1. Quality Circle and 8 D Methodology Dr. Mohamed Riyazh Khan - DoMS

2. Walter A. Shewhart Walter A. Shewhart could be considered the "Father of Quality." This title is most often associated with W. Edwards Deming, but Deming learned "at the feet" of Shewhart. Shewhart laid the first seed of the quality movement with his book "Economic Control of Quality of Manufactured Product." This book introduced the concept of Statistical Process Control. SPC has become the cornerstone for process control in industry.

3. Walter A. Shewhart An idea that is commonly credited to Deming, but in actuality belongs to Shewhart is the PDCA (or PDSA) cycle of management. This is the Plan-Do-Check (or Study)-Act cycle that should be used for all management projects. Plan what you want to do, do it, study the results, make corrections, and then plan for the improvements (starting the cycle again).

4. Walter A. Shewhart The Shewhart Cycle - The Deming Wheel - Plan-Do-Check-Act

5. Walter A. Shewhart PLAN Establish the objectives and processes necessary to deliver results in accordance with the specifications.specifications DO Implement the processes. CHECK Monitor and evaluate the processes and results against objectives and Specifications and report the outcome. ACT Apply actions to the outcome for necessary improvement. This means reviewing all steps (Plan, Do, Check, Act) and modifying the process to improve it before its next implementation.

6. Shigeo Shigeo Shingo's life-long work has contributed to the well being of everyone in the world. Shigeo Shingo along with Taiichi Ohno, Kaoru Ishikawa and others has helped to revolutionize the way we manufacture goods. His improvement principles vastly reduce the cost of manufacturing - which means more products to more people. They make the manufacturing process more responsive while opening the way to new and innovative products with less defects and better quality.

7. Shigeo He is one of the pioneers of change management. He brought about many new concepts such as ZD (Zero Defects), shifting use of statistics for acceptance or rejection from SQC (Statistical Quality Control) to SPC (Statistical Process Control), SMED (Single Minute Exchange of Dies), POKA-YOKE (mistake proofing), Defining Processes & Operations in two-dimensions of VA (Value Addition) and non-VA, etc.

8. Increase Motivation Create the will to work Improve communication Create problem solving capability Build an attitude of problem prevention QUALITY CIRCLE Inspire Employees to come together Team work Create positive work attitude in employees Develop knowledge and skill Develop safety awareness Reduce job errors Develop harmonious supervisor employees relationship

9. Steering Committee COORDINATOR STRUCTURE OF QUALITY CIRCLES IN AN INDUSTRY

10. TOP MANAGEMENT Chairman and managing director, directors, chief executives, general managers and other top executives Lends total support to the philosophy and activities of QC Motivates by meeting circle leaders and members occasionally. Incorporates QC promotion as one of the company's broad objective.

11. STEERING COMMITTEE Comprises of representatives of all major functions Responsible for establishing objectives and resources Meets regularly once in two months with facilitators as invitees Provide guidance and direction Gives thrust by promoting qc as a way of life

12. FACILITATOR Responsible for the successful operation of the circles on his area Trains members by assisting leaders Solves interface problems between circles Demonstrates support of the management Works closely with steering committee Maintains activity level records of circles Reports to the steering committee Takes timely corrective action to revitalize inactive circles.

13. LEADER Chosen by members Guides, trains members Involves every member in circle activities Prepares agenda and conducts meetings regularly and effectively and ensures discipline and decorum. Chalks out action plan

14. Members Voluntary group of people coming from the same work area Meet regularly (One hour in week) and actively participate in circle meetings Identify, analyses and recommend solutions to work related problems Assist leader

15. 8D is a problem-solving methodology for product and process improvement. It is structured into eight disciplines, emphasizing team synergy. The team as whole is better and smarter than the quality sum of the individuals. Each discipline is supported by a checklist of assessment questions, such as “what is wrong with what”, “what, when, where, how much”. 8D METHODOLOGY

16. 1. Use Team Approach Establish a small group of people with the knowledge, time, authority and skill to solve the problem and implement corrective actions. The group must select a team leader. 2. Describe the Problem Describe the problem in measurable terms. Specify the internal or external customer problem by describing it in specific terms. 8D METHODOLOGY

17. 3. Implement and Verify Short-Term Corrective Actions Define and implement those intermediate actions that will protect the customer from the problem until permanent corrective action is implemented. Verify with data the effectiveness of these actions. 4. Define end Verify Root Causes Identify all potential causes which could explain why the problem occurred. Test each potential cause against the problem description and data. Identify alternative corrective actions to eliminate root cause. 8D METHODOLOGY

18. 5. Verify Corrective Actions Confirm that the selected corrective actions will resolve the problem for the customer and will not cause undesirable side effects. Define other actions, if necessary, based on potential severity of problem. 6. Implement Permanent Corrective Actions Define and implement the permanent corrective actions needed. Choose on-going controls to insure the root cause is eliminated. Once in production, monitor the long-term effects and implement additional controls as necessary. 8D METHODOLOGY

19. 7. Prevent Recurrence Modify specifications, update training, review work flow, improve practices and procedures to prevent recurrence of this and all similar problems. 8. Congratulate Your Team Recognize the collective efforts of your team. Publicize your achievement. Share your knowledge and learning. 8D METHODOLOGY