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Rev. 06/05/07 SJSU Bus 140 - David Bentley 1
Chapter 6 – Management of Quality
Dimensions, determinants, definition, pioneers, Cost of Quality,
awards, ISO registration, TQM, process improvement methodology,
quality tools, PDCA (PDSA) cycle, Quality Circles
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What’s your definition of quality? High price? Reliable? Attractive? Durable? Other?
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Dimensions of Quality Performance Aesthetics Special features Safety Reliability Durability Perceived quality Service after sale
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Quality - a Definition - 1 “Fitness for use” - Juran Based on various factors: reliability,
durability, performance, usefulness, aesthetics, price, etc. - Various
“Meets customer requirements” – Various
“Consistently meets or exceeds customer expectations” – Stevenson
“Ability of a product or service to meet customer needs” - Heizer
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Quality - a Definition - 2 “Consistently meets or exceeds
customer requirements” – Bentley Emphasis on requirements Includes understanding of expectations Implies an agreement
explicit or Implicit
Concept: “Do it right the first time and every time”
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Determinants of Quality How well a product satisfies its
intended purpose based on 4 factors Design Conformance to the design Ease of use Service after delivery
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Case Study – a personal experience
Program introduction General manager kickoff talk Key question – “What do we do at the
end of the month if we’re not sure that a product meets quality requirements?”
The answer – “That all depends…” Possible consequences Program results
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Quality Gurus / Pioneers - 1
Frederick Taylor (1856-1915) Inspection Gauging
Walter Shewhart (Bell Labs) (1891-1967) Developed Statistical control charts Mentored Deming PDCA cycle (shared with Deming) Identified 2 causes of variation: chance and
assignable
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Quality Gurus / Pioneers - 2
H.G. Romig (????-????) and Harold Dodge (1893-????) (Bell Labs) Acceptance sampling tables
W. (William) Edwards Deming (1900-1993) Trained in engineering, mathematics, and physics Physics professor, U.S. Census Bureau, consultant Taught SQC to Japanese QC people (1947-1965) PDCA cycle (shared with Shewhart) Honored by Japanese prize in his name
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Quality Gurus / Pioneers - 3
W. (William) Edwards Deming (cont’d.) 14 points based on:
Constancy of purpose Continual improvement Profound knowledge
Appreciation for a system A theory of variation A theory of knowledge
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Quality Gurus / Pioneers - 4
Joseph M. Juran (Bell Labs) (1904- ) Also lectured in Japan Authored/Edited Quality Control Handbook Conceived idea of “Cost of Quality” Built on Pareto concept “Quality Trilogy” concept
Quality planning Quality control Quality improvement
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Quality Gurus / Pioneers - 5
Armand Feigenbaum (GE, General Systems Company) (????- ) “Cost of nonconformance” Total quality control concept Authored Total Quality Control 40 steps in quality principles
TQC is system for integration… Standards, appraisal, corrective action Technological and human factors 4 categories of quality costs Control quality at the source
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Quality Gurus / Pioneers - 6
Philip Crosby (Martin Marietta, ITT, PCA) (1926-2001) Zero Defects Authored Quality is Free, Quality
Without Tears Started Quality College (multiple sites)
Company teams trained Emphasized behavioral change
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Quality Gurus / Pioneers - 7
Kaoru Ishikawa (1915-1989) Quality Circles Cause and effect [“fishbone” or Ishikawa] diagram Promoted statistical methods Recognized internal customer Conceived “company wide quality
control”
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Quality Gurus / Pioneers - 8
Genichi Taguchi (1924- ) Emphasized variation reduction Taguchi loss function
Shigeo Shingo (1909-1990) Not focused on quality but had significant
impact Setup standardization Poka-yoke Source inspection systems
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Cost of Quality External Failure
Internal Failure
Prevention
Appraisal
External Failure
Internal Failure
Prevention
Appraisal
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Awards & Prizes Deming Prize
Awarded by Union of Japanese Scientists & Engineers
First awarded in 1951 Named after W. Edwards Deming
Malcolm Baldrige Award Awarded by US Department of
Commerce 1987 legislation Named after Malcolm Baldrige
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Awards & Prizes (cont’d)
European Quality Award Award for “organizational excellence” Originally one per year Now several categories
Other awards Most developed nations have some
form of Quality awards or prizes
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Value of Awards & Prizes Shows effort Largely dependent on money spent Used in advertising Doesn’t reflect customer view
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International Standards Org’n
ISO 9000 (QMS - Fundamentals and vocabulary)
ISO 9001 (QMS - Requirements) ISO 9004 (QMS Guidance for performance
improvement) ISO 19011 (Guidelines on Quality and/or
Environmental Management Systems Auditing)
ISO 14000 (environmental responsibility)
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ISO Registration What’s been good
Focus on quality Demonstrates effort
What’s been bad (mostly fixed in ISO 9000:2000 Becomes mechanical Emphasizes conformance to
documentation, not meeting QUALITY Doesn’t include customer view
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Quality Today Reflects a blend of concepts and
contributions from the “pioneers” (“gurus”)
Stresses organization-wide TQM Emphasizes the role of the front-line
worker (authority and responsibility) Seeks to recognize achievement
through prizes and certification
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TQM Approach Know customer requirements and wants Design a product to delight the customer Design a process to do the job right (the
first time and) every time Apply fail-safing techniques (“poka-yoke”
devices) Monitor and record results for
improvement ideas Work with suppliers and customers
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Poka-Yoke(Mistake-Proofing)
Developed by Shigeo Shingo An approach for mistake-proofing
processes using automatic devices or methods to avoid simple human or machine error, such as forgetfulness, misunderstanding, errors in identification, lack of experience, absentmindedness, delays, or malfunctions
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Poka-Yoke Examples (from John Grout’s Poka-Yoke Page)(refer to www.campbell.berry.edu/pokayoke) mod. 09/15/02 DAB
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Other TQM Points Continual improvement (“kaizen”) Competitive benchmarking Employee enablement Use of teams Training Extension to suppliers Traditional vs. TQM cultures
areas, redundancy, unnecessary loops, and where simplification may be possible
Compares and contrasts actual versus ideal flow of a process
Allows a team to reach agreement on process steps and identify activities that may impact performance
Serves as a training tool
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Check Sheet Creates easy-to-understand data Builds, with each observation, a
clearer picture of the facts Forces agreement on the definition
of each condition or event of interest Makes patterns in the data become
obvious quickly
xx xxxxxx x
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Scatter Diagram
Supplies the data to confirm a hypothesis that two variables are related
Provides both a visual and statistical means to test the strength of a relationship
Provides a good follow-up to cause and effect diagrams
* * ** * *
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Histogram Displays large amounts of data that are
difficult to interpret in tabular form Shows centering, variation, and shape Illustrates the underlying distribution of
the data Provides useful information for
predicting future performance Helps to answer the question “Is the
process capable of meeting requirements?
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Pareto Diagram Helps a team focus on causes that
have the greatest impact Displays the relative importance of
problems in a simple visual format Helps prevent “shifting the problem”
where the solution removes some causes but worsens others
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Cause and Effect Diagram
Enables a team to focus on the content of a problem, not on the history of the problem or differing personal interests of team members
Creates a snapshot of collective knowledge and consensus of a team; builds support for solutions
Focuses the team on causes, not symptoms
Effect
Cause
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Control Chart Focuses attention on detecting and
monitoring process variation over time Distinguishes special from common
causes of variation Serves as a tool for on-going control Provides a common language for
discussion process performance* * * * *
* *
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Run Chart Monitors performance of one or more processes
over time to detect trends, shifts, or cycles Allows a team to compare performance before
and after implementation of a solution to measure its impact
Focuses attention on truly vital changes in the process
* * * * *
* *
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Process Improvement Sequence - 1
Management responsibility Develop process improvement plan Determine process or area to
examine Form and train Process/Quality
Improvement Team
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Process Improvement Sequence - 2
Team: use coarse tools Process flowchart Check sheets and histograms Pareto analysis <--- (iterative Fishbone chart ---> steps)
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Process Improvement Sequence - 3
Team: use fine tools Process control charts Run diagrams Scatter diagrams Failsafing
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Process Improvement Sequence - 4
Team Determine process changes Implement pilot process improvement Measure and evaluate results Repeat if results unsatisfactory; deploy
full implementation if results satisfactory
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PDCA (or PDSA) Cycle Also known as the Deming wheel, or
Deming/Shewhart cycle or wheel 4 parts to the cycle
Plan - document and analyze Do - implement “improvement” Check (or Study) - compare to desired
state Act - correct or standardize
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Quality Circles vs. QITs Quality Circles
Limited authority Focus within department Often seen as added work Ongoing
Quality Improvement Teams Greater authority Focus on total process Recognized as important part of job End when process improvement complete
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5W2H Approach What? Subject Why? Purpose Where? Location When? Timing/sequence Who? People involved How? Method How much? Cost/impact
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Six Sigma Quality Latest popular approach to Quality ± 6 standard deviations (6) from the
process mean = 0.0003% defects Represents a goal Certification from ASQ on processes
to support Six Sigma Many consulting and training firms
on how to implement Six Sigma
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Six Sigma at GE “The central idea behind Six Sigma
is that if you can measure how many ‘defects’ you have in a process, you can systematically figure out how to eliminate them and get as close to ‘zero defects’ as possible.”