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Total Quality Management BUS 3 – 142 Tools of Quality Week of Mar 7, 2011

Total Quality Management BUS 3 – 142 Tools of Quality Week of Mar 7, 2011. Ishikawa’s Basic Seven (7) Tools of Quality. Process Maps Check Sheets Histograms Scatter Plots Control Charts Cause & Effect (“Fishbone”) Diagrams Pareto Analysis. Process map.

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Total Quality Management BUS 3 – 142 Tools of Quality Week of Mar 7, 2011

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  1. Total Quality ManagementBUS 3 – 142Tools of QualityWeek of Mar 7, 2011

  2. Ishikawa’s Basic Seven (7) Tools of Quality • Process Maps • Check Sheets • Histograms • Scatter Plots • Control Charts • Cause & Effect (“Fishbone”) Diagrams • Pareto Analysis

  3. Process map Create a flow chart , from beginning to end • Specific symbols for specific definitions • Processing • Decision • Input / Output • Start / Stop • Flow Line • Page Connector

  4. Steps in creating process maps • Communicate the purpose to impacted individuals • Observe behavior • Interview participants and stakeholdrrs • Review reports and outputs • Draw the flow chart using the symbols • Evaluate Value Added (VA) and Non Value Added (NVA) activities • Review multiple times to ensure accuracy and buy-in Use the map to streamline and simplify the process, including eliminating NVA steps Use the map for the Vision of the improved Future Process

  5. High Level Supply Chain Flow Product Planning Demand Planning Master Production Scheduling Material Planning Production Delivery & Service

  6. Forecast Process (Sample)

  7. Enter Items into Forecast (Sample)

  8. Work Example – Process Map for Future State No FGI / Hub Coverage? • Hub buffer below target • Discrete Orders • Revised Targets Start per Authorized Pool No Avail. in WIP? Yes Hub buffer below Target? Yes Fill from STX Stock Yes Prioritize / Reconfigure No No Action Major Assumptions / Process Changes • xxx • xxx • xxx • xxx • xxx • xxx

  9. Work Example – Vision for Phase 2 No FGI / Hub Coverage? • Hub buffer below target • Discrete Orders • Revised Targets Start per Authorized Pool Avail. in Testers? Avail. in Test Queue? No No Yes Hub buffer below Target? Yes Fill from STX Stock Yes Yes Fill After Test Prioritize / Reconfigure No No Action Major Assumptions / Process Changes • xxx • xxx • xxx • xxx • xxx • xxx

  10. Check Sheets - for DATA GATHERING • After common defects are identified, operators and machines track how often they occur • Setup routine not followed • Missing equipment • Machine breakdown • Parts shortage • Etc • A table is created to track the defects over time (hours / shifts / days / weeks) • The data from the check sheets are then used to populate histograms and Pareto charts

  11. Check Sheet Example

  12. Histogram

  13. Work Example – Histogram Median: 18 days Average: 25 days Mode: 1 day 80% of units invoiced under 36 days of age Root Cause? Median Drive Age at Invoice Average Drive Age at Invoice

  14. Grade Distribution – Histogram

  15. Scatter Diagrams

  16. Fishbone Chart

  17. Use a Hammer to build the house and a Paintbrush to paint it

  18. Key Points regarding Tools • Know if you are looking at time and trend data or at static / population data • Process Maps are static • Check sheets can be both • Histograms, Scatter Plots, Pareto Charts are for populations • Control Charts / SPC look at time and trend • Data gathering and analysis enables a more effective “Plan-Do-Check-Act” cycle • The data TELL you something! … Act on what the data tell you • Root Cause identification • Separating Causes from Effects (“5 Whys”) • Planning and Implementing improved performance and Results • Refine the Measurement System so that focus is on facts and collaborative problem solving – not blame or “spin” • Precision vs. Enough (Diminishing Returns)

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