[ppt]quality improvement: problem solving - saint...
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Quality Improvement: Problem Solving
Week 6AgendaAgenda Review homework
• Problems Ch 3: 2, 4 Ch 3: Quality tools desksides
• Flow chart• Pareto Diagram• Histogram• Cause and Effect Diagram• Check sheet• Scatter diagram• Control chart• Why-why• Force field analysis• Brainstorming
Week 7 assignment • Read chapter 4• Homework problems:
Ch 3 - 9, 11, 33• Case Study: "How
We Slashed Response Time"
Quality Improvement: Problem Solving
Quality ToolsQuality ToolsChapter 3: Problem Solving
Quality Improvement: Problem Solving
Quality Control ToolsQuality Control Tools• Pareto chart• Histogram • Process flow diagram• Check sheet• Scatter diagram• Control chart
• Run chart• Cause and effect diagram
Quality Improvement: Problem Solving
Pareto PrinciplePareto Principle Vilfredo Pareto (1848-1923) Italian
economist• 20% of the population has 80% of the
wealth Juran used the term “vital few, trivial
many”. He noted that 20% of the quality problems caused 80% of the dollar loss.
7 Quality Tools7 Quality Tools
Quality Improvement: Problem Solving
Pareto chartPareto chart
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28
1612 12
64 3
0
5
10
15
20
25
30
LooseThreads
Stitchingflaws
Buttonproblems
Materialflaws
% C
ompl
aint
s
Quality Improvement: Problem Solving
Pareto Pareto Chart Chart
Per
cent
from
eac
h ca
use
Causes of poor quality
Machin
e cali
brati
ons
Defecti
ve pa
rts
Wro
ng di
mensio
ns
Poor D
esign
Opera
tor er
rors
Defecti
ve m
ateria
ls
Surfac
e abr
asion
s
0
10
20
30
40
50
60
70(64)
(13)(10)
(6)(3) (2) (2)
Quality Improvement: Problem Solving
HistogramHistogram
0
5
10
15
20
25
Category
Freq
uenc
y
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Quality Improvement: Problem Solving
HistogramHistogram
05
10152025303540
1 2 6 13 10 16 19 17 12 16 20 17 13 5 6 2 1
Quality Improvement: Problem Solving
FlowchartsFlowcharts Flowcharts
• Graphical description of how work is done.• Used to describe processes that are to be
improved.
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Quality Improvement: Problem Solving
Flow DiagramsFlow Diagrams" Draw a flowchart for whatever you do. Until you do, you do not know what you are doing, you just have a job.”
-- Dr. W. Edwards Deming.
Quality Improvement: Problem Solving
FlowchartActivity
DecisionYesYes
NoNo
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Quality Improvement: Problem Solving
FlowchartFlowchart
Quality Improvement: Problem Solving
Flow DiagramsFlow Diagrams
Quality Improvement: Problem Solving
Flow DiagramsFlow Diagrams
Process Chart SymbolsProcess Chart Symbols
Operations
Inspection
Transportation
Delay
Storage
Quality Improvement: Problem Solving
Process ChartProcess ChartSt
ep
Ope
ratio
nTr
ansp
ort
Insp
ect
Del
aySt
orag
e
Dis
tanc
e(fe
et)
Tim
e(m
in)Description
ofprocess
123456789
1011
Unload apples from truckMove to inspection stationWeigh, inspect, sortMove to storageWait until neededMove to peelerApples peeled and coredSoak in water until neededPlace in conveyorMove to mixing areaWeigh, inspect, sort
TotalPage 1 0f 3 480
30
52015
360
30
20
190 ft
20 ft
20 ft
50 ft
100 ft
Date: 9-30-00Analyst: TLR
Location: Graves MountainProcess: Apple Sauce
Quality Improvement: Problem Solving
Quality Improvement: Problem Solving
Check SheetCheck Sheet
ShiftsShifts
Def
ect T
ype
Def
ect T
ype
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Quality Improvement: Problem Solving
Check SheetCheck Sheet
COMPONENTS REPLACED BY LABTIME PERIOD: 22 Feb to 27 Feb 1998REPAIR TECHNICIAN: Bob
TV SET MODEL 1013
Integrated Circuits ||||Capacitors |||| |||| |||| |||| |||| ||Resistors ||Transformers ||||CommandsCRT |
Quality Improvement: Problem Solving
Cause-and-Effect DiagramsCause-and-Effect Diagrams Show the relationships between a
problem and its possible causes. Developed by Kaoru Ishikawa (1953) Also known as …
• Fishbone diagrams• Ishikawa diagrams
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Quality Improvement: Problem Solving
Cause and Effect Cause and Effect “Skeleton”“Skeleton”
QualityProblem
Materials
EquipmentPeople
Procedures
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Quality Improvement: Problem Solving
Fishbone Diagram Fishbone Diagram
QualityProblem
MachinesMeasurement Human
ProcessEnvironment Materials
Faulty testing equipment
Incorrect specifications
Improper methods
Poor supervision
Lack of concentration
Inadequate training
Out of adjustment
Tooling problems
Old / worn
Defective from vendor
Not to specifications
Material-handling problems
Deficienciesin product design
Ineffective qualitymanagement
Poor process design
Inaccuratetemperature control
Dust and Dirt
Quality Improvement: Problem Solving
Cause and effect diagramsCause and effect diagrams Advantages
• making the diagram is educational in itself• diagram demonstrates knowledge of
problem solving team• diagram results in active searches for
causes• diagram is a guide for data collection
Quality Improvement: Problem Solving
Cause and effect diagramsCause and effect diagrams
To construct the skeleton, remember: For manufacturing - the 4 M’s
man, method, machine, material For service applications
equipment, policies, procedures, people
Quality Improvement: Problem Solving
Scatter DiagramScatter Diagram
.
Quality Improvement: Problem Solving
Run ChartsRun Charts Run Charts (time series plot)
• Examine the behavior of a variable over time.
• Basis for Control Charts
Quality Improvement: Problem Solving
Control ChartControl Chart
18
12
6
3
9
15
21
24
27
2 4 6 8 10 12 14 16
Sample number
Num
ber o
f def
ects
UCL = 23.35
LCL = 1.99
c = 12.67
Quality Improvement: Problem Solving
Control ChartsControl Charts
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Quality Improvement: Problem Solving
““Stem and leaf” displaysStem and leaf” displays
4.6 4.0 3.7 4.1 4.1 5.6 4.5 6.0 6.0 3.43.4 4.6 3.7 4.2 4.6 4.7 4.1 3.7 3.4 3.33.7 4.1 4.5 4.6 4.4 4.8 4.3 4.4 5.1 3.9
DataIntegrated Circuit Response Time (ps)
Quality Improvement: Problem Solving
““Stem and leaf” displaysStem and leaf” displays
3 7 4 4 7 7 4 3 7 9
4 6 0 1 5 6 2 6 7 1 1 5 6 4 8 3 4
5 6 1
6 0 0
Integrated Circuit Response Time (ps)
Quality Improvement: Problem Solving
Dot diagramsDot diagrams
3 4 5 6Plant A
Plant B
Integrated Circuit Response Time (ps)