session 4 qc seven step-1

7/31/2019 Session 4 QC Seven Step-1

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Industrial Skill Enhancement ProgramTESDEC-SIRIM Bhd.

QC Seven-Step Formula


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Key No 2 : QC Seven-StepFormula

Solving Problems the QC Way


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Industrial Skill Enhancement

ProgramTESDEC-SIRIM Bhd.

Pendekatan Penyelesaian MasalahKita tidak akan berjaya tanpa mengetahui asasnya

Pendedahan Masalah

Pengalaman, gerak hatiinspirasi

Laksanakan tindakan

Expose problem

Analisa sebab-sebab

Implement counter-measures

Fahami masalah tetapkan sasaran kenalpasti jurang perbezaanantara keadaan sekarang

dan sasaran

Siasat sebab-sebab

Rancang tindakan Lakasana tindakan selaraskan tindakan

1) Pendekatan penyelesaian masalahsecara konvensional 2) Pendekatan Penyelesaian msalah QC

Pendedahan Masalah

Laksanakan tindakan


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ProgramTESDEC-SIRIM Bhd. Tentukan ahli-ahli dan ketua dalam pasukan

Pastikan ahli-ahli mempunyai pengetahuanberkenaan proses dan pengalaman bekerja

Menilai keperluan untuk kemahiran khas (specialskills) dantentukan penasihat

Kenalpasti The Expected Commitment FromTeam Members.

Members Should Train With Problem SolvingTechnique.

Coming together Is A Beginning

Keeping Together Is Progress

Working Together Is Success

QC Seven-Step Problem Solving Formula


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Are the people affected by the peoplerepresented?

What should team membership/size consist of?

Do team members agree on the membership?

Are team members responsibilities clear?

Is the decision making authority at the lowestlevel?

Is the customer viewpoint represented?

Is there a designated champion of the team?

Assessing Question

QC Seven

-Step Problem Solving Formula


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QC Seven

-Step Problem Solving FormulaFind and address the causes

Select Topic

Understand SituationAnd Set Targets

Plan Activities

Analyse Causes

Consider and ImplementCountermeasures

Check Results

Standardise and

Establish Control

PLAN

D0

CHECK

ACT


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QC Seven-Step Problem Solving FormulaStep 1

Select Topic


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Select Topic

Identify and List Problems

What kind of problems are giving us trouble?What things would we like to improve further?

Evaluate the Problems and Select a TopicSelect one important topic from among the problems listed.

Decide easily by discussionProblem evaluation chart

Expressing/Describing Topic

1. Brainstorming

2. Pareto Chart

3. Customer Complaints

4. Worker Suggestions

5. Management Decision


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Action(Verb) Object(Noun) Location

How?(direction of improvement, level)

What?(control of characteristics)

Where?(process,machine,operations

Product,region,work station,

etc)

Reduce welding defects in automobile assembly process

Reduce setup time of dialyzer.

Increase number of shopping-club cards in Klang Valley region

Describing a Topic

Well chosen topics satisfy the following 5 conditionsCommon to all circle member

Highly necessary and relevant to ones jobChallenging but achievable

Linked to divisional and departmental policies and objectives

Able to raise the ability levels of the circle or group


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QC Seven-Step Problem Solving FormulaStep 2


Know your enemy, know yourself, and your victory will not be threatened. Know the terrain, know the weather, and your victory will be

completed.

1. Decide on the characteristic to beaddressed

2. Understand situation

3. Decide on targets and time limits fortheir achievement


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The Set Target Must Be

Specific : Not Broad Or Of General Nature

Measurable : Tangible

Achievable : Not To Easy And Hard to Achieve

Realistic : Possible With Known Available Resources

Timed : Given Carefully Designated Time Scale

Understand Situation

And Set Targets


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Rate of Occurrence

Of Rim Warping

6.0%2.5%

30th Mar 2004

Rate of Occurrence

Of Rim Warping

6.0%2.5%

30th Mar 2004

Target

Rate of Occurrence

Of Rim Warping

6.0% 2.5%

30th Mar 2004

What?

By How Much

By When

Predicting savings : RM900/month



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Example of Topics and Target

Example of Topic Example of Target

Standardization Enactment of Standard Number of standard

Quality Decrease of defectives Number of defectives

ProductivityImprovement

Increase of production Output, yield

Speed up of machine time Machine time, productivity

Shorten the working hours / or setuptime

Shortened times, productivity

Make up space, put in order. Extended area

Cost reduction Decrease of scrap Decreased quality

Safety Eradicate of industrial accident No of accident


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Industrial Skill Enhancement ProgramTESDEC-SIRIM Bhd.Step 3


Plan Activities


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Plan Activities

Circle Name : Right On Target Date Prepared : 1 Jan 04

No Action Item Leader April May June July August

1 Select Topic MustaqimUnderstand Situat ion and Set Targets Syakir

Plan Activities Anshar

Analyse Causes Rajihah

Consider and Implement Countermeasures Raihanah

Check Results Rahman

Standardise and Establish Control Ahmad

Period


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Analyse Causes


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Analyse Causes

Summarise the system of characteristics and causeson a cause and effect diagram

Analyse the relationships between characteristics and causes using

QC Tools.

Summarise the results of the analysis

Decide what items to tackle


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Brainstorm Using A Cause And Effect Diagram

Obtain Input From All Team Members

Ask Why As Many Times As Necessary To DriveThe Process To Root Cause.

No Training

Analyse Causes


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RULES OF BRAINSTORMING

Dont monopolize the discussion

Dont show verbal or nonverbal disapproval of ideas, even if you

disagree with it Ask open-ended questions to stimulate discussion

Frame problems in positive terms. Dont ask if its possible to a goal.

Ask How can we achieve our goal

Dont allow senior members of the group to dominate the discussion

Using meeting procedures that require the participation of allmembers

Analyse Causes


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5 WHY (example)Question 1 : Why did the machine stop ?

Answer 1 : Because the fuse blew due to an overland

Question 2 : Why was there an overload ?Answer 2 : Because the bearing lubrication was inadequate

Question 3 : Why the lubrication inadequate ?

Answer 3 : Because the lubrication pump not function right ?

Question 4 : Why lubrication pump not function right ?

Answer 4 : Because the pump axle was worn out ?

Question 5 : Why it worn out ?

Answer 5 : Because the sludge got in

Analyse Causes


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CAUSE AND EFFECT DIAGRAM

Dispersion ofstrip forces

Machine

MethodMan

Material

Extrusionpressure

Mixing material

preheat

Material life

Plasticizer lot

Wrong procedure

Skill

Operation mistake

Test machine

Polyethelyenelot

Cooling water

Analyse Causes


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WHEN IT HAPPEN : GO TO DETAIL?

0

5

10

15

20

25

9.0

0~1

0.0

0

3.0

0~

4.0

0

9.0

0~1

0.0

0

3.0

0~

4.0

0

9.0

0~1

0.0

0

3.0

0~

4.0

0

9.0

0~1

0.0

0

3.0

0~

4.0

0

9.0

0~1

0.0

0

East

0

5

10

15

20

25

'10-Oc

t

11-Oc

t

12-Oc

t

13-Oc

t

14-Oc

t

15-Oc

t

16-Oc

t

East

Defect rateaveraged per hourDefect rate

averaged per day

Find facts high % defect rate in the evening

Analyse Causes


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WHO RESPONSIBLES ?

En. X En. Y En. Z

Consider also which machine, shift and line

Analyse Causes


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4 M CHECKLIST (MAN)

1. Does he follow standard

2. Is his work efficiency acceptable

3. Is he problem-conscious ?4. Is he responsible ?

5. Is he qualified ?

6. Is he experienced ?

7. Is he assigned to the right job ?

8. Does he maintain good human relations ?

9. Is he healthy ?

10. Is he willing to improve ?

Analyse Causes


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4 M CHECKLIST (MACHINE)

1. Does it meet production requirement ?

2. Does it meet process capability

3. Is the oiling adequate4. Is the stopped often because of mechanical trouble

5. Is operation stopped

6. Does it meet precision requirements

7. Does it make any unusual noises

8. Is the layout adequate

9. Are there enough machines / facilities

10. Is everything in good working order

Analyse Causes


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4 M CHECKLIST (MATERIAL)

1. Are there any mistakes in volume

2. Are there any mistakes in grade

3. Are there any mistake in brand name

4. Are there impurities mixed in

5. Is the inventory level adequate

6. Is there any waste in material

7. Is the work in process abandoned

8. Is the layout adequate9. Is the layout adequate

10. Is the quality standard adequate

Analyse Causes


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4 M CHECKLIST (METHOD)

1. Are the work standard adequate

2. Is the work standard upgrade

3. Is it a safe method

4. Is it a method that ensure a good product

5. Is it an efficient method

6. Is the sequence of work adequate

7. Is the setup adequate

8. Are the temperature and humidity adequate9. Are the lightning and ventilation adequate

10. Is there adequate contact with the previous and next process

Analyse Causes


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A : Positive liner relationship (strong)

B : Positive linear relationship (moderate)

C : No relationship

D : Negative relationship (moderate)

E : Negative linear relationship (strong)

SCATTERED DIAGRAM

Analyse Causes


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PURPOSE OF CHECKING TYPE OF CHECKSHEET

1. Determine defect details Defective item check sheet

2. Determine occurrence of defects by dayof the week, operator, machine, etc.

Defect factor check sheet

3. Determine where defects occur Defect position check sheet

4. Determine dispersion of dimensions,hardness, weight, etc.

Process distribution check sheet

5. Inspect machines or equipment orcheck the operating procedure

Inspection and validation check sheet

Analyse Causes


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Industrial Skill EnhancementProgram

TESDEC-SIRIM Bhd.Produk : LCD

Peringkat Pengeluaran : Akhir

Jumlah no pemeriksaan : 2530

Catitan : semua item diperiksa

Tarikh : 21/07/95Syarikat : V Sdn

Lot no : 107

Order no : 566

Pencatit : Ahmad

Item Semakan Sub-Total

Permukaan calar

Pecah

Tidak lengkap

Bentuk salahLainlain

IIII IIII IIII IIII I

IIII IIII IIII IIII III

IIII IIII IIII IIII IIII IIII

I I I IIIII I I I

21

23

30

4

Jumlah 85

Analyse Causes


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TESDEC-SIRIM Bhd.

Analyse Causes


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TESDEC-SIRIM Bhd.

Identify/List potential solution

Select solution

Implement the solution

Identify what new problems might this solution create

Technique

- Tree diagram

- Action plan

- Gantt chart

- Error preventive action



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TESDEC-SIRIM Bhd.

List possible solutions

Select best solutionsSolutions A B C D E F G Total

A B C D A F G A=1

B B B D B B B B=5

C C B C C F G C=3

D D D C D F G D=4

E A B C D F G E=0

F F B F F F G F=4

G G B G D G G G=4



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TESDEC-SIRIM Bhd.

J

AMN

OTSETTING

Brix readingnot achieve 65o

Fruit notripe used

pH not inrange 3.2 4.2

Take 5 sampleOf finish goodand checkthe pH

4 and 5 sampleis not in therange

The pH meter is

not calibrated

Method ofputting of acidis not correct

Mistake inquality of acid

Brix meter is

Calibrated every day N

Acid must put atthe end of process

Mistake inquality of acid

Y

N

Check thefruit use-Make sure the70 % of thefruit use isripe enough

90% of fruitused is ripeenough

Take 5sample offinish goodand checkthe brix

3 and 5sampleIs not achieve65%

The brix meter isnot calibrated

Method of testingis not correct

Mistake inquality of sugar

Brix meter iscalibrate every week

The method oftesting is notefficient enough

The quality ofSugar is followingrecipe

N

Y

N



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TESDEC-SIRIM Bhd.

Action to be taken Person responsible Deadline Completed

Next meeting schedule for :________________________________________



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TESDEC-SIRIM Bhd.

Impact Calculate cost Preventive action Responsible



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TESDEC-SIRIM Bhd.Gantt Chart



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Check Results


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TESDEC-SIRIM Bhd.

Evaluate the solution see if the problem has truly been solved

Collect data to compare the situation before and after theimprovement

No effect means is the action is not correct, come back the causeanalyze

Technique

- Pareto chart, control chart, line graph, histogram, bar chart

Continue the cycle until target achieved

Check Results


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TESDEC-SIRIM Bhd.

0

1

2

3

4

5

6

7

8

9

9 12 3 6 9 12 3 6 9 12 3 6 9 12

Average= 5.9 %

Target = 1.5%

Average= 2.5 %

Check Results


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Standardize andEstablish Control


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TESDEC-SIRIM Bhd. After the result show improvement and effectiveness, start to thinkthe method of prevention and then standardize the new process.

Standardization must agreed by respective personal.

Follow up again after standardization

Calculate the cost saving

Countermeasures with process, product or

service improvement or procedure

Standardize andEstablish Control


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TESDEC-SIRIM Bhd.

0

1

2

3

4

5

6

7

8

9

10

Line 1

Range Chart for Missing Doses / Nursing UnitICU s

Standardise andEstablish Control


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TESDEC-SIRIM Bhd.
http://a/QCC%20Project%20Report%20Example.doc


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TESDEC-SIRIM Bhd.

Congratulate Your Team


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TESDEC-SIRIM Bhd.

POSSIBLE DIFFICULTY IN ACHIEVINGSUCCESS

Poor prioritizing

Insufficient leader influence

Poor project definition

Deficient problem solving skills

Lack of team involvement

Inadequate detail in the plan

Unclear responsibilities of team members

Poor performance data collection, recording and analysis

Lack of knowledge and experience Lack of technical knowledge

Team members already overloaded

session 4 qc seven step-1

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