Chapter sixQuality tools and

techniques

Learning objectives

• Identify the different tools of quality

• Understand the purpose and function of each of the tools

• Describe the use of each tool for quality improvement

• Apply some of the tools and be able to interpret the data.

6.1 Introduction

• Tools of quality are used to:– Identify problems– Identify root causes• Solutions can then be planned

• Implementation of solutions by means of quality improvement techniques

6.2 Tools of quality • Flow charts• Figure 6.2

6.2 Tools of quality (cont.)• Run charts• Figure 6.3

6.2 Tools of quality (cont.)• Control charts• Figure 6.4

6.2 Tools of quality (cont.)• Check sheets

• Refer to Table 6.1 on page on page 140 of the textbook.

6.2 Tools of quality (cont.)• Histograms

• Figure 6.5

6.2 Tools of quality (cont.)• Pareto analysis• Figure 6.6

6.2 Tools of quality (cont.)• Cause-and-effect diagrams• Figure 6.7

6.2 Tools of quality (cont.)• Scatter diagrams• Figure 6.8

6.2 Tools of quality (cont.)• FMECA

• Failure mode, effects and criticality analysis

• Class discussion – Table 6.4.

6.3 Quality improvement techniques

• Benchmarking– Compare key performance measures with– Best performers– To ensure improvement– Categories:

• Internal• Functional• Generic• Competitive.

6.3 Quality improvement techniques (cont.)

• Benchmarking (cont.)– 5 steps– Purpose:

• Change• Compare practices• Challenge current practice• Improvement.

6.3 Quality improvement techniques (cont.)

• Six-sigma– Motorola (1980’s)– Reduce mistakes/deficits– Stages: measure, analyse, improve, control– Benefits– Requirements

6.3 Quality improvement techniques (cont.)

• Six-sigma (cont.)– Phases:

• Define phase• Measure phase• Analyse phase• Improve phase• Control phase.

6.3 Quality improvement techniques (cont.)

• Six-sigma (cont.)– Figure 6.9:

– Problems

SIX SIGMA

SIX SIGMA

6.3 Quality improvement techniques (cont.)

• Lean manufacturing– ‘getting rid of any waste’

• Deming cycle– PDSA (Plan, Do, Study, Act)– Class discussion (Figure 6.10).

LEAN MANUFACTURING

6.3 Quality improvement techniques (cont.)

• Pokayoke– Error proofing a process– Use of devices to prevent human error– 2 functions:

• Preventon• Detection

6.3 Quality improvement techniques (cont.)

• Pokayoke– Five error-proofing principles:

• Elimination• Replacement• Facilitation• Detection• Mitigation

POKAYOKE

6.3 Quality improvement techniques (cont.)

• The five ‘S’ model– Improve the quality of housekeeping– Sort - remove and clear all unwanted items– Set – Arrange items so easy to find and retrieve– Shine – Sweep, wash, polish. Keep everything clean– Standardised – Make good housekeeping habits a

habit– Sustain – Create optimum conditions for good

housekeeping i.e. rewards/recognition

Summary

• Various quality tools

• Quality improvement techniques.