Session 4: Total Quality Management Total Quality Tools and Statistical Thinking (2) Santiago Ibarreche © 2003

Reasons for Using Tools According to Joseph Juran: … most people devote too much attention to control and too little to planning and improvement … Santiago Ibarreche © 2003

Types of Tools Tools for Quality Planning: Quality Function deployment  Concurrent Engineering The New Seven management and Planning Tools Tools for Continuous Improvement: Tools for data Collection and Analysis  The Deming Cycle Poka-Yoke (Mistake Proofing) Benchmarking Creativity and Innovation Statistical Thinking Santiago Ibarreche © 2003

Concurrent Engineering Objectives: Distinguishing the character of the product in order to determine appropriate design, production or operation methods, and ensuring the rapid repair of products or solution of conflicts Analyzing product and operation functions so all design decisions can be made with full knowledge of how the item is supposed to work and so all team members understand it well enough to contribute. Relating product function to production methods. Computer-aided design tools allow a designer to simulate product performance by varying assumptions within a computer model. Santiago Ibarreche © 2003

Objectives: (Cont.) Performing a design-for-manufacturability study to determine if the design can be made easier to produce without affecting performance. Designing an assembly sequence that integrates quality control and ensures that each part is designed so that its quality is compatible with the assembly method. Designing a factory or operation system that fully involves workers in the production strategy, operates on minimal inventory, and is integrated with suppliers' methods and capabilities. Santiago Ibarreche © 2003

The Seven New Management and Planning Tools: Affinity Diagram / KJ Method Interrelationship Diagraphs Tree Diagrams Matrix Diagrams Matrix data Analysis Process Decision Program Chart Arrow Diagrams Santiago Ibarreche © 2003

Affinity Diagram / KJ Method Santiago Ibarreche © 2003

Interrelations Diagraphs Santiago Ibarreche © 2003

Tree Diagram Santiago Ibarreche © 2003

Matrix Diagrams Santiago Ibarreche © 2003

Matrix Data Analysis Santiago Ibarreche © 2003

Process Decision Program Chart (PDPC) Santiago Ibarreche © 2003

Example of a CPM Chart Santiago Ibarreche © 2003

Types of Tools Tools for Quality Planning: Quality Function deployment  Concurrent Engineering  The New Seven management and Planning Tools  Tools for Continuous Improvement: Tools for data Collection and Analysis  The Deming Cycle Poka-Yoke (Mistake Proofing) Benchmarking Creativity and Innovation Statistical Thinking Santiago Ibarreche © 2003

The Deming Cycle Plan Do Act Study Santiago Ibarreche © 2003

Ishikawa (Fishbone or Cause Effect) Santiago Ibarreche © 2003