Transcript Quality Tools and Techniques

Quality Tools and Techniques
Quality Tools and Techniques
Practicing quality techniques
Author:
Dr Rhys Rowland-Jones
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Quality Tools and Techniques
Session plan
– Demonstrate the differing types of quality tools/techniques
attributed to the Japanese.
– Illustrate the applicability of tools and techniques of quality
improvement.
– Describe individual applications of appropriate quality tools.
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Quality Tools and Techniques
Continual improvement
• Continual improvement is a type of change that is focused on
increasing the effectiveness and/or efficiency of an organization to
fulfil its policy and objectives.
• It is not limited to quality initiatives.
• Improvement in business strategy, business results, customer,
employee and supplier relationships can be subject to continual
improvement.
Source: IQA. 2007
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Quality Tools and Techniques
Basic steps in problem solving
1.
2.
3.
4.
5.
6.
7.
Define the problem and establish an improvement goal.
Collect data.
Analyze the problem.
Generate potential solutions.
Choose a solution.
Implement the solution.
Monitor the solution to see if it accomplishes the goal.
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Quality Tools and Techniques
Traditionally, a Japanese Samurai carried seven
tools into battle.
•
After World War II the Japanese adopted 'quality' as a philosophy for
economic recovery and, in line with this traditional approach, sought seven
tools to accomplish the economic rejuvenation. The seven tools chosen
were:
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Histograms
Cause and Effect Diagrams
Check Sheets
Pareto Diagrams
Graphs
Control Charts
Scatter Diagrams
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Quality Tools and Techniques
The seven tools
Control Chart
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Scatter Plot
Pareto
Chart
Data Collecting
Ishikawa Chart
Stratification
Histogram
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Quality Tools and Techniques
Inputs
Techniques For Improvement.
Scatter Diagrams
Outputs
Input-Output analysis
Flow Charts
Cause-Effect Diagrams
Pareto Analysis
x x
x
x
x
x x
x
Why - why analysis
Why?
Why?
Why?
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Quality Tools and Techniques
Cause-and-Effect Diagram
Methods
Materials
Cause
Cause
Cause
Cause
Cause
Cause
Environment
Effect
Cause
Cause
Cause
People
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Cause
Cause
Cause
Equipment
Quality Tools and Techniques
Check Sheet
Billing Errors
Wrong Account
Wrong Amount
A/R Errors
Wrong Account
Wrong Amount
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Monday
80% of the
problems
may be
attributed to
20% of the
causes.
Pareto Analysis
Number of defects
Quality Tools and Techniques
Off
Smeared Missing Loose Other
centre print
label
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Quality Tools and Techniques
Statistical Process Control (SPC)
•
A process by which a product/service is checked during its creation using
certain set parameters and statistical techniques to measure and analyze
the variation within the process.
•
WHAT IS IT USED FOR:
•
To monitor the consistency of product/service quality and maintain
processes to a fixed target as designed.
To drive improvement actions within an organization.
•
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Quality Tools and Techniques
Control Chart
1020
UCL
1010
1000
990
LCL
980
970
0
1
2
3
4
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5
6
7
8
9 10 11 12 13 14 15
Quality Tools and Techniques
Diameter
Run Chart
Time (Hours)
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Quality Tools and Techniques
Tracking Improvements
UCL
UCL
UCL
LCL
LCL
LCL
Process not centred
and not stable
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Process centred
and stable
Additional improvements
made to the process
Quality Tools and Techniques
Process Variation
Process Variability
Variations due to:
Natural Causes:
• Temperature variation
• Material variation
• Customer differences
• Operator performance
Must be monitored
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Special Causes:
• Machine is breaking
• Untrained operative
• Machine movement
• Process has changed
Early and visible
warning required
Quality Tools and Techniques
What can be controlled using SPC?
• VARIABLES.
•
Variable Measures are those
that can be measured on a
continuous scale, for example
length, time, weight....
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• ATTRIBUTES.
•
Attributes are characteristics
that are assessed by judgment
and are dichotomous, i.e. have
two states such as right or
wrong, looks OK or not OK.
Quality Tools and Techniques
Quality at the source
The philosophy of making each
worker responsible for the quality
of his or her work.
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Quality Tools and Techniques
Genichi Taguchi’s theory of Quality loss
– Quality is a predictable degree of uniformity and dependability,
at low cost and suited to the market.
– Losses begin to accrue as soon as a quality characteristic of a
product or service deviates from the nominal value.
– Once the specification limits are reached the loss suddenly
becomes positive and constant, regardless of the deviation from
the nominal value beyond the specification limits.
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Quality Tools and Techniques
Taguchi Loss Function
Traditional
cost function
Cost
Taguchi
cost function
Lower
spec
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Target
Upper
spec
Quality Tools and Techniques
Quality Function Deployment
The House of Quality
KEY
Design Characteristics
Customer
Perceptions
1 2 3 4 5
Customer
Attributes
weak (1)
strong (3)
very strong (9)
Absolute Weight
attribute weights x
relationship strength
Sales Points
Feasibility
Evaluation
1= weak; 10 = strong
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1=easy, 10=difficult
(AW x SP) / Feasibility
Quality Tools and Techniques
QFD The House Of Quality.
Parts
Characteristics
Key Process
Operations
The QFD methodology has been developed into a
continuous process, and it can be applied equally well to
service or manufacturing environments
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Production
Requirements
Key Process
Operations
Parts
Characteristics
Engineering
Characteristics
Customer
Requirements
Engineering
Characteristics
Quality Tools and Techniques
Summary
• We have looked at a range of quality tools/techniques for
improvement.
• Statistical process control.
• Taguchi’s theory of quality loss.
• Quality Function deployment.
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