“ “ A journey of a A journey of a thousand miles must thousand miles must begin with a single begin with a single step.” step.” Lao Tsu
Jan 02, 2016
““A journey of a A journey of a thousand miles must thousand miles must begin with a single begin with a single step.”step.”
Lao Tsu
Basic Quality Concept
Understanding and Implementing of Quality Control; QC Mind, QC Story, QC Method
Sharing Subjects
1. The Meaning of Quality
2. What is TQM and other related terms.
3. Quality Control (QC) QC Mind, QC Story (Problem Solving), QC
Tools
4. Quality Assurance
The Importance of Quality
Company’s Goal:
To gain good profit
Others
Meet with the market demand
Reduce Defect
Increase effectiveness and efficiency
Company Image
Quality =
•Standard
•Checking and Control
•Maintaining
• Improvement
•Assurance
The Growth of TQMThe Growth of TQM
Quality Control
Productivity
Control by Product
First First GenerationGeneration
Total Quality Control
Second Second GenerationGeneration
Product Competitive
Control by Process
Total Quality Management
Third Third GenerationGeneration
Good Image of Product
Control by Management
TQM Concept
Focus onCustomer
ContinuousImprovement
TotalParticipation
TQM Activitie
s
House of Total Quality Management
General Education /Political StabilityGeneral Education /Political Stability
Intrinsic Technology (Capability)Intrinsic Technology (Capability)
Motivational Approach (Willingness)Motivational Approach (Willingness)
Bas
ic C
once
pt
(QC
)
Tec
hn
iqu
es
Veh
icle
Strategy
Customer & Employee Satisfaction (QA)
Things to be Concerned
Commitment of Top Management
Execute by all department and staff and coordination among department and staff.
Works in several committed criteria beside the “Quality”; e.g. Cost, Delivery, Safety, Moral, etc.
TQM Related Terms
Quality Control QC Mind QC Problem Solving QC Tools/Method
Quality Assurance
Definition of QC
System that will make the product or service meet the the customer’s need/demand
Sometime being called as Statistical Quality Control (SQC)
Implementation of QC at the Company Wide can be called as Total Quality Control
QC Mind
Base on Concept of Quality by Company Part of organization improvement, Company wide, Standardize capability, Base on the human capacity, etc.
Using basic QC Concept Base on fact and using the QC Method/Tools Controlling Improvement (Kaizen) Assurance
Basic QC Concept
Quality First Never sacrifice the quality
Customer Oriented Product out become Market in
Implement in the Company wide
Process Control Managing result become Managing process
Basic QC Concept
Use PDCA Cycle as a vehicle; For regular activities can be implemented CAPD Cycle. Function of CA = Corrective, Maintain, Improvement
Focus on the Important Problem
Management of Differences Eliminated deviant product and maintain performance
Basic QC Concept
Managing source of problem Analyze the process, and related sources of problem
Customers are the receiver of post production (Total Customer Satisfaction)
Always provide Preventive Action
Standardization
QC 7 Tools
Tools/Method Function
1. Pareto Diagram Find the major problem.
2. Cause & Effect Diagram
Determine all causes.
3. Graphic Present data to be more understood
4. Check Sheet To get complete data
5. Scatter Diagram To see relation between variables
6. Histogram To see distribution of data
7. Control Chart To see the stability of data/production
Relation Between New 7 Q.C. Tools and Basic 7 Tools
FACTS
Data
Numerical Data Verbal Data
Organize
The Seven New Tools
Information
The Basic Seven Tools
•Generate Ideas
•Formulate plans
•Analytical approach
Define problem after collecting numerical data
Define problem before collecting numerical data
Source: Nayatani, Y., The Seven New QC Tools (Tokyo, Japan, 3A Corporation, 1984)
Enhanced Capabilities Organize verbal data Generate ideas
Improve planning Eliminate errors and omissions Explain problems intelligibly Secure full cooperation Persuade powerfully
Benefits of Incorporating New Seven Q.C. Tools
Enhanced Keys to Organizational Reform Assess situations from various angles Clarify the desired situation
Prioritize tasks effectively Proceed systematically Anticipate future events Change proactively Get things right the first time
Benefits of Incorporating New Seven Q.C. Tools
Five Objectives of Organizational Reform which will establish a Culture that:1. Identifies problems 2. Gives importance to planning 3. Stresses the importance of the process 4. Prioritizes tasks 5. Encourages everyone to think systematically
Benefits of Incorporating New Seven Q.C. Tools
Benefits of Incorporating New Seven Q.C. Tools
Unstructured Problem [must be put into solvable form]
Problem is mapped
Problem becomesobvious to all
Problem is in solvable formProblem is in solvable form
The Seven New ToolsThe Seven New Tools
Thoughts are easily organized
Things go well
People understandproblem
Cooperation is obtained
Countermeasuresare on target
Problem becomesobvious to all
Nub of problem is identified
Problem can be clearly articulated
Plans are easily laid
Nothing is omitted
Source: Nayatani, Y., The Seven New QC Tools (Tokyo, Japan, 3A Corporation, 1984)
New QC 7 ToolsTools/Method Function
1. Relation Diagram To find relation among logically related fact
2. Systematic Diagram Systematical approach to achieve target.
3. Matrix Diagram Explain problem with multidimensional factors
4. Affinity Diagram Rearrange the problem to find the important one.
5. Arrow Diagram To see activities network and control the schedule
6. PDPC Chart Set the each process to find the correct one.
7. Data Analysis Matrix Arrange all data to be more understood
Mental Attitudes - Keen awareness to the actual problem - Eagerness to solve problem - Be highly motivated for the challenge
Keys to Successfully Using the New Q.C. 7 Tools
Four Specific Keys Understand the problem Select the right tool for the job Obtain appropriate verbal data Interpret analytical results
Understand the problem
Stage 1 - problem is unclear and not obvious what exact issue should be addressed
Stage 2 - problem is obvious, but causes unknown explore causes and single out valid ones
Stage 3 - problem and causes are known required action is unknown strategies and plan must be developed
4 Specific Keys (1)
Selecting Right tool for the Job
Stage 1 - Collect verbal information on events (Affinity Diagram)
Stage 2 - Choose tool to identify causes (Relations Diagram / Matrix Diagram)
Stage 3 - List strategies and activities (Tree Diagram / Relations Diagram) Plan actual activities (Arrow Diagram / PDPC Chart)
4 Specific Keys (2)
Obtaining appropriate verbal data
Three types of verbal data:- Facts; factual observations expressed in words
- Opinions; factual information colored by opinion - Ideas; New concepts created by analyzing facts
Group Discussions:- Ensures common understanding- All data should be without bias or distortion- Data should fit objective of the analysis
4 Specific Keys (3)
Interpreting Analytical Results Information must be obtained for
accomplishing objectives from: - Completed diagrams; or
- Process of completing diagrams
Analyze actual information obtained: Prepare summarized report with findings,
conclusions, and processes used Check if necessary data has been obtained, if
not… Discover the cause and take appropriate action
4 Specific Keys (4)
QC Story (Problem Solving)
1. Create Theme of Problem
2. Understanding the Existing Condition
3. Set Up Activities Plan
4. Analyze Causes
5. Execution/Consideration and Testing Activities
6. Result Confirmation (Checking Result)
7. Standardizing
8. Evaluation and Determine Next Theme.
Create Theme of Problem
Look at the items that cause the problem.
Compare with the ideal condition.
Compare with the policy
Look at the item that will have bad impact to other processes.
Compare with the Specification
Compare with the standard.
Compare with the past condition.
Compare with other place’s doing
1. Find Problems
2. Organize
3. Evaluate
4. Choose the
“THEME of PROBLEM”
Existing Condition
Understand the problem and set a target
Good Target Prefer thins that have big impact than need more cost
and effort to achieve it. Have a strong motivation. There is a possibility and opportunity. Can be checked Gaining trust from related people. Encourage group willingness and movement. Considering the upper level policies and relation with
other department.
Activities Plan
Activities List
Time Frame
Person In-charge
Addition info such as: Target/Result, Requirement,etc
Analyze CausesFind as much as possible causes (5W1H, 3M Muda/Pemborosan, Mura/Tidak Teratur, Muri/Tidak Memungkinkan)
Never refuse to take any input related to the causes.
Organize causes into major topics (e.g. Man, Machine, Method, Material, Environment, Infra-Structure, etc.)
Use a method Fish Bone, Tree, some of New QC 7 Tools.
Testing Causes
Choose the most significant causes to be checked.
Take data from several treatments for each causes.
Record each improvement that came from treatment at each causes.
Result Confirmation
Write down the improvement from the treatment and connect to the economical aspect.
Check the final result from the treatment to make sure the improvement is significant.
Standardizing
Create system that will maintain the improvement such as:
Standard Operation Procedure Basic requirement Control Chart/Table
Create control system that can be implemented.
Review & Find Next Theme
Have to make a “serious” review to the:
Result of improvement.
Each step of Problem Solving.
Improvement Process.
Quality Assurance
Scope of Activities:
Find the customer’s need.
Create system for quality improvement in all stage of process; Development/design sales activities
Provide evidence or facts as s support of above activities.
QA Activities TransitionReducing Defect
Function and Performance Improvement
Emphasis on the Reliability
Emphasis on the Customer Satisfaction
Emphasis on the Social Quality
Quality Policies
…is the priority that focus on the approaches.
Should be realistic and achievable.
Must go through to planning stage.
Can be differentiated between “Should do” and “Want to do”.
It showing the employee’s understanding.
Clearly notice the basic policies.