Traditional Economic Model of Quality of Conformance

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Traditional Economic Model of Quality of
Conformance
Total cost
Cost due to nonconformance
Cost of quality assurance
100
optimal level of quality
2
Modern Economic Model of Quality of Conformance
Total cost
Cost due to nonconformance
Cost of quality assurance
100
3
Problem Solving Process

• Redefining and analyzing the problem
• Generating ideas
• Evaluating and
• selecting ideas
• 4. Implementing ideas

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The Deming (Shewhart) Cycle
Plan
Act
Do
Study
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PDSA Cycle (1 of 3)

• PLAN
• Select a Problem
• Understand and analyze the present situation
• Identify appropriate countermeasures

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PDSA Cycle (2 of 3)

• DO
• Set the countermeasures in action (i.e., conduct
  a trial run)
• STUDY
• Study the effectiveness of countermeasures

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PDSA Cycle (3 of 3)

• ACT
• Revise standard operating procedures
• Train affected employees
• Establish a plan for future actions

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Ways to Improve A Process (1of 2)

• Reducing handoffs
• Combining or eliminating steps
• Performing steps in parallel rather than in
  serial order
• Using technology

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Ways to Improve A Process (2 of 2)

• Involving key people early
• Creating more consistent inputs
• Eliminating waste
• Correcting inadequate measures or adding new
  measures to a process

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Creative Problem Solving

• Mess Finding identify symptoms
• Fact Finding gather data operational
  definitions
• Problem Finding find the root cause
• Idea Finding brainstorming
• Solution Finding evaluate ideas and proposals
• Implementation make the solution work

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The Seven QC Tools

1. Flowchart
2. Run chart/Control chart
3. Check sheet
4. Pareto diagram
5. Histogram
6. Cause-and-effect diagram
7. Scatter diagram

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Flowchart

• Shows unexpected complexity, problem 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

13
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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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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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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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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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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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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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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Tools for Problem Solving
Problem Solving Step Principal Tools
Understanding the mess . Flowcharts, run
charts,
control charts Finding facts
. Check sheets Identifying problems
... Pareto diagrams,
histograms Generating
ideas . Cause and effect diagrams Developing
solutions .. Scatter diagrams Implementation
... The 7 Management and
Planning tools
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Poka-Yoke (Mistake-Proofing)

• 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