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Quality Improvement

Class 05

2012. Luis Ral Martnez Castillo

Traditional Economic Model of Quality of Conformance

Total cost

Cost due to nonconformance

Cost of quality assurance

100% optimal level of quality

2012. Luis Ral Martnez Castillo

Modern Economic Model of Quality of Conformance

Total cost Cost due to nonconformance Cost of quality assurance

100%
2012. Luis Ral Martnez Castillo

Problem Solving
Problem: any deviation between what should be and what is that is important enough to need correcting Structured Semi structured Ill-structured Problem Solving: the activity associated with changing the state of what is to what should be

2012. Luis Ral Martnez Castillo

Quality Problem Types

1. 2. 3.

Conformance problems Unstructured performance problems Efficiency problems

4.
5.

Product design problems

Process design problems

2012. Luis Ral Martnez Castillo

Problem Solving Process

1. 2. 3. 4.

Redefining and analyzing the problem Generating ideas Evaluating and selecting ideas Implementing ideas

2012. Luis Ral Martnez Castillo

The Deming Cycle

Act Study

Plan Do

2012. Luis Ral Martnez Castillo

Jurans Improvement Program

Proof of the need Project identification Organization for breakthrough

Diagnostic journey
Remedial journey Holding the gains

2012. Luis Ral Martnez Castillo

Crosby Quality Improvement Program

1. 2. 3. 4. 5. 6. 7. Management commitment Quality improvement team Quality measurement Cost of quality evaluation Quality awareness 12. Recognition Corrective action 13. Quality councils Zero defect committee 14. Do it over again

8. 9.

Supervisor training Zero defects day

10. Goal setting 11. Error cause removal

2012. Luis Ral Martnez Castillo

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Creative Problem Solving

Mess Finding identify symptoms Fact Finding gather data; operational definitions Problem Finding find the root cause Idea Finding brainstorming Solution Finding evaluate ideas and proposals Implementation make the solution work

2012. Luis Ral Martnez Castillo

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Six-Sigma Quality
Ensuring that process variation is half the design tolerance (Cp = 2.0) while allowing the mean to shift as much as 1.5 standard deviations.

2012. Luis Ral Martnez Castillo

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Six-Sigma Metrics
Defects per unit (DPU) = number of defects discovered number of units produced Defects per million opportunities (dpmo) = DPU 1,000,000 opportunities for error

2012. Luis Ral Martnez Castillo

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k-Sigma Quality Levels

Six sigma results in at most 3.4 defects per million opportunities

2012. Luis Ral Martnez Castillo

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Six-Sigma Implementation

1. 2. 3. 4. 5. 6.

Emphasize dpmo as a standard metric Provide extensive training Focus on corporate sponsor support Create qualified process improvement experts Ensure identification of appropriate metrics Set stretch objectives

2012. Luis Ral Martnez Castillo

GEs Six-Sigma Problem Solving Approach

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1. 2. 3. 4. 5.
2012. Luis Ral Martnez Castillo

Define Measure Analyze Improve Control

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Tools for Six-Sigma and Quality Improvement

Elementary statistics Advanced statistics Product design and reliability Measurement Process control Process improvement Implementation and teamwork

2012. Luis Ral Martnez Castillo

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The Seven QC Tools

1. 2. 3. 4. 5. 6. 7.

Flowcharts Check sheets Histograms Cause-and-effect diagrams Pareto diagrams Scatter diagrams Control charts

2012. Luis Ral Martnez Castillo

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Poka-Yoke (Mistake-Proofing)
An approach for mistake-proofing processes using automatic devices or methods to avoid simple human or machine error, such as forgetfulness, misunderstanding, errors in identification, lack of experience, absentmindedness, delays, or malfunctions

2012. Luis Ral Martnez Castillo