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Meaning of Quality
Final Perspective of quality includes both the producers and customers perspective.
Customers view must dominate.
Fitness for consumer use at the lowest cost.
Meaning
Meaning of
of Quality
Quality
Production
Production
Producers
Producers Perspective
Perspective
Consumers
Consumers Perspective
Perspective
Quality
Quality of
of Conformance
Conformance
Quality
Quality of
of Design
Design
Conformance to
specifications
Cost
Quality
characteristics
Price
Fitness
Fitness for
for
Consumer
Consumer Use
Use
Marketing
Marketing
Contd
Phase of Quality Movement
Quality
Quality
Inspection
Control
Quality
InspectionQuality
Quality
Control Quality Assurance
Assurance
Primary Concern
Detection
Control
Coordination
Strategic View
Product Uniformity
Product Uniformity
with Reduced
Inspection
Entire Production
Chain
Gauging and
Measuring
Inspection,
Acceptance Sampling
Quality Measurement,
Planning and Program
Design
Goal Setting,
Education, Training
and Consultation
Inspection Department
Manufacturing and
Engineering
Department
All Departments
Everyone in the
Organization
Inspects in Quality
Control in Quality
Builds in Quality
Manages in Quality
Emphasis
Methods
Role of Quality
Professionals
Who has responsibility
for quality?
Orientation and
Approach
TQM TQM
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Approach
Scope
Scale
Management Led
Company Wide
Everyone is responsible for Quality
Philosophy
Standard
Control
Cost of Quality
Theme
On going Improvement
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Traditional Approach
TQM
Definition
Product-oriented
Customer-oriented
Priorities
Focus
Short-term
Long-term
Emphasis
Detection
Prevention
Errors
Operations
System
Responsibility
Quality Control
Everyone
Problem solving
Managers
Teams
Procurement
Price
Life-cycle costs
Managers role
Contd
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The
Japanese
description
effectiveness of a quality
expressed as:
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of
the
circle is
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QCC:
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Stratification
Check sheets
Histograms
Scatter charts
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QIT Process
Adequate training in appropriate skills must be
provided before the QIT starts work
How Does Quality Improvement Team Work?
Identify the project and form the team
Define the problem accurately
Identify and verify root causes
Plan and implement corrective action
Standardize and seek other applications
Conduct a review of the project
5S
What it is
Japanese concept of housekeeping
This philosophy focuses on
Effective workplace organization and
Standardize work procedure.
It simplifies work environment, reduces waste and non-value
added actvity while improving quality, effciency and safety.
What these are
Seiri (sort)- Put things in order (remove what is not needed and
keep what is needed)
It focuses on
Eliminating the unnecessary items
Removing broken tools and
Getting rid of dust and oil
from the workplace.
5S
Contd
5S
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5S
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5S
What these are
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...contd
5S
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How to Acieve 5S
5S can be achieved in the following ways:
First S (Sorting)- Sort out all the components, spears and
materials as Good and Bad, Usable and Non-usable.
Second S (Systematic Arrangement)- Once sorted, keep those
systematically to have traceability.
Third S (Spic and Span/Neatness)- Keep arranged things always
ready to use in dirt free and tidy status.
Fourth S (Standardize)- Make a process for above three stages,
make standards and aslo keep on reviewing these.
Fifth S Self descipline an individual has to commit.
The Benefits of 5S implemetation
If fully implemented, the 5S process can
Increase morale,
Create positive impression on customers, and
Increase efficiency
Not only will employee feel better about where they work, the effect on
continuous improvement can lead to less waste, better quality, and faster
lead times.
Organization becomes more profitable and competitive in the
market place.
Quality Planning
Quality planning is process identifying which quality
standards are relevant to the project and determining how
to satisfy them.
Developing a process to achieve goals involving
customer satisfaction
Input: Quality policy, scope statement, product
description, standards and regulations, and other
process Output.
Tools and techniques used: benefit / cost analysis,
benchmarking, flowcharting, and design of
experiments
Output: Quality management plan, operational
definitions, checklists, and Input to other processes.
The subject of quality planning can be anything:
an engineering process for designing new products,
a production process for making goods, or
a service process for responding to customer requests.
Quality Planning:
Outputs
Techniques, and
Quality Planning:
Input
Quality Planning:
Cost-Benefit Analysis
Quality planning must consider cost-benefits tradeoffs.
The primary benefit of meeting quality requirements is less rework,
which means higher productivity, lower costs, and increased
stakeholder satisfaction
Benchmarking
Involves comparing actual or planned project practices to those of
other projects to generate ideas for improvement
Also provide a basis by which to measure performance.
Design of Experiments (DOE)
Statistical method that helps identify which factors may influence
specific variables of a product in production or process under
development.
Cost of Quality (COQ)
Quality costs are the total costs incurred by investment in
preventing nonconformance to requirements,
appraising the product or service for conformance to
requirements, and
failing to meet requirements (rework).
Failure costs are often categorized into internal and external.
Failure costs are also called cost of poor quality.
Additional Quality Planning Tools
brainstorming, affinity diagrams, force field analysis, nominal group
techniques, matrix diagrams, flowcharts, and prioritization matrices
Quality Planning:
Output
Quality Planning:
Output
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Quality Baseline
The quality baseline
records the quality objectives of the project.
is the basis for measuring and reporting quality
performance as part of the performance
measurement baseline.
Process Improvement Plan/Project Management Plan
Requested changes (additions, modifications, deletions)
to the project management plan and its subsidiary plans
are processed
By review and disposition through the Integrated
Change Control process.
Other outputs
Quality roles list, Implementation test chart , Project
Monitoring Checklist, Project Review Checklist,
Operational Definitions Table.
Quality Planning:
Jurans Roadmap
Quality Planning:
Take Action
Fully implement if
expected outcomes
achieved
Initiate QI if outcomes not
achieved
Service/Process
Develop activity to meet
needs
Establish outcome
measures
Implement service/process
Monitor Impact/Results of
Service
Measure Outputs and Outcomes
Compare actual results to
expected results
MarMason Consulting
Benchmarking
Selecting best practices to use as a standard for
performance
Steps to be followed:
Determine what to benchmark
Form benchmarking team
Identify benchmarking partners
Collect benchmarking information
Take action to meet or exceed benchmark
Brainstorming
Brainstorming:
Procedure
Brainstorming:
Procedure
...Contd
Brainstorming:
Rules
...Contd
...Contd
Stages
Preparation
Preparation
Introduction
Introduction
Idea
Idea Generation
Generation
Idea
Idea Sharing
Sharing
Discussion
Discussion
Voting/Ranking
Voting/Ranking
...Contd
Preparation
A team is assembled including
participants from varying areas.
Materials needed:
Pen and paper for each member
Flip chart
Markers
Tape
Sticky notes (optional)
...Contd
Introduction
A facilitator introduces him/herself,
and explains the NGT process.
The key problem or question is
presented, explaining the purpose
of the meeting.
Telling team members about
problem sooner allows them to
come prepared.
...Contd
Introduction
Role of Facilitator:
A facilitator is chosen from among group
members.
His/her responsibilities include:
Helping group avoid conflict
Encouraging participation
Keeping time
Facilitating rounds
Recording ideas
...Contd
Idea Generation
Individuals silently and
independently write down as
many ideas as possible
during pre-determined time
period. (usually 10 minutes)
Idea Sharing
...Contd
...Contd
Idea Sharing
Anonymous approach:
Facilitator
collects idea cards and
records ideas on flipchart
eliminating duplicates.
Non-anonymous approach:
Ideas are shared one at a time in a
circular direction.
Members can pass at any point.
...Contd
Idea Sharing
This round ends when
All members have passed on
sharing their ideas
Time limit is reached (usually 15-20
minutes)
...Contd
Discussion
Now ideas are discussed.
Members can ask for details or
clarification.
The purpose is clarification not
changing peoples opinions.
Ideas are not eliminated.
Ideas can be re-worded.
...Contd
Discussion
Facilitator tries to
keep all members involved,
continue the flow of discussion, and
not get caught on any point for too
long.
This phase typically lasts 30-40
minutes.
...Contd
Discussion
If there are many ideas
(over 40), there can be an
elimination stage before
voting.
Members can choose to
eliminate their own
ideas or combine ideas
together.
Alternatively, idea
elimination can require
approval by all
members.
...Contd
Voting/Ranking
Voting or ranking determines
the NGTs output.
Facilitator should number the
ideas to make voting easier.
Members either vote
anonymously, with the
facilitator totaling points, or
they can publicly write their
votes on the flipchart.
...Contd
Voting/Ranking
Voting Method 1:
Members can vote for ideas based
on a chart like the following:
Number of ideas
Number of
votes
Value of votes
Less than 20
1, 2, 3, 4
20-35
1, 2, 3, 4, 5, 6
Over 35
1, 2, 3, 4, 5, 6, 7,
8
...Contd
Voting/Ranking
Voting Method 2:
Members rank all ideas, with the
highest number as the most
favored idea.
Points are totaled after all
members rank ideas.
The idea with the most points
wins.
...Contd
Voting/Ranking
If the top 5 ideas are all within
several points of each other, a
second round of votes will best
determine the real winner.
Repeat the voting stage using
only the top 5 ideas.
...Contd
Visibility
Throughout the process, all charts should remain
visible.
Tape them to the walls around the room.
Affinity Diagram
Affinity Diagram
How to use it:
...Contd
4. Silently, as a team, sort the cards by grouping together
similar items on the basis of their affinity.
Don't just use reason, use feelings too. You should feel
that the cards belong together.
Repeat this process until clear groupings are formed.
Cards which are strange or inappropriately filed should
be taken out of the group and returned to the pre-sorting
file.
Cards which do not fit into any of the groups should
be isolated and left to one side.
Continue this sorting process until everyone is happy with
the groupings. It is common to end up with 5-10
groupings.
5. Construct the affinity diagram from the cards and reach
consensus on a title for each grouping. If appropriate, break
each grouping into sub-sections with titles.
6. In presenting the data expect to use phrases like: we
feel..., our impression is..., it appears....
Affinity Diagram
...Contd
Delphi Technique
Leader summarizes
responses and sends
to group members,
requesting additional
ideas
Team ranks ideas and
returns to leader
Process repeated until
consensus is reached
and decision is made
Matrix Diagram
A graphical comparison of two or more sets of data to identify the interrelationships between these sets.
It is very effective for identifying priorities and relationships for possible
improvement.
It can be used to
evaluate how well a solution meets given requirements and
expectations (during analysis phase).
translate customer requirements and expectations into processes
and products (in design phase and as part of house of quality)
Customer
priority
(1 to 5)
4
1
4
3
5
5
Unweighted total
Weighted total
P rio rity s h ip p in g
L o c a l c o u n try a g e n ts
S p e c ia lis t e n g in e e rs
O n -s ite e d u c a tio n
U n w e ig h te d to ta l
W e ig h te d to ta l
Service features
9
1
9
9
3
9
22
97
9
1
9
45
4
14
9
10
0
3
12
10
36
10
0
9
60
50
Matrix Diagram:
Matrix Diagram:
Types
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