Summer School – Bejaia University, Algeria, 1 – 5 August 2017 د. محمد أحمد عيشوني Continuous Process Improvement – Concepts and Applications in Manufacturing and Services Mohamed Aichouni Professor of Quality Engineering Research Project Leader; ASQ, SQC Member The Engineering College, University of Hail, Saudi Arabia http://faculty.uoh.edu.sa/m.aichouni m.aichouni@uoh.edu.sa Summer School – Bejaia University, Algeria, 1 – 5 August 2017 الأسبوع الوطني للجودة : 06-10 محرم 1435 هـ الموافق لـ 10-14 نوفمبر 2013

Workshop`s Material http://cutt.us/doctoriales-2017 My facebook : Mohamed Aichouni

Cost of Poor Quality https://www.youtube.com/watch?v=jYj_R4oCTPI أ. د. محمد أحمد عيشوني

Quality in Developing World – Example from the Construction Industry In search for Quality of life أ. د. محمد أحمد عيشوني

Quality in Developing World – Example from the Construction Industry Catastrophic Accidents and Losses أ. د. محمد أحمد عيشوني

Recent Research Trends in Quality Engineering (4New Researchers )

Recent Research Trends

Recent Research Trends

Recent Research Trends

Recent Research Trends

Fundamental Concepts and Tools (Why, How, What) Why do we need Continuous Process Improvement ? How can we achieve CPI in Processes ? What are the CPI tools ?

Why ? أ. د. محمد أحمد عيشوني

Why do we have Quality Problems ? Out of the Crisis, 1982 أ. د. محمد أحمد عيشوني

The 3 Demons of Quality and Performance Excellence Delays Delays in production, in delivering services …… In taking decisions Defects Errors in service delivery Defects in products Medical Errors, ……. Deviation Deviation of products characteristics from Design specifications Variations in product or services characteristics

أ. د. محمد أحمد عيشوني

Total Quality and Performance Excellence أ. د. محمد أحمد عيشوني

Process Improvement Process and Performance improvement is about reducing and eliminating the 3 Demons (Delays, Defects and Deviation). = Six Sigma, Lean-Six Sigma, etc… If your organization stops improving – it starts falling! Edward Deming أ. د. محمد أحمد عيشوني

Process Improvement Continual search for improvement opportunities through problem solving. Methodology = Deming PDCA Cycle. OR DMAIC Cycle for Six Sigma approach Study and understand your process. أ. د. محمد أحمد عيشوني

Output (Product / service) Process Approach Input (Raw Material) Process Output (Product / service) Man Machine Measurements Methods Customer Environment Quality characteristics exhibit variations (deviations) , mainly due to variations in the components of the process (5 M and E): Man Power Machines Methods Materials Measurements Environment

Process Variations Quality Tools أ. د. محمد أحمد عيشوني

Lean Six Sigma Improvement Methodology Lean Six Sigma is an approach focused on improving quality, reducing variation, and eliminating waste in an organization. DMAIC Cycle: Able to achieve a level of 3.4 defects per Million Opportunity (DPMO). Improvement Team (Yellow, Green, Black and Master Black belts) focus on problem solving. Improve Analyze Control Measure Define أ. د. محمد أحمد عيشوني

Benefits of Lean Six Sigma The early adopters were Motorola and GE in the 1980s. Since then, many manufacturing and service organizations have successfully deployed Lean Sigma to deliver measurable cost, quality and time based improvements. Organizational Benefits include: Performance improvement Higher Customer satisfaction Higher team morale through collaboration and ownership More relevant metrics أ. د. محمد أحمد عيشوني

Lean Six Sigma Fundamental Steps Process Focus Customer Focus Team Based Rigorous Project Methodology (DMAIC) Project Based Data Driven Variation and Waste Reduction Tools and Techniques Roles and Responsibilities (between belts) Programme Infrastructure أ. د. محمد أحمد عيشوني

Step 1. in Process Improvement : Determine and Clarify the problem أ. د. محمد أحمد عيشوني

Quality Requirements for Manufacturing and services Companies Input Process Output Set Customer Requirements. Product Specifications Raw materials specifications Continuous Process improvement (PDCA, Six Sigma, Lean Six Sigma …) Product Specifications before shipment Customer Satisfaction. أ. د. محمد أحمد عيشوني

Continuous Process improvement Techniques and Tools Quality Requirements for Manufacturing and services Companies – Tools and Techniques Input Process Output Quality Function Deployment /house of Quality Acceptance Sampling Continuous Process improvement Techniques and Tools Acceptance Sampling Customer Complaints (ISO 10002:2004) أ. د. محمد أحمد عيشوني

QFD: Quality Function Deployment أ. د. محمد أحمد عيشوني

Acceptance Sampling Plans ISO 2859-1:1999 Sampling procedures for inspection by attributes — Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection. Many other standards… أ. د. محمد أحمد عيشوني

Process Improvement Tools Quality and Excellence Tools and Techniques Basic Quality Tools New Tools for Management and Planning Other Tools Tools and Techniques for SPC, Quality Control, Process Improvement, Six Sigma, Lean Six Sigma , Innovation and Creativity. أ. د. محمد أحمد عيشوني

Seven Basic Quality Tools Kaoru Ishikawa (1972) BA 499/599 Williams Seven Basic Quality Tools Kaoru Ishikawa (1972) 1 2 3 4 Dirt Old Temp Fault x UCL LCL 5 Process Called the Magnificent Seven They are simple visual tools based on the use of data to study and understand the Process ; So that we can improve the quality of products and Services. Chapter 5

Seven Basic Quality Control Tools Magnificent Seven BA 499/599 Williams Seven Basic Quality Control Tools Magnificent Seven 1 2 3 4 Dirt Old Temp Fault x UCL LCL 5 Process Flow Chart Check Sheet Pareto Analysis Histogram – Process Capability Cause-and-Effect Diagram Scatter Diagram Control Charts – Process Stability Chapter 5

أ. د. محمد أحمد عيشوني

Tool 1 - Process Flow Chart A schematic diagram that shows the flow of the product or service as it moves through the process. Visualize the entire process, identify potential trouble spots, and locate activities that cause delays. Improve the “as is Process” to “as it should be process”

أ. د. محمد أحمد عيشوني

Tool 2 - Check Sheets Process Data can be collected carefully and accurately by operating personnel for process control and problem solving. A check sheet is the easiest way to track information in processes (e.g: problems, defects, etc.)

Check Sheets أ. د. محمد أحمد عيشوني

Tool 3 - The Pareto Diagram Graph that ranks data classifications in descending order from left to right Pareto diagrams are used to identify the most important problems Provide a visual impact of those vital few characteristics that need attention

Tool 3 - The Pareto Diagram (80/20) 80/20 Rule Applications: 80% of process defects arise from 20% of the process issues. 80% of customer complaints arise from 20% of your products or services.

Tool 4 - Histogram A Histogram takes process data and displays its distribution. A Histogram reveals the amount of variation that any process has within it. It shows the process capability to meet customer requirements or design specifications.

Histogram The shape of the histogram help us to determine : a.) Whether the “spread” of the distribution falls within product specifications. If not, how much falls outside of specifications. (VARIABILITY) b.) Whether the distribution is centered at the right place. Are most items on the “high or low side?”(SKEWNESS)

Application in a Manufacturing Process

Applications in RMC Industry أ. د. محمد أحمد عيشوني

Tool 5 - Cause-and-Effect Diagram Dr. Kaoru Ishikawa in 1943 Picture composed of lines and symbols designed to represent a meaningful relationship between an effect and its causes Effect (characteristics that need improvement) on the right and causes on the left. Called also Fishbone diagram or Ishikawa diagram.

Cause and Effect Analysis Quality Problem Machines Measurement Man Methods (Process) Environment Materials Faulty testing equipment Incorrect specifications Improper methods Poor supervision Lack of concentration Inadequate training Out of adjustment Tooling problems Old/worn Defective from vendor Not to specifications Material- handling problems Deficiencies in product design Ineffective quality management Poor process design Inaccurate temperature control Dust and Dirt This is a graphical method of creating a tree diagram. This is a good format for manual drawing, as detail can be filled out from top down. The generic categories of problems should be used whenever possible, with changes as necessary. An indented text outline contains the same information, and is easy to create using the outline tools in wordprocessors.

Tool 6 - Scatter Diagram A Scatter Diagram is used to study the possible relationship between two variables. Used to test for possible cause and effect relationships.

أ. د. محمد أحمد عيشوني

Scatter Diagram – Examples from Manufacturing and Services Average of Manufacturing Errors / Week Average of Overtime Hours / Week

Tool 7 - Control Chart Focuses attention on detecting and monitoring process variation over time. Distinguishes special from common causes of variation

Control Charts Distinguishes special from common causes of variation. Control charts can be used to monitor processes and make continuous process improvement by reducing process variability (removing special causes variation).

Control Charts أ. د. محمد أحمد عيشوني

Applications in RMC Industry أ. د. محمد أحمد عيشوني

SPC Tools : The 7 Basic Quality Tools The SPC tools are Problem Solving Tools which can: Help to identify and prioritize problems quickly and effectively. Assist the decision making process. Simple and powerful tools for continuous improvement projects. Provide a vehicle for communicating problems through extraction of information from process data . 1 2 3 4 Dirt Old Temp Fault x UCL LCL 5 Process

Applications of CPI in Manufacturing and Services Part (II) Applications of CPI in Manufacturing and Services

Applications of CPI in Manufacturing and Services – Minitab Report 2017

World Class Companies adopting CPI Gains More Lives Saved Increased Customer Satisfaction Increased Production Increased Sales Ensure Consistency Create a Data-Driven Culture Boost Resource Recovery Speed Regulatory Approval

More information about Quality Improvement ضبط الجودة الإحصائي الابستور والقوقل بلاي أ. د. محمد أحمد عيشوني

شكرا لحسن المتابعة نسعد بتواصلكم m_aichouni@yahoo.co.uk m.aichouni@uoh.edu.sa http://faculty.uoh.edu.sa/m.aichouni/ أ. د. محمد أحمد عيشوني