Upload
vsganesh
View
229
Download
0
Embed Size (px)
Citation preview
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 1/43
PROBLEM SOLVING
Quality Improvement: Problem Solving
Quality Tools
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 2/43
Quality Improvement: Problem Solving
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 3/43
Quality management activities
Quality assurance Establish organisational procedures and standards for quality.
Quality planning Select applicable procedures and standards for a particular project
and modify these as required.Quality control Ensure that procedures and standards are followed by the software
development team.
Quality management should be separate from project
management to ensure independence.
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 4/43
Six Problem Solving Steps
Identify recognie the symptoms
Define !gree on the problem and set boundaries
Investigate "ollect data
Analyze #se quality tools to aid
Solve $evelop the solution and implement
Confir %ollow up to ensure that the solution is effective
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 5/43
Quality "ontrol Tools
Quality Improvement: Problem Solving
Pareto chart
&istogram
Process flow diagram
"hec' sheet
Scatter diagram "ontrol chart
(un chart
"ause and effect diagram
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 6/43
Pareto Principle
Quality Improvement: Problem Solving
)ilfredo Pareto *+,-,+/012 3talian economist 045 of the population has ,45 of the wealth
6uran used the term 7vital few8 trivial many9. &e
noted that 045 of the quality problems caused ,45of the dollar loss.
7 Quality Tools7 Quality Tools
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 7/43
Pareto "hartsP!r"ose#Prioritie problems.
$o% is it done&"reate a preliminary list ofproblem classifications.
Tally the occurrences in each
problem classification. !rrange each classification
in order from highest tolowest
"onstruct the bar chart
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 8/43
Pareto "harts
Benefits:Benefits: Pareto analysisPareto analysis
helpshelps
graphicallygraphically
display resultsdisplay resultsso theso the
significant fewsignificant few
problemsproblems
emerge fromemerge fromthe generalthe general
backgroundbackground
It tells you whatIt tells you what
to work on firstto work on first
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 9/43
Pareto chart
Quality Improvement: Problem Solving
7 Quality Tools7 Quality Tools
% Complaints
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 10/43
Pareto
"hart
Quality Improvement: Problem Solving
P e r c e n t f r o m e
a c h c a u s e
Causes of poor quality
M a c h i n e
c a l i b
r a t i o
n s
D e f e c
t i v e p
a r t s
W r o n g
d i m e
n s i o n
s
P o o r
D e s i g n
O p e r a t o
r e r r o
r s
D e f e c
t i v e m
a t e r i a l s
S u r f a
c e a b r a s i o
n s0
10
0
!0
"0
#0
$0
%0
&$"'
&1!'&10'
&$'&!' &' &'
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 11/4311
(istograms
What is it)* + (istogram is a bar graph
* usually used to present frequency data
(o, does it Wor-)* Define Categories for Data
* Collect Data. sort them into the categories
* Count the Data for each category
* Dra, the Diagram/ each category finds its place on the +is/
* 2he bars ,ill be as high as the value for the category
What is its use)* (istograms provide an easy ,ay to evaluate the distribution of
Data over different categories
LSL SL
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 12/431!
(istograms
LSL SL
"#ample:
take the failure rate of a machine
over a period of # weeks$ %ow
&ssign every week the number of
failures that occurred$ 'raw the(istogram$ Let the bar represent the
weeks$ )he height of the Bar on the
y*a#is is the number of failures that
occurred during that week$
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 13/43
%low $iagrams
Quality Improvement: Problem Solving
: $raw a flowchart for whatever you do. #ntil youdo8 you do not 'now what you are doing8 you justhave a job.9
$r. ;. Edwards $eming.
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 14/43
%lowcharts
Quality Improvement: Problem Solving
%lowcharts <raphical description of how wor' is done.
#sed to describe processes that are to be improved.
7 Quality Tools7 Quality Tools
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 15/43
%low "hartsP!r"ose#
)isual illustration of the sequence of operations requiredto complete a tas'
Schematic drawing of the process to measure or improve. Starting point for process improvement Potential wea'ness in the process are made visual. Picture of process as it should be.
Benefits#
3dentify process improvements #nderstand the process
Shows duplicated effort and other nonvalueadded steps "larify wor'ing relationships between people and
organiations Target specific steps in the process for improvement.
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 16/43
%low charts=inearBenefits
Show what actually happensat each step in the process
Show what happens whennonstandard events occur
<raphically display processes
to identify redundancies andother wasted effort
$o% is it done& ;rite the process step inside
each symbol
"onnect the Symbols witharrows showing the directionof flow
)oolbo#
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 17/43
%low $iagrams
Quality Improvement: Problem Solving
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 18/43
%low $iagrams
Quality Improvement: Problem Solving
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 19/43
Process "hart
Quality Improvement: Problem Solving
S t e p
+ p e r a t i o n
) r a n s p o r t
I n s p e c t
' e l a y
S t o r a g e
' i s t a n c e
, f e e t -
) i m e
, m i n -'escription
of
process
1
!
.
/
0
2
3
4
15
11
nload apples from truck
6ove to inspection station
7eigh8 inspect8 sort
6ove to storage
7ait until needed
6ove to peeler
&pples peeled and cored
Soak in water until needed
Place in conveyor
6ove to mi#ing area
7eigh8 inspect8 sort
)otalPage 1 5f . /35
.5
0
!5
10
.5
.5
!5
145 ft
!5 ft
!5 ft
05 ft
155 ft
'ate: 4*.5*55
&nalyst: )L9
Location: raves 6ountain
Process: &pple Sauce
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 20/43
Quality Improvement: Problem Solving
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 21/43
"hec' Sheet
Quality Improvement: Problem Solving
√
√
√ √
√
√
√ √ √
√
√
√ √ √ √ √
√ √ √
√ √ √
ShiftsShifts
D
e f e c t 2 y p e
D
e f e c t 2 y p e
7 Quality Tools7 Quality Tools
√ √ √ √
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 22/43
"hec'sheetsP!r"ose#
Tool for collecting andorganiing measured orcounted data
$ata collected can be used asinput data for other qualitytools
Benefits#"ollect data in a systematic and
organied manner
To determine source of problemTo facilitate classification of
data *stratification2
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 23/43
"hec' Sheet
Quality Improvement: Problem Solving
COMPO3432S 54P6+C4D 78 6+7
29M4 P459OD: ;eb to % ;eb 1<<=
54P+95 24C(39C9+3: 7ob
2> S42 MOD46 101!
9ntegrated Circuits ;;;;
Capacitors ;;;; ;;;; ;;;; ;;;; ;;;; ;;
5esistors ;;2ransformers ;;;;
Commands
C52 ;
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 24/43
"auseandEffect $iagrams
Quality Improvement: Problem Solving
Show the relationships between a problem and itspossible causes.
$eveloped by >aoru 3shi'awa *+/?12
!lso 'nown as @ %ishbone diagrams
3shi'awa diagrams
7 Quality Tools7 Quality Tools
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 25/43
"ause and Effect 7S'eleton9
Quality Improvement: Problem Solving
Quality
Problem
6aterials
"<uipmentPeople
Procedures
7 Quality Tools7 Quality Tools
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 26/43
%ishbone $iagramPurpose:Purpose: raphicalraphical
representation of the trailrepresentation of the trailleading to the root cause of aleading to the root cause of a
problemproblem
(ow is it done=(ow is it done=
* 'ecide which <uality'ecide which <ualitycharacteristic8 outcome orcharacteristic8 outcome or
effect you want to e#amineeffect you want to e#amine
,may use Pareto chart-,may use Pareto chart-
* Backbone >draw straightBackbone >draw straight
lineline
* 9ibs > categories9ibs > categories
* 6edium si?e bones >6edium si?e bones >
secondary causessecondary causes
* Small bones > root causesSmall bones > root causes
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 27/43
"ause A Effect $iagrams
Benefits#Brea's problems down into bitesie pieces to find root
cause
%osters team wor'
"ommon understanding of factors causing the problem
(oad map to verify picture of the process
%ollows brainstorming relationship
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 28/43
%ishbone $iagram
Quality Improvement: Problem Solving
?uality
Problem
MachinesMeasurement (uman
Process4nvironment Materials
;aulty testing equipment
9ncorrect specifications
9mproper methods
Poor supervision
6ac- of concentration
9nadequate training
Out of ad@ustment
2ooling problems
Old A ,orn
Defective from vendor
3ot to specifications
Materialhandling problems Deficienciesin product
design
9neffective quality
management
Poor process
design
9naccurate
temperature
control
Dust and
Dirt
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 29/43
@ause A "ffect 'iagramsSample
Incorrect
shipping
documents
6anpower 6aterials
6ethods 6achine
"nvironment eyboard
sticks
7rong source info
7rong purchaseorder
)yposSource info
incorrect
'ysle#ic)ransposition
'idnCt follow
proc$ P o o r t r a
i n i n g
lare on
display)emp$
%o
procedure%o communications
%o training
Software
problem
@orrupt
data
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 30/43
"ause and effect diagrams
Quality Improvement: Problem Solving
!dvantages ma'ing the diagram is educational in itself
diagram demonstrates 'nowledge of problem solving team
diagram results in active searches for causes
diagram is a guide for data collection
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 31/43
"ause and effect diagrams
Quality Improvement: Problem Solving
To construct the s'eleton8 rememberC
%or manufacturing the - Ds man8 method8 machine8 material
%or service applications equipment8 policies8 procedures8 people
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 32/43
Quality "ontrol Tool
@ontrol @harts
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 33/43
"ontrol "harts
P!r"ose#The primary purpose of a control chart is topredict expected product outcome.
Benefits# Predict process out of control and out of
specification limits
$istinguish between specific8 identifiablecauses of variation
"an be used for statistical process control
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 34/43
"ontrol "hartsStrategy for eliinating assigna'le()a!se variation# Get timely data so that you see the efect o the
assignable cause soon ater it occurs. As soon as you see something that indicates that an
assignable cause o variation has happened, searchor the cause.
Change tools to compensate or the assignable cause.Strategy for reducing common-cause variation: Do not attempt to explain the diference between any
o the values or data points produced by a stablesystem in control.
Reducing commoncause variation usually re!uiresma"ing undamental changes in your process
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 35/43
"ontrol "harts
Control C*art De)ision +ree
$etermine Sample sie *n2
)ariable or !ttribute $ata
)ariable is measured on a continuous scale
!ttribute is occurrences in n observations
$etermine if sample sie is constant or changing
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 36/43
1!D54D10 .2
Scatter Diagrams
What is it)* Statistical tool sho,ing a trend in a series of values/
(o, does it Wor-)* Bain values series
* Dra, graph ,ith value points
* Dra, trend line: maE Calculate m value
E Calculate a value
E Calculate points for trend line/
What is its use)* Demonstrating correlations bet,een values and sho,ing trends
for value changes/
E
F
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 37/43
Scatter DiagramsPurpose:
2o identify the correlations that might eistbet,een a quality characteristic and a factorthat might be driving it
* + scatter diagram sho,s the correlationbet,een t,o variables in a process/
F 2hese variables could be a Critical 2o
?uality &C2?' characteristic and a factoraffecting it t,o factors affecting a C2? ort,o related quality characteristics/
* Dots representing data points are scattered onthe diagram/
F 2he etent to ,hich the dots cluster togetherin a line across the diagram sho,s the
strength ,ith ,hich the t,o factors arerelated/
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 38/43
Scatter Diagrams* If the variables are correlated8
when one changes the other
probably also changes$
* 'ots that look like they are
trying to form a line are
strongly correlated$
* Sometimes the scatter plot
may show little correlation
when all the data areconsidered at once$
Stratifying the data8 that
is8 breaking it into two or
more groups based on
some difference such as
the e<uipment used8 thetime of day8 some
variation in materials or
differences in the people
involved8 may show
surprising results
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 39/43
Scatter Diagrams(ow is it done=:
* Decide ,hich paired factors you ,ant to eamine/ 7oth
factors must be measurable on some incremental linear
scale/
* Collect !0 to 100 paired data points/* ;ind the highest and lo,est value for both variables/
* Dra, the vertical &y' and horiGontal &' aes of a graph/
* Plot the data
* 2itle the diagram
The shape that the cluster of dots takes will tell you something
about the relationship between the two variables that you tested.
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 40/43
1!D54D10 /1
5un Charts
What is it)* 5un Charts are representing change
* in measurement over a sequence or time
(o, does it Wor-)* Bather Data
* OrganiGe DataE Measurements &y' must be confronted ,ith time or sequence of the
events/
* Chart Data
* 9nterpreting Data
What is its use)* Determining Cyclic 4vents and there average character
)ime
6 e a s u
r e m e n t
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 41/43
Control Charts
5un Charts
7hat does it look7hat does it look
like=like=o &dding the element of&dding the element of
time will help clarifytime will help clarify
your understanding ofyour understanding of
the causes of variationthe causes of variationin the processes$in the processes$
o & run chart is a line& run chart is a line
graph of data pointsgraph of data points
organi?ed in timeorgani?ed in timese<uence and centeredse<uence and centered
on the median dataon the median data
value$value$
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 42/43
1!D54D10 /.
5un Charts
4ample* Oil consumption of a specific machine over a period of time/
)ime
6 e a s u r e m
e n t
7/23/2019 7 QC Tools.ppt
http://slidepdf.com/reader/full/7-qc-toolsppt 43/43
Control Charts
What is it)* Statistical tool. sho,ing ,hether
* + process is in control or not
(o, does it Wor-)* Define Hpper limit. lo,er limit and medium value
* Dra, Chart/
* Bather values and dra, them into chart
What is its use)* 2a-ing samples of a process and detect possibility of process being out
of control
E
F
pper limit
Lower limit
&verageDSpec