History of SPC World War 2 and aftermath 1980’s Taguchi, Design of Experiments

Cost of Manufacturing

Taguchi Loss Function Loss = k (x- target) 2 Accounting for: Defects Inspection Customer Dissatisfaction Rework Engineering Attention

Modern Day Quality Deming Award, Baldrige Award, ISO9000 Legacy of Deming and Juran Motorola, IBM, GE >>>> 6 Sigma

Motorola’s Process Improvement Flowchart 3 Map the process flow / critical processes 1 Prioritize opportunities for improvement 2 Select a viable team 4 Perform measurement system analysis 5 Verify critical processes

8 Monitor processes - keep them stable - do not over-correct 8 Monitor processes - keep them stable - do not over-correct 9 Experiment for reduction of common variation for continuous improvement. 9 Experiment for reduction of common variation for continuous improvement. 7 Implement optimal operating conditions, preventive and corrective action plans. 7 Implement optimal operating conditions, preventive and corrective action plans. 6 Apply SPC, remove special causes of variation, perform process capability 6 Apply SPC, remove special causes of variation, perform process capability 10 Implement engineering changes from experiment results and re-check capabilities 10 Implement engineering changes from experiment results and re-check capabilities

Quality Costs Prevention - pay now to improve later Appraisal Failure

Advantages of Histograms Pictures are easily understood  Measure the effect of corrective actions (histograms before and after)  Compare parallel processing equipment  Compare sample data to specifications

Some disadvantages of histograms:  Large sample sizes are needed  Time effects are not visible Special cause variability is not easily separated

Homework for Sept 9 from Text Problems on p.77-81, 2-2, 2-6, 2- 35, Also: #1A - Referring to prevention, appraisal, and failure costs, what is the preferred method for a company to manage its total quality cost ? Write a paragraph.