1. ENGM 620: Quality Management
Magnificent 7 – 16 October, 2012
Quality Tools
Ishikawa’s Basic Seven
The New Seven
Bonus Tools

2. Why look at Management Tools?
Find out where we are
Prevent problems from occurring
Solve problems when they do happen
Choose the right tool for the problem!

3. Problem Solving Scientific Method Osborne & Parnes
1. Define the Problem
2. Gather Information
3. Develop Alternatives
4. Evaluate Alternatives
5. Implement Solutions
6. Follow Up
Osborne & Parnes
1. Understand the “Mess”
2. Find the Facts
3. Identify Specific Problems
4. Generate Ideas
5. Develop Solutions
6. Implementation

4. Tools of Quality Ishikawa’s Basic Process Maps Check Sheets Histograms
CE Diagrams
Scatter Plots
Control Charts
Pareto Analysis
The New Seven
Affinity Diagram
Interrelationship Diagraph
Tree Diagram
Prioritization Grid
Matrix Diagram
Process Decision Program
Activity Network Diagram

5. Process Mapping Many types of process maps.
If we can draw a picture of the process, we can
communicate it
wrap our minds around it
describe the baseline.
Using simple symbols chart the process from the beginning (or the end).
Start with general, then add detail
Types include flow charts, SIPOC diagrams, value stream maps.

6. Using the Process Map Verify Simplify Expand your scope
Which steps add value, which don’t
Simplify
Remove or reduce steps that are unnecessary
Expand your scope
Map macro processes

7. Flow Charting: A Type of Process Map
Mix Dry
Ingredients
Mix Wet
& Dry
Fold 10
Minutes
Add Chips
Fold 2
Extrude
Dough
Cut Dough
Bake 10 OK
Poor
Qual.
Pack and
Ship
Feed to Hogs

8. Check Sheet Data gathering tool Can be either tabular or schematic
Often used as basis for other tools

9. Check Sheet; Cookies Type Check Total Burnt Crumbly Too Few Chips
Poor Taste
Other 11 5 14 6 3

10. Histograms A representation of data in a bar chart format
Also used to observe the shape (distribution) of data.
The width of the histogram bars must be consistent
The classes mutually exclusive and all-inclusive (or collective exhaustive)
Rule of thumb for the number of classes in the text.

11. Histograms Defects by Category 5 10 15 Burnt Crumbly Few Chips5 10 15
Burnt
Crumbly
Few Chips
Poor Taste
Other
Type Defect
Frequency

12. Pareto Analysis 80/20 Rule Collect data based on or typed into classes
80% of the problems are created by … 20% of the causes
Collect data based on or typed into classes
Create an ordered frequency chart
Focus on the tallest bars first

13. Pareto Chart

14. Cause and Effect Diagrams
Also called Fishbone or Ishikawa Diagrams
Determine problem statement
Start with major potential causes
Work down to potential sub-causes

15. Cause & Effect
Effect
People
Methods
Handling
Design
Tools

16. Cause & Effect Too Few Chips Automate Mix Chips in Dry Fold Longer
Drop Liquid
Place Chips on
by hand

17. As a first step, let’s try
Increasing
Folding Time

18. Scatter Diagram
Chips vs Fold Time 5 10 15 20 25
Fold Time
# Chips

19. Scatter Diagrams Used to examine the relationship between variables
Sometimes used to identify indicator variables in organization

20. Control Charts
Used to determine whether a process will produce a product or process with consistent measurable properties
We will cover these after Exam II

21. Evaluate; Control Chart
Avg Chips
Time 18 15 12