1. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Multi-State Advanced Manufacturing Consortium US DOL SPONSORED TAACCCT GRANT: TC23767 RELEASE DATE12/3/2015 VERSIONv 001 PAGE1 of 41 PRIMARY DEVELOPER – Janaina Gasparelo, Henry Ford College I NTEGRATED Q UALITY S ESSION 3 P ROFESSOR J ANAINA G ASPARELO H ENRY F ORD C OLLEGE J ANUARY, 2015 US D EPARTMENT OF L ABOR M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM

2. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Quiz Session 1-2 In Spec - Out of Spec (Concept Introduction) Basic Quality Control Tools (Brief Overview 7 Basic Tools) Pareto Charts Histogram (Introduction) Characteristics Matrix Process Flow Check Sheet Dimensional / Performance Report Ishikawa & Fishbone Diagram Procedure 5 Why’s Benchmarking TIP: Pay attention to Data! AGENDA

3. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Valves made for class example only IN SPEC – OUT OF SPEC

4. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License IN SPEC – OUT OF SPEC Diameter Chamfer

5. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS When you encounter problems with your car, you need to know what tools are needed to fix the problem, and how and when to use each tool.

6. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS The same is true when you want to fix problems within your company. There are seven basic quality tools that are remarkably being applied in the industry :  Cause-and-effect diagram  Check sheet  Control charts  Histogram  Pareto chart  Scatter diagram  Stratification

7. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS 1.Cause-and-effect diagram (also called Ishikawa or fishbone chart): 1.Cause-and-effect diagram (also called Ishikawa or fishbone chart): Identifies many possible causes for an effect or problem and sorts ideas into useful categories. 2.Check sheet: 2.Check sheet: A structured, prepared form for collecting and analyzing data; a generic tool that can be adapted for a wide variety of purposes. 3.Control charts: 3.Control charts: Graphs used to study how a process changes over time. 4.Histogram: 4.Histogram: The most commonly used graph for showing frequency distributions, or how often each different value in a set of data occurs. 5.Pareto chart: 5.Pareto chart: Shows on a bar graph which factors are more significant. 6.Scatter diagram: 6.Scatter diagram: Graphs pairs of numerical data, one variable on each axis, to look for a relationship. 7.Stratification: 7.Stratification: A technique that separates data gathered from a variety of sources so that patterns can be seen (some lists replace “stratification” with “flowchart” or “run chart”).

8. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: PARETO Pareto charts are a type of bar chart in which the horizontal axis represents categories rather than a continuous scale – The categories are often defects, errors or sources (causes) of defects/errors The height of the bar represent a count or percent of errors/defects or their impact in terms of delays, rework, cost, etc. By arranging the bars from largest to smallest, a Pareto chart can help you determine which categories will yield the biggest gains if addressed, and which are only minor contributors to the problem Reference: Lean Six Sigma Pocket ToolBook p.142

9. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: PARETO Let's pretend that each different color candy is a different problem that we face in our job, and these represent one week's worth of problems Our days are so rushed that it can be quite confusing to make any sense out of our problems. Sometimes it's hard to know where to start

10. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: PARETO To take advantage of the power of the Pareto Principle, you need to take a few moments out of your busy day to take a snapshot of the problems you are having. Then you can start to gather information and analyze each problem.

11. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: PARETO Next you need to identify and categorize the problems you are having and establish how many times each problem occurs over a given period of time. There, that looks better already doesn't it?

12. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: PARETO Then using your count of each group, you can get an idea of how each problem stacks up against each other. Then put the largest groups to the left descending to the right. You now have a basic Pareto chart. One of the purposes of Pareto charts is to identify the most significant items which will show you where to focus your efforts.

13. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Vilfredo Pareto was an Italian economist that observed the unequal distribution of wealth in his country. Vilfredo Pareto observed that: a)Not everyone in his country shared the same amount of wealth b)There were far more poor people than rich c)He actually created a mathematical formula that said 20% of the people owned 80% of the wealth d)And 80% of the people owned 20% of the wealth BASIC QUALITY CONTROL TOOLS: PARETO PRINCIPLE

14. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License "vital few and trivial many” Dr. Joseph Juran applied Pareto's observations about economics to the world of Quality and established a principle he named the "vital few and trivial many” This principle means that 80% of the problems you face come from 20% of the causes. For instance, if you discover there are 10 reasons or causes for the problems you are having, two of those causes are responsible for 80% of your problems BASIC QUALITY CONTROL TOOLS: PARETO PRINCIPLE

15. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License If you focus your efforts on eliminating those two causes or, the vital few, 80% of your problems go away That means that 80% of the causes of your problems are trivial and will not yield the same benefits as eliminating the vital few. In this example, we could spend a lot of time eliminating 3 of the 5 causes and only eliminate 20% of our problems as shown. That is a lot of work for such a minor improvement. BASIC QUALITY CONTROL TOOLS: PARETO PRINCIPLE

16. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Histograms sometimes are also called Frequency Plot and its purpose is to evaluate the distribution of a set of data (to learn about its basic proprieties and to evaluate whether you can apply certain statistical tests) Histograms display bars representing the count within different ranges of data rather then plotting individual data points The groups represent non-overlapping segments in the range of data Reference: Lean Six Sigma Pocket ToolBook p.142 BASIC QUALITY CONTROL TOOLS: HISTOGRAM

17. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License A characteristics matrix is a recommended analytical technique for displaying the relationship between process parameters and manufacturing stations. BASIC QUALITY CONTROL TOOLS: CHARACTERISTICS MATRIX

18. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License A method of developing he characteristics matrix is to number the dimensions and/or features on the part print and each manufacturing operation. All manufacturing operations and stations appear across the top, and the process parameters are listed down the left-hand column. The more manufacturing relationships there are, the more important the control of a characteristics becomes. Regardless of matrix size, the upstream relationships of characteristics are evident. BASIC QUALITY CONTROL TOOLS: CHARACTERISTICS MATRIX

19. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License The process flow chart is a schematic representation of the current or proposed process flow. It can be used to analyze sources of variations of machines, materials, methods, and manpower from the beginning to end of a manufacturing or assembly process. It is used to emphasize the impact of sources of variation in the process. BASIC QUALITY CONTROL TOOLS: PROCESS FLOW

20. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License The flow chart helps to analyze the total process rather than individual steps in the process. The flow chart assists the organization’s product quality planning team to focus on the process when conducting a PFMEA and designing the Control Plan. BASIC QUALITY CONTROL TOOLS: PROCESS FLOW

21. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: PROCESS FLOW Process Flow Diagram (PFD) Example

22. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: CHECK SHEETS Check sheets are a great tool to help you gather the basic information about the problems you face on a daily basis. You can list the types of problems you are having and how often they occurred each day. From this information you can create a Pareto chart which will help steer you in the right direction. One can say that a check sheet is also a dimensional or performance report

23. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: CHECK SHEETS Check sheets are a great tool to help you gather the basic information about the problems you face on a daily basis. You can list the types of problems you are having and how often they occurred each day. From this information you can create a Pareto chart which will help steer you in the right direction. One can say that a check sheet is also a dimensional or performance report

24. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: CHECK SHEETS It is recommended to design a new check sheet every time you collect data and the check sheet is tailored to that situation. Having standard forms make it easy to collect reliable, useful data Enable faster capture and compiling of data Ensures consistent data from different people Captures essential descriptors (stratification factors) that otherwise might be overlooked or forgotten Reference: Lean Six Sigma Pocket ToolBook p.78

25. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: CHECK SHEETS

26. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: DIMENSIONAL / PERFORMANCE REPORT Dimensional or Performance inspection is one kind of sample testing that concentrate on dimensions of the material and dimensional tolerance as defined as criteria of acceptance. Dimensional inspection reports are generate for the sample testing on various level that can be basic samples testing of dimension, in between randomly taken samples from production line that is also called sample testing but during production operation and also can be lot wise or batch wise samples randomly taken as per sample plans.

27. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: DIMENSIONAL / PERFORMANCE REPORT Sample testing as per sample plan can be different testing criteria than dimensional inspection; in the dimensional inspection all the concern the sample dimensions are checks with by various methods and various types of test, there are three to five different test with nos. of testing that multiply tests are done on single sample to ensure the result of the dimensional testing is accurate and reliable for the further actions.

28. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: DIMENSIONAL / PERFORMANCE REPORT Dimensional Inspection process ends that match with drawings which form prepared by development and planning department to ensure as per drawing material / part is accurately designed for the application requirements. Dimensional Inspection report, major require and need to focus on follows points: – Drawing of material – Tolerance as per drawing requirements – Measuring instrument – Action measured dimensions – Status : Accepted / rejected / rework

29. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: DIMENSIONAL / PERFORMANCE REPORT

30. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: ISHIKAWA Ishikawa Kaoru, July 13, 1915 - April 16, 1989) was a Japanese organizational theorist, Professor at the Faculty of Engineering at The University of Tokyo, noted for his quality management innovations. He is considered a key figure in the development of quality initiatives in Japan, particularly the quality circle. He is best known outside Japan for the Ishikawa or cause and effect diagram (also known as fishbone diagram) often used in the analysis of industrial processes

31. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: ISHIKAWA The fishbone diagram identifies many possible causes for an effect or problem. It can be used to structure a brainstorming session. It immediately sorts ideas into useful categories. When to Use a Fishbone Diagram  When identifying possible causes for a problem.  Especially when a team’s thinking tends to fall into ruts.

32. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Materials needed: flipchart or whiteboard, marking pens Agree on a problem statement (effect). Write it at the center right of the flipchart or whiteboard. Draw a box around it and draw a horizontal arrow running to it. Brainstorm the major categories of causes of the problem. If this is difficult use generic headings: – Methods – Machines (equipment) – People (manpower) – Materials – Measurement – Environment BASIC QUALITY CONTROL TOOLS: FISHBONE DIAGRAM PROCEDURE

33. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Write the categories of causes as branches from the main arrow. Brainstorm all the possible causes of the problem. Ask: “Why does this happen?” As each idea is given, the facilitator writes it as a branch from the appropriate category. Causes can be written in several places if they relate to several categories. BASIC QUALITY CONTROL TOOLS: FISHBONE DIAGRAM PROCEDURE

34. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Again ask “why does this happen?” about each cause. Write sub–causes branching off the causes. Continue to ask “Why?” and generate deeper levels of causes. Layers of branches indicate causal relationships. When the group runs out of ideas, focus attention to places on the chart where ideas are few. BASIC QUALITY CONTROL TOOLS: FISHBONE DIAGRAM PROCEDURE

35. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Example: This fishbone diagram was drawn by a manufacturing team to try to understand the source of periodic iron contamination. The team used the six generic headings to prompt ideas. Layers of branches show thorough thinking about the causes of the problem. BASIC QUALITY CONTROL TOOLS: FISHBONE DIAGRAM PROCEDURE

36. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: FISHBONE DIAGRAM PROCEDURE For example, under the heading “Machines,” the idea “materials of construction” shows four kinds of equipment and then several specific machine numbers. Note that some ideas appear in two different places. “Calibration” shows up under “Methods” as a factor in the analytical procedure, and also under “Measurement” as a cause of lab error. “Iron tools” can be considered a “Methods” problem when taking samples or a “Manpower” problem with maintenance personnel. Excerpted from Nancy R. Tague’s The Quality Toolbox, Second Edition, ASQ Quality Press, 2005, pages 247–249.

37. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: 5 WHY’S Method for pursuing people to think about root causes Prevents a team from being satisfied with superficial solutions that won’t fix the problem in the long run Why?

38. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: BENCHMARKING Benchmarking is a systematic approach to identifying standards for comparison. It provides input to the establishment of measurable performance targets, as well as ideas for product design and process and work procedures. Product and process benchmarking should include the identification of world class or best-in-class based on customer and internal objective performance measures and research into how this performance was achieved.

39. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: BENCHMARKING Benchmarking should provide a stepping stone for developing new designs and processes that exceed the capabilities of the benchmark companies.

40. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License BASIC QUALITY CONTROL TOOLS: DATA TIP: Pay attention to data! An analysis is only as Good as the Data on which it is based

41. M ULTI -S TATE A DVANCED M ANUFACTURING C ONSORTIUM 20151203_v001_msamc_courseware_quality_ppt320151203_v001_msamc_courseware_quality_ppt3 found in Resources by the M-SAMC Multi-State Advanced Manufacturing Consortium www.msamc.org is licensed under a Creative Commons Attribution 4.0 International License.www.msamc.org Creative Commons Attribution 4.0 International License Multi-State Advanced Manufacturing Consortium US DOL SPONSORED TAACCCT GRANT: TC23767 RELEASE DATE12/3/2015 VERSIONv 001 PAGE41 of 41 PRIMARY DEVELOPER – Janaina Gasparelo, Henry Ford College SAFETY DISCLAIMER: M-SAMC educational resources are in no way meant to be a substitute for occupational safety and health standards. No guarantee is made to resource thoroughness, statutory or regulatory compliance, and related media may depict situations that are not in compliance with OSHA and other safety requirements. It is the responsibility of educators/employers and their students/employees, or anybody using our resources, to comply fully with all pertinent OSHA, and any other, rules and regulations in any jurisdiction in which they learn/work. M-SAMC will not be liable for any damages or other claims and demands arising out of the use of these educational resources. By using these resources, the user releases the Multi-State Advanced Manufacturing Consortium and participating educational institutions and their respective Boards, individual trustees, employees, contractors, and sub-contractors from any liability for injuries resulting from the use of the educational resources. DOL DISCLAIMER: This product was funded by a grant awarded by the U.S. Department of Labor’s Employment and Training Administration. The product was created by the grantee and does not necessarily reflect the official position of the U.S. Department of Labor. The Department of Labor makes no guarantees, warranties, or assurances of any kind, express or implied, with respect to such information, including any information on linked sites and including, but not limited to, accuracy of the information or its completeness, timeliness, usefulness, adequacy, continued availability, or ownership. RELEVANCY REMINDER: M-SAMC resources reflect a shared understanding of grant partners at the time of development. In keeping with our industry and college partner requirements, our products are continuously improved. Updated versions of our work can be found here: http://www.msamc.org/resources.html.http://www.msamc.org/resources.html