Quality improvement model
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Quality Improvement Model. Define Process. Select Measures. Collect & Interpret Data. Purpose: To provide a sequence of steps to improve any process so that the customers will realize the highest quality and value. Is Process Stable ?. No. Investigate & Fix Special Causes. Yes.

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Quality Improvement Model

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Quality improvement model

Quality Improvement Model

Define Process

Select Measures

Collect & Interpret Data

Purpose:To provide a sequence of steps to improve any process so that the customers will realize the highest quality and value.

IsProcessStable?

No

Investigate & Fix Special Causes

Yes

IsProcessCapable?

No

Improve Process Capability

Yes

Develop Control Plan to Maintain Current Process


Define process

Define Process

Define Process

Select Measures

Collect & Interpret Data

IsProcessStable?

No

Investigate & Fix Special Causes

1)Communicate to an individual or a team a clear understanding of the process under study.

2)Establish improved and consistent process operations.

1)Identify and list Suppliers, Inputs, Outputs, and Customers (SIPOC/Big Block)

2)Develop flow chart of process steps (Schematic).

3)Develop process map

3)Assure understanding of related procedures.

  • Verify practice vs. procedure of S.O.P's

    1)Process Map Excel Workbook

    2)Flow Charts or Schematic/SIPOC or Big Block/Process

    Map/Detailed Process Map

    3) S.O.P's

Yes

IsProcessCapable?

Improve Process Capability

No

Yes

Develop Control Plan to Maintain Current Process

Purposes:

Activities:

Tools:


Select measures

Purposes:

  • 1)Develop understanding of customer needs.

  • 2)Determine "possible" process response control points.

  • 1)Review customer needs.

  • 2)Identify/Develop measures that reflect those needs.

  • Describe/Review sampling/testing plans and methods.

  • Process Map Details

  • Types of Process Control (Monitor, SPC, EPC, SOP)

  • 1)Customer Input

  • Sampling and measurement techniques

  • Process Map Master.XLS

Activities:

Tools:

Select Measures

Define Process

Select Measures

Collect & Interpret Data

IsProcessStable?

No

Investigate & Fix Special Causes

Yes

IsProcessCapable?

Improve Process Capability

No

Yes

Develop Control Plan to Maintain Current Process


Collect interpret data

Purposes:

  • 1)Begin collecting and analyzing data from the process.

  • 1)Analyze existing data from the process.

  • Determine needs for new data and develop systems for collecting data.

  • Understand sources of variation in process data

  • 1)Run Charts

  • 2)Histograms

  • 3)Pareto Charts

  • Cause-Effect Matrix (CandE_Matrix.XLS)

  • Minitab Software

Activities:

Tools:

Collect & Interpret Data

Define Process

Select Measures

Collect & Interpret Data

IsProcessStable?

No

Investigate & Fix Special Causes

Yes

IsProcessCapable?

Improve Process Capability

No

Yes

Develop Control Plan to Maintain Current Process


Is process stable

Purposes:

  • Determine stability of key measures of the product.

  • Understand differences between common and special cause sources of variation.

  • 3)If not stable, proceed to block on "Investigate and Fix Special Causes".

  • 4)If stable, proceed to block on "Is Process Capable?"

  • 1)Collect data from process in time order.

  • Identify presence of special causes.

  • Understand how to calculate control limits

  • Use Minitab to create control charts

  • Understand differences between Sigma_S and Sigma_C.

  • Understand differences between control limits and specifications.

  • Control Charts

  • Minitab Software

Activities:

Tools:

Is Process Stable?

Define Process

Select Measures

Collect & Interpret Data

IsProcessStable?

No

Investigate & Fix Special Causes

Yes

IsProcessCapable?

Improve Process Capability

No

Yes

Develop Control Plan to Maintain Current Process


Investigate fix special causes

Purposes:

  • 1)Achieve stability of the measures.

  • 2)Establish permanency of solutions to recurring special causes.

  • 3)Improve procedures and training.

  • Daily Operations

  • 1)Assure consistent operations

  • Investigate reasons for instabilities

  • Compensate process when needed

  • Document root causes of instabilities and compensation effects

  • Long-Term System Changes

  • 1)Implement preventive & corrective actions for special causes

  • 2)Assure stability of raw materials

  • Analyze data for stability problems, e.g., differences among crews, equipment, etc. (Exploratory Data Analysis

  • 1)Control Charts

  • 2)Special Cause Action Plans

  • 3)SOP's

  • FMEA

  • Process Map (Details!), C&E Matrix

Activities:

Tools:

Investigate& Fix Special Causes

Define Process

Select Measures

Collect & Interpret Data

IsProcessStable?

No

Investigate & Fix Special Causes

Yes

IsProcessCapable?

Improve Process Capability

No

Yes

Develop Control Plan to Maintain Current Process


Is process capable

Purposes:

  • 1)Determine process adequacy.

  • 2)If not capable, proceed to block on "Improve Process Capability".

  • If capable, proceed to block on "Develop Control Plan to Maintain Current Process".

  • Determine test method adequacy.

  • Compare histogram to customer requirements (specifications).

  • Calculate C-Family (Cp, Cpk) and P-Family (Pp, Ppk) capability indicies.

  • Analytical Labs: Calculate percent variation due to the test, percent gauge R&R and P/T Ratio.

  • 1)Control Charts

  • Histogram

  • Minitab Software

Activities:

Tools:

Is Process Capable?

Define Process

Select Measures

Collect & Interpret Data

IsProcessStable?

No

Investigate & Fix Special Causes

Yes

IsProcessCapable?

Improve Process Capability

No

Yes

Develop Control Plan to Maintain Current Process


Improve process capability

Purposes:

  • 1)Determine/Identify fundamental changes to the process to improve capability.

  • 1)Analyze data statistically (Exploratory Data Analysis - EDA)

  • 2)Perform trials of possible fundamental changes to the process.

  • 3)Implement changes (if positive results occur.)

  • 1) Standardization

  • 2)Designed experiments (DOE)

  • 3)Breaking out process steps (Process Map)

  • 4)Isolating sources of variability (ASM/DOE)

  • 5)Separating out common causes (stratification. ASM)

  • Brainstorming

  • Scatter Plots (C&E / ASM)

  • Mintab Software

Activities:

Tools:

Improve Process Capability

Define Process

Select Measures

Collect & Interpret Data

IsProcessStable?

No

Investigate & Fix Special Causes

Yes

IsProcessCapable?

Improve Process Capability

No

Yes

Develop Control Plan to Maintain Current Process


Develop control plan to maintain current process

Purposes:

  • 1)To maintain the process improvements that have been made

  • 2)To continually improve the process.

  • 1)Implement control charts, strategies for real-time problem solving, SOP and EPC.

  • Implement systems for summarizing and analyzing data for recurring special causes.

  • Develop documentation package for process.

  • Use results from DOE and data analysis to determine critical inputs to control.

  • 1)Control Charts

  • 2)Cause-Effect Matrix

  • 3)Pareto Charts

  • 4)Brainstorming

  • 5)FMEA

  • SCAP

  • SOP's

  • Control Plan Summary Sheet.XLS

  • Process Map Details

Activities:

Tools:

Develop Control Plan to Maintain Current Process

Define Process

Select Measures

Collect & Interpret Data

IsProcessStable?

No

Investigate & Fix Special Causes

Yes

IsProcessCapable?

Improve Process Capability

No

Yes

Develop Control Plan to Maintain Current Process


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