Group Method Approach(cont.)

Slide 5 0f 7

Move data cards into groups of similarthemes (natural affinity for each other)

Combine statements on data cards to

new Affinity statementMake new card with Affinity statementContinue to combine until less than 5

groups


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Slide 6 0f 7

Lay the groups outs, keeping the affinityclusters together

Next, complete the diagram


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Affinity DiagramsCompleting an Affinity Diagram

Slide 7 0f 7

TopicAffinity Statement

Data CardData Card

Data CardData Card

Affinity Statement

Data CardData Card

Data CardData Card

Affinity Statement

Data CardData Card

Data Card

Affinity Statement

Data CardData Card

Data CardData Card

Data Card Data Card

Source:Nayatani, Y., The Seven New QC Tools (Tokyo, Japan, 3A Corporation, 1984)


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Relations DiagramsFor Finding Solutions Strategies by Clarifying

Relationships with Complex Interrelated Causes Resolves tangled issues by unraveling

the logical connection

Allows for Multi-directional thinking

rather than linear

Also known as Interrelationship

diagrams

Slide 1 0f 7


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Relations DiagramsAdvantages of Relations Diagrams

Useful at planning stage for obtaining

perspective on overall situation

Facilitates consensus among team

Assists to develop and change peoples

thinking

Enables priorities to be identified

accurately

Slide 2 0f 7


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Relations DiagramsAdvantages of Relations Diagrams(cont.)

Makes the problem recognizable by

clarifying the relationships among causes

Slide 3 0f 7

Why doesnt

X happen?

Primary Cause

Primary Cause

Primary Cause

Primary Cause

Tertiary

Cause

Secondary

Cause

Secondary

Cause

Secondary

Cause

Secondary

Cause

Tertiary

Cause

4th levelCause

Tertiary

Cause

Tertiary

Cause

4th level

Cause 5th levelCause

6th level

Cause

Tertiary

Cause

SecondaryCause


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Relations DiagramsConstructing a Relations Diagram

Group Method Approach

Slide 4 0f 7

Express the problem in form of Whyisnt something happening? Each member lists 5 causes affecting

problem

Discuss info collected until everyoneunderstands it thoroughly

Write each item on a card


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Slide 5 0f 7

Move cards into similar groupsAsking why, explore the cause-effect

relationships, and divide the cards into

primary, secondary and tertiary causesConnect all cards by these relationships

Further discuss until all possible causes

have been identified


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Slide 6 0f 7

Connect all related groups


Review whole diagram looking forrelationships among causes


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Relations DiagramsCompleting a Relations Diagram

Slide 7 0f 7

Why doesnt

X happen?

Primary Cause

Primary Cause

Primary Cause

Primary Cause

Tertiary

Cause

Secondary

Cause

Secondary

Cause

Secondary

Cause

Secondary

Cause

Tertiary

Cause

4th level

Cause

Tertiary

Cause

Tertiary

Cause

4th level

Cause

5th level

Cause

6th level

Cause

Tertiary

Cause

Secondary

Cause



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Tree DiagramsFor Systematically Pursuing the Best Strategies

for Attaining an Objective Develops a succession of strategies for

achieving objectives

Reveals methods to achieve the results.Also known as Systematic diagrams or

Dendrograms

Slide 1 0f 5


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Tree DiagramsAdvantages of Tree Diagrams

Systematic and logical approach is less

likely that items are omitted Facilitates agreement among team

Are extremely convincing with strategies

Slide 2 0f 5

To

Accomplish

Primary means

Constraints

Secondary means

Secondary means

3rd means

3rd means

3rd means

3rd means

4th means4th means

4th means

4th means

4th means

4th means

4th means


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Discuss means of achieving objective(primary means, first level strategy)


Tree DiagramsConstructing a Tree Diagram

Group Method Approach

Slide 3 0f 5

Write Relations Diagram topic (Objectivecard) Identify constraints on how objective

can be achieved

Take each primary mean, write ob-

jective for achieving it (secondary means)


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Tree DiagramsConstructing an Tree Diagram


Slide 4 0f 5

Continue to expand to the fourth levelReview each system of means in both

directions (from objective to means and means toobjective)

Add more cards if needed

Connect all levels



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Tree DiagramsCompleting a Tree Diagram Slide 5 0f 5

To

Accomplish

3rd means

3rd means

Primary means

3rd means

3rd means

Constraints

Primary means

Secondary means

Secondary means

Secondary means

Secondary means

3rd means

3rd means

3rd means

3rd means

4th means

4th means

4th means

4th means

4th means

4th means

4th means

4th means

4th means

4th means

4th means

4th means



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Matrix DiagramsFor Clarifying Problems by Thinking

Multidimensionally Consists of a two-dimensional array to

determine location and nature of

problem

Discovers key ideas by relationships

represented by the cells in matrix.

Slide 1 0f 7


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Matrix DiagramsAdvantages of Matrix Diagrams

Enable data on ideas based on extensive

experience Clarifies relationships among different

elements

Makes overall structure of problemimmediately obvious

Combined from two to four types of

diagrams, location of problem is clearer.

Slide 2 0f 7


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Matrix DiagramsAdvantages of Matrix Diagrams(cont.)

5 types: L-shaped, T-shaped, Y-shaped, X-

shaped, and C-shaped

Slide 3 0f 7

O O =1 O =4 Principal

O =2 O X =5 O Subsidiary

=3 X =6

Efficacy

Practica

bility

Rank

SiteQCcircle

Section/Plant

QCcirclesupporter

Section/Plant

Manager

Leader

Member

4th level means

from Tree diagram O O 1 O

4th level means

from Tree diagram O O 1 O Hold 4 times/month4th level means

from Tree diagram O 3 O At every meeting4th level means

from Tree diagram O 2 O

4th level means

from Tree diagram O X 5 O At least 3 times/year/person4th level means

from Tree diagram O O 1 O O4th level means

from Tree diagram 4 O

Evaluation Responsibilities

Remarks


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Matrix DiagramsConstructing a Matrix Diagram

Slide 4 0f 7

Write final-level means from Treediagram forming vertical axis

Write in Evaluation categories (efficacy,practicability, and rank) on horizontal axis.

Write names along horizontal axis

Examine final-level means to identifywhom will implement them


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Matrix DiagramsConstructing a Matrix Diagram(cont.)

Slide 5 0f 7

Label group of columns as Responsibilities

Label right-hand end of horizontal axisasRemarks

Examine each cell and insert the

appropriate symbol:Efficacy: O=good,=satisfactory, X=none

Practicability: O=good,=satisfactory, X=none


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Matrix DiagramsConstructing a Matrix Diagram(cont.)

Slide 6 0f 7

Fill out remarks column and recordmeanings of symbol


Examine cells under ResponsibilityColumns, insert double-circle for

Principaland single-circle for Subsidiary

Determine score for each combination

of symbols, record in rank column


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Matrix DiagramsCompleting a Matrix Diagram Slide 7 0f 7

O O =1 O =4 Principal

O =2 O X =5 O Subsidiary

=3 X =6

Efficacy

Practicability

Rank

SiteQCcircle

Section/Plant

QCcirclesupporter

Section/Plant

Manager

Leader

Member

4th level means

from Tree diagramO O 1 O

4th level means


Hold 4 times/month

4th level means

from Tree diagram

O 3 OAt every meeting4th level means

from Tree diagramO 2 O

4th level means

from Tree diagramO X 5 O

At least 3 times/year/person

4th level means

from Tree diagramO O 1 O O

4th level means

from Tree diagram4 O

4th level means

from Tree diagramO 2 O

4th level means


4th level meansfrom Tree diagram

O O 1 O

Evaluation Responsibilities

Remarks



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Arrow DiagramsFor Working Out Optimal Schedules and

Controlling Them Effectively

Shows relationships among tasks

needed to implement a plan

Network technique using nodes for

events and arrows for activities

Used in PERT (Program Evaluation and Review

Technique) and CPM (Critical Path Method)

Slide 1 0f 7


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Arrow DiagramsAdvantages of Arrow Diagrams

Allows overall task to viewed and potential

snags to be identified before work starts

Leads to discovery of possible

improvements

Makes it easy to monitor progress of work

Deals promptly with changes to plan

Improves communication among team

Slide 2 0f 7


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Arrow DiagramsAdvantages of Arrow Diagrams(cont.)

Promotes understanding and agreement

among group

Slide 3 0f 7

Strategy

1

Constraints

Activity

2

4

3 5 9

6 8

7

10 13

12

11


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Arrow DiagramsConstructing an Arrow Diagram

Slide 4 0f 7

From strategies on Tree diagram, selectone (Objective of Arrow Diagram) Identify constraints to Objective

Write all essential activities on separatecards

List all activities necessary to achievingObjective


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Arrow DiagramsConstructing an Arrow Diagram(cont.)

Slide 5 0f 7

Organize cards in sequential order of

activitiesRemove any duplicate activities

Review order of activities, find

sequence with greatest amount ofactivitiesArrange parallel activities


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Arrow DiagramsConstructing an Arrow Diagram(cont.)

Slide 6 0f 7

Record names and other necessaryinformation


Examine path, number nodes insequence from left to right


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Arrow DiagramsCompleting an Arrow Diagram Slide 7 0f 7

Strategy

1

Constraints

Activity

2

4

3 5 9

6 8

7

10 13

12

11




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Q

Process Decisions Program

ChartsFor Producing the Desired Result from Many

Possible Outcomes

Used to plan various contingencies

Used for getting activities back on track

Steers events in required direction ifunanticipated problems occur

Finds feasible counter measures to

overcome problems

Slide 1 0f 7



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Advantages of Process Decisions ProgramCharts (PDPCs)

Facilitates forecasting Uses past to anticipate contingencies

Enables problems to pinpointed

Illustrates how events will be directed tosuccessful conclusion

Enables those involved to understand

decision-makers intentions

Slide 2 0f 7

Q


Charts



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Advantages of PDPCs(cont.) Fosters cooperation and communication in

group Easily modified and easily understood

Slide 3 0f 7


Charts

Start

GOAL

YESYES

NONONO

NO

NO

YES

NONO



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Constructing a PDPC

Slide 4 0f 7

Select a highly effective, but difficultstrategy from the Tree diagramDecide on a goal (most desirable outcome)

Identify constraints of objective

Identify existing situation (Starting point)


Charts

List activities to reach goal and potentialproblems with each activity



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Constructing an PDPC(cont.)

Slide 5 0f 7

Review list. Add extra activities or

problems not thought of previously Prepare contingency plan for each step

and review what action is needed if

step is not achieved Examine carefully to check for

inconsistencies and all important factors

are included


Charts



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Constructing an PDPC(cont.)

Slide 6 0f 7


Examine to make sure all contingency

plans are adequate


Charts



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Completing a PDPC Slide 7 0f 7Process Decisions Program

ChartsStart

GOAL

YESYES

NONONO

NO

NO

YES

NO

NO



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Matrix Data AnalysisPrincipal Component Analysis

Technique quantifies and arranges data

presented in Matrix

Based solely on numerical data

Finds indicators that differentiate and

attempt to clarify large amount of

information

Slide 1 0f 6


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Matrix Data AnalysisAdvantages of Principal Component Analysis

Can be used in various fields (market surveys,

new product planning, process analysis)

Can be when used when Matrix diagram

does not give sufficient information

Useful as Prioritization Grid

Slide 2 0f 6


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Matrix Data AnalysisConstructing a Prioritization Grid

Source:Foster, S., Managing Quality(Upper Saddle River, NJ: Prentice Hall, 2001)

Slide 3 0f 6

Determine your goal, your alternatives,

and criteria for decision

Place selection in order of importance

Sum individual ratings to establishoverall ranking (Divide by number of optionsfor average ranking)

Apply percentage weight to each option

(all weights should add up to 1)


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Matrix Data AnalysisConstructing a Prioritization Grid(cont.)

Slide 4 0f 6

Rank order each option with respect to

criterion (Average the rankings and apply acompleted ranking)

Multiply weight by associated rank inMatrix (in example, 4 is best, 1 is worst)

Result is Importance Score

Add up Importance Scoresfor eachoption


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Matrix Data AnalysisConstructing a Prioritization Grid(cont.)

Slide 5 0f 6

See completed the diagram

Rank order the alternatives according to

importance


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Completing a Prioritization GridSlide 6 0f 6


Matrix Data Analysis

Source: Foster, S., Managing Quality(Upper Saddle River, NJ: Prentice Hall, 2001)

Cost Reliability

Options

Design A

.30 .203 3

.90 .60 3.2 1 (tie)

Design B

.40 .10

4 1

1.6 .10 3.0 2

Design C

.25 .252 4

.50 1 2.5 3

Design D

.10 .20

1 3

.10 .60 3.2 1 (tie)

1.05 .75

.26 .19

2 4

Importance

Sum Score

Option

Ranking(least important)

Strength

Importance score

RankPercentage weight

Percentage weight

Rank

Importance score

Percentage weightRank

Importance score

Percentage weight

Rank

Importance score

Sum of weights

Average weight

Criterion Ranking

Customer Acceptance

(most important)

.404

1.6

.30

3

.90

.251

.25

0.3

3

.90

1.25

2

.40

.25

.75

.101

.10

.20

.95

.24

3

Criteria

.40

4

3

1.6

.31

1


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Dr.K.Baranidharan

THANK YOU

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