1. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Quality Tools and Techniques Practicing quality techniques Author: Dr Rhys Rowland-Jones

2. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Session plan –Demonstrate the differing types of quality tools/techniques attributed to the Japanese. –Illustrate the applicability of tools and techniques of quality improvement. –Describe individual applications of appropriate quality tools.

3. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Continual improvement Continual improvement is a type of change that is focused on increasing the effectiveness and/or efficiency of an organization to fulfil its policy and objectives. It is not limited to quality initiatives. Improvement in business strategy, business results, customer, employee and supplier relationships can be subject to continual improvement. Source: IQA. 2007

4. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Basic steps in problem solving 1.Define the problem and establish an improvement goal. 2.Collect data. 3.Analyze the problem. 4.Generate potential solutions. 5.Choose a solution. 6.Implement the solution. 7.Monitor the solution to see if it accomplishes the goal.

5. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Traditionally, a Japanese Samurai carried seven tools into battle. After World War II the Japanese adopted 'quality' as a philosophy for economic recovery and, in line with this traditional approach, sought seven tools to accomplish the economic rejuvenation. The seven tools chosen were: –Histograms –Cause and Effect Diagrams –Check Sheets –Pareto Diagrams –Graphs –Control Charts –Scatter Diagrams

6. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Control Chart Pareto Chart Data Collecting Scatter Plot Ishikawa Chart Histogram Stratification * * * * **** * * The seven tools

7. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Techniques For Improvement. Inputs Outputs Input-Output analysis Flow Charts x x x x x x x x Scatter Diagrams Cause-Effect Diagrams Pareto Analysis Why - why analysis Why?

8. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Cause-and-Effect Diagram Effect MaterialsMethods EquipmentPeople Environment Cause

9. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Check Sheet Billing Errors Wrong Account Wrong Amount A/R Errors Wrong Account Wrong Amount Monday

10. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Pareto Analysis 80% of the problems may be attributed to 20% of the causes. 80% of the problems may be attributed to 20% of the causes. Smeared print Number of defects Off centre Missing label Loose Other

11. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Statistical Process Control (SPC) A process by which a product/service is checked during its creation using certain set parameters and statistical techniques to measure and analyze the variation within the process. WHAT IS IT USED FOR: To monitor the consistency of product/service quality and maintain processes to a fixed target as designed. To drive improvement actions within an organization.

12. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Control Chart 970 980 990 1000 1010 1020 0123456789101112131415 UCL LCL

13. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Run Chart Time (Hours) Diameter

14. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Tracking Improvements UCL LCL UCL Process not centred and not stable Process centred and stable Additional improvements made to the process

15. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Process Variation Process Variability Variations due to: Natural Causes: Temperature variation Material variation Customer differences Operator performance Special Causes: Machine is breaking Untrained operative Machine movement Process has changed Must be monitored Early and visible warning required

16. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction What can be controlled using SPC? VARIABLES. Variable Measures are those that can be measured on a continuous scale, for example length, time, weight.... ATTRIBUTES. Attributes are characteristics that are assessed by judgment and are dichotomous, i.e. have two states such as right or wrong, looks OK or not OK.

17. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Quality at the source The philosophy of making each worker responsible for the quality of his or her work.

18. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction –Quality is a predictable degree of uniformity and dependability, at low cost and suited to the market. –Losses begin to accrue as soon as a quality characteristic of a product or service deviates from the nominal value. –Once the specification limits are reached the loss suddenly becomes positive and constant, regardless of the deviation from the nominal value beyond the specification limits. Genichi Taguchi’s theory of Quality loss

19. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Taguchi Loss Function Cost Target Lower spec Upper spec Traditional cost function Taguchi cost function

20. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction strong (3) Quality Function Deployment Absolute Weight Sales Points Feasibility Evaluation attribute weights x relationship strength 1= weak; 10 = strong 1=easy, 10=difficult (AW x SP) / Feasibility weak (1) very strong (9) KEY Customer Attributes Customer Perceptions Design Characteristics 23415 The House of Quality

21. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Engineering Characteristics Parts Characteristics Parts Characteristics Key Process Operations Customer Requirements Engineering Characteristics Key Process Operations Production Requirements QFD The House Of Quality. The QFD methodology has been developed into a continuous process, and it can be applied equally well to service or manufacturing environments

22. Quality Tools and Techniques Standards in Action www.bsieducation.org/standardsinaction Summary We have looked at a range of quality tools/techniques for improvement. Statistical process control. Taguchi’s theory of quality loss. Quality Function deployment.