2. Lesson 4
Improve the Process

3. Objectives You will be able to understand:
The advantages of continual process improvement
The key activities associated with process improvement

4. 5. Repeat step 1 with new knowledge
Improve the Process
4. Act on what
was learned
1. Plan a change
for improvement
ACT
PLAN
CHECK DO
3. Analyze and
interpret effects
of the change
2. Carry out the
change on a
small scale
5. Repeat step 1 with new knowledge
6. Repeat step 2 and onward

5. The Batavia Incident Offshore: Less variation Batavia: More variation10 20 30 40 50 60 70 80 90
LSL
USL
Target

6. Specifications as Goals
Loss
No Loss
Loss
(Bad)
(Good)
(Bad)
Does not meet
customer
expectations
Does not meet
customer
expectations
Meets
customer
expectations
LSL
Target
USL
Measure of quality characteristic

7. Quality Loss Function Increasing Value Lost Increasing Value Lost
Curve
LSL
Target
USL
Measure of quality characteristic

8. Continual Improvement and the Quality Loss Function
Distributions A B C
Value Lost
Increasing
Value Lost
Increasing
Loss A
Loss B
Loss C
Loss B
Loss A
LSL
Target
USL
Measure of quality characteristic

9. Activity 4.1 Plan ACT PLAN CHECK DO
Plan what changes might lead to improvements
Decide what data are needed
Determine how, when, and by whom data will be collected
ACT
PLAN
CHECK DO

10. Cause & Effect Diagram Equipment Methods Reliable elevators Better
tools
Assembly
procedures
Better
training
Skids &
yellowgear
Better
training
Weapons
movement
Reduced
weapons
assembly
and
delivery
time
Assembly
jigs
Better
training
Pre-assembled
Components
Closer storage
spaces
Improved
watchbill
Better/faster
elevators
Fewer weapons
types
Lights&
ventilation
Training
priority
Better “C”
schools
Grease
Viscosity
Straight thru
elevators
People
Materials
Environment

11. Activity 4.2 Do ACT PLAN CHECK DO Gather or review baseline data
Make planned changes on a small scale
Gather data to determine what happened after the changes

12. Activity 4.3 Check ACT PLAN CHECK DO
Compare results of changes with what was planned
Determine whether changes led to improvements
CHECK DO

13. Activity 4.4 Act ACT PLAN CHECK DO Decide on changes Make the changes
Standardize
Educate & train
Monitor the process
Repeat the cycle
ACT
PLAN
CHECK DO

14. PDCA Cycle & Process Improvement
Decide on changes
Make the changes
Standardize
Educate & train
Monitor the process
Repeat the cycle
Plan what changes might lead to improvements
Decide what data are needed
Determine how, when, and by whom data will be collected
ACT
PLAN
Compare results of changes with what was planned
Determine whether changes led to improvements
CHECK DO
Gather or review baseline data
Make planned changes on a small scale
Gather data to determine what happened after the changes

15. Leadership Involvement
Study & learn PDCA
Actively participate in quality improvement
Develop a TQL implementation plan
Choose initial efforts that are: - Customer or mission-driven - Likely to succeed - Measurable - Designed with strategic intent

16. TQL Teams & Activities ESC QMB PAT A P C D 1.1 Clarify The Mission
(only if required)
1.1 Clarify The
Mission
Clarify the
Charter
Task (or Charter)
a PAT
Train ESC
Build commitment in ESC
Write Implementation Plan
2.1 Describe the Process
2.2 Simplify, &
2.3 Standardize the Process
PAT
ID & Prioritize:
1.2 Org’s Customers
1.3 Customer Reqmts
1.4 Significant Processes
3.1 Determine Measures
Assist
the
QMB
3.2 Construct Control Chart
2.1 Describe Processes
Charter QMBs
Stable ? No
3.3 Act on Special
Causes
Help with Flow Chart
Collect data
ID & remove special causes
Provide ideas
Assess the Organization
Develop Critical Mass
Create the Environment
Refine Mission
Improve the TQL Impl Plan
Support and Extend CPI
Yes
4.4
4.1 A P
3.4 Check for
Capability
4.3
4.2 C D
(MOM 6)

17. Summary of Key Activities
Identify
1.1 Clarify the mission
1.2 Identify & prioritize customers
1.3 Identify & prioritize customer requirements
1.4 Identify significant processes that meet
customer requirements
Simplify &
Standardize
2.1 Describe the process
2.2 Simplify the process
2.3 Standardize the process
Stabilize
3.1 Determine process measures
3.2 Examine the process by using control
charts
3.3 Act on special causes
3.4 Check for capability
Improve
4.4
ACT
4.1
PLAN
4.3
CHECK
4.2 DO

18. Chapter Summary Process improvement is a job for everyone
Process improvement must be continual
Process improvement affects organizational systems
You are responsible for leading process improvement

19. Summarize Your
Responsibilities for
Implementing TQL