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Fundamentals of a QualityProgram

Scott Cornishscott@practicalprocessimprovement.com

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Today in History

1936: Federal Register, first magazine of

the US government, publishes first issue 1971: Rolling Stones left England for

France to escape taxes

1992: Soviet newspaper "Pravda"

suspends publication

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Efficiency vs. Effectiveness

What is efficiency

What is effectiveness Example failure to calibrate

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Project Selection

Start with a small project

Commitment of top management Find something that slightly hurts

Set up a tracking system before you begin

Review team size and skills

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Six Sigma and DMAIC

Six Sigma:

A quality attribute As an approach

Five Stages of Six Sigma:

Define

Measure

Analyze

Improve

Control

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Seven Basic Quality Tools

Flowchart

Check sheet, or tally sheet A cause-and-effect, or C-E diagram

Pareto chart

Histograms Scatter diagram

Control chart

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Flowchart

Shows input, actions and outcome.

Map of steps and decision point. Common understanding tool.

Various levels.

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Flowchart Example

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Checksheet

List of items and indicator.

Easier data collection.

Gather data on frequency of occurrence.

Very good for determining root causes.

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Checksheet Example

Days per week carrier delivered last paper on

route by 6:00 AM

Route Week 1 Week 2 Week 3 Week 4

A IIII IIII I IIII IIII I

B II III IIII IIII

C IIII II IIII II IIII IIII II

D III II IIII IIII

E IIII IIII III IIII

F IIII I IIII I IIII IIII II

`

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Cause & Effect Diagram

Organize graphically group knowledge.

Also known as fishbone or Ishikawadiagrams.

Should have many twigs.

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Cause & Effect Example

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Pareto Chart

Based on Pareto Principle or the 80/20

rule. Named after Vilfredo Pareto.

Determines next steps.

Use a checksheet to gather data.

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Pareto Chart ExampleDelay Categories

10

9

4

3 3 3

2

0

2

4

6

8

10

12

Prep

ressS

ystem

Problem

s

Pres

sMecha

nicalPr

oblem

s

Late

EditC

loses

Page

flowto

Plater

oom

Late

Arriving

Ads

Excessive

Web

Brea

ks

Diffic

ultPres

sConfig

uratio

n

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Histogram

Pictorial representation of the shape of a

data set. Depicts frequency distribution.

Detects distribution shapes.

Shows process spread and central

tendency.

Valuable troubleshooting tool.

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Histogram ExampleFinal Newspaper Delivery Time

0

1

2

3

4

5

6

7

8

9

10

5:00 to 5:20 5:21 to 5:40 5:41 to 6:00 6:01 to 6:20 6:21 to 6:40

Time

Occurance

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Scatter Diagram

Plot of two variables to show possible

correlation. X-axis is independent variable.

Y-axis is dependent variable.

Correlation DOES NOT always mean

causation.

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Scatter Diagram Example

Home Delivery by 6:00 AM Project

Comparison of Press Off Time to Number of Color Pages

-50

-40

-30

-20

-10

0

10

20

30

40

0 5 10 15 20 25 30

Number of Color Pages Per Issue

PressO

ffTimefromT

arget-Early+/Late-

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Control Chart

Two categories:

Variable or continuous data.Attribute or discrete data.

Two types of variation: Special cause 15% and operator corrects.

Common cause 85% and managementcorrects.

Control charts direct toward special or commoncauses

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Variable Control Charts

Individuals and Moving Range

Charts. X-bar and R Charts verbally called

X bar and R charts.

X-bar and s Charts. Median Charts.

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Attribute Control Charts

The p Chart for Proportion

Nonconforming. The np Chart for Number

Nonconforming.

The u Chart for Nonconformities per

Unit. The c Chart for Nonconformities.

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Quick Approach One AVariable Data Project

Gather data instrument measurements.

Test the data source reliable? Plot data X-bar and R chart.

Interpret data patterns and rules.

Next step gather more data or ?

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Quick Approach Two AAttribute Data Project

Gather data check sheet

T

est the data how reliable is the source? Plot data histogram or scatter diagram.

Interpret data:

Histogram dispersion of data?

Scatter pattern of correlation? Next step gather more data?

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Thank You !

Scott Cornish

scott@practicalprocessimprovement.com

Web Site

www.practicalprocessimprovement.com