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Chapter 8
Quality Management
2
OBJECTIVES
Total Quality Management Defined
Quality Specifications and Costs
External Benchmarking
ISO 9000
Quality Specifications
Costs of Quality
Appraisal Costs
Internal Failure
Costs
6
Number
of defects
DPMO = x1,000,000
Number of
opportunit
ies xNo.of units
forerrorper
unit
8
200
DPMO = = 1, 000
x1,000,000
[ 1] x200,000
Cost
Cost of
of Quality:
Quality:What
Whatmight
mightthat
that DPMO
DPMO mean
mean in
in terms
terms
of
of over-time
over-timeemployment
employment to
tocorrect
correct the
theerrors?
errors?
9
Step 1 - Define
2 - Measure
measure?
14
2 – Measure (continued)
Let’s assume that the government
says that we must be within ± 5
percent of the weight advertised on
the box.
Upper Tolerance Limit = 16 + .05(16)
= 16.8 ounces
Lower Tolerance Limit = 16 – .05(16)
= 15.2 ounces
15
2. Measure (continued)
We go out and buy 1,000 boxes of
cereal and find that they weight an
average of 15.875 ounces with a
standard deviation of .529 ounces.
What percentage of boxes are
Process
Lower Tolerance Mean = 15.875 Upper Tolerance
= 15.2 Std. Dev. = .529 = 16.8
What percentage of boxes are defective (i.e. less than 15.2 oz)?
12σ
6σ
3 2 1 0 1 2 3
19
12σ
3 2 1 0 1 2 3
20
Step 5 – Control
Statistical Process Control (SPC)
– Use data from the actual process
– Estimate distributions
– Look at capability - is good quality
possible
– Statistically monitor the process
over time
21
Yes
Can
Canbebeused
usedto
to
find
findquality
quality Return to
problems
problems Supplier
for Credit
22
specifications
specifications
0.58
0.56
0.54
0.52
0.5
0.48
0.46
0.44
1 2 3 4 5 6 7 8 9 10 11 12
Time (Hours)
23
Can 80%
Can be be used
used
to
to find
find when
when
80%
80% of of the
the
problems
problems Frequency
may
may be be
attributed
attributed to to
20%
20% of of the
the
causes
causes
Design Assy. Purch. Training
Instruct.
Analytical Tools for Six Sigma 24
Wrong Account
Wrong Amount
A/R Errors
Wrong Account
Wrong Amount
25
Analytical Tools for Six Sigma
and Continuous Improvement:
Histogram
Can
Canbebeused
usedto
toidentify
identifythe
thefrequency
frequencyof ofquality
quality
Number of Lots
defect
defectoccurrence
occurrenceand
anddisplay
displayquality
quality
performance
performance
0 1 2 3 4 Defects
Data Ranges in lot
26
Possible The
Theresults
Possiblecauses:
causes: results
or
or effect
effect
Machine Man
Environment Effect
Method Material
Can
Canbebeused
usedto
tosystematically
systematicallytrack
trackbackwards
backwardsto
to
find
findaapossible
possiblecause
causeof
ofaaquality
qualityproblem
problem(or
(or
effect)
effect)
Analytical Tools for Six Sigma and 27
Can
Canbebeused
usedto
tomonitor
monitorongoing
ongoingproduction
productionprocess
process
quality
qualityand
andquality
qualityconformance
conformanceto
tostated
statedstandards
standardsof
of
quality
quality
1020
UCL
1010
1000
990
980
LCL
970
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
28
Shingo’s argument:
– SQC methods do not prevent defects
– Defects arise when people make errors
– Defects can be prevented by providing
workers with feedback on errors
Poka-Yoke includes:
– Checklists
– Special tooling that prevents workers from
making errors
31
ISO 9000
Series of standards agreed upon by the
International Organization for
Standardization (ISO)
Adopted in 1987
More than 100 countries
A prerequisite for global competition?
ISO 9000 directs you to "document
what you do and then do as you
documented"
32
Steps
4. Analyze data
34
Service Quality
Measurement:Servqual
A perceived service quality
questionnaire survey methodology
Measurement: Servqual
(Continued)
New version of this methodology is
called “e-Service Quality” dealing
service on the Internet
Dimensions of Service Quality on the e-
Service methodology include:
Reliability, Responsiveness, Access,
Flexibility, Ease of Navigation,
Efficiency, Assurance/Trust,
Security/Privacy, Price Knowledge, Site
Aesthetics, and
Customization/Personalization
36
Question Bowl
Question Bowl
Question Bowl
Question Bowl
Which of the following are functions of
a quality control department?
a. Testing product designs for reliability
b. Gathering product performance data
c. Planning and budgeting the QC
program
d. All of the above
e. None of the above
Question Bowl
Which of the following is a Critical
Customer Requirement (CCR) in the
context of a Six Sigma program?
a. DMAIC
b. DPMO Answer: e. None of the
c. PCDA above (The CCR is the
d. DOE criteria that is used to
e. None of the above define desired quality.
Processing a loan in 10
days is an example of a
CCR.)
41
Question Bowl
Question Bowl
Question Bowl
Which of the following analytical
tools depict trends in quality data
over time?
a. Flowcharts
b. Run charts
c. Pareto charts
d. Checksheets
e. Cause and effect diagrams
End of Chapter 8