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PRACTICAL HANDBOOK PRACTICAL HANDBOOK for Quality Improvement Team Dr Ibrahim Nor 1
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Transcript of PDCA(slides)
PRACTICAL HANDBOOKPRACTICAL HANDBOOK
for
Quality Improvement Team
Dr Ibrahim Nor 1
COMPETENCY IMPROVEMENT TEAM
USING PDCA CYCLEUSING PDCA CYCLEDr Ibrahim Nor 2
THE PDCA CYCLE
PLAN
CHECK
DOAC
TION PDCA
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SELECT THE THEME
From:-• Customer
complaints.• Department’s
objectives.• The big ‘Q’• The small ‘q”PLAN
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PLAN THE SCHEDULE
• List all the 8 steps in the PDCA cycle.
• Indicate the expected time frame.
• Use the milestone chart.
PLAN
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GRASP THE CURRENT STATUS
Obtain and review data using checksheet.Study the effects of the problem from various perspectives.Present available data in graphs, and Pareto charts.PLAN
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SET THE TARGET
• Indicate clearly the statement of result to be achieved.
• Target must be reasonable and realistic.
• Use SMART concept.
PLAN
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ANALYSE THE CAUSE & DETERMINE CORRECTIVE ACTION
• Prepare cause and effect diagram.
• Prepare hypothesis and verify most probable causes.
• Determine corrective action.
PLAN
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IMPLEMENT CORRECTIVE ACTION
• Take immediate action by following exactly as planned.
• Collect data on results and record any deviations.
• Provide adequate training.
DO
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EVALUATE THE RESULT
• Check the effect of the corrective action.
• Compare results with target
• Use paired Pareto Chart.
CHECK
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STANDARDISE THE PROCESS
• Document as standard operating procedure (SOP).
• Set parameters to monitor and control the successful process.
• Ensure appropriate training on the new methods.
ACTION
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QUALITY TOOLS
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CHECKSHEET
• A Checksheet is used to gather relevant data in a simple, standardised format. The use of checksheet makes the collection of data easier and more systematic.
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CHECKSHEET
Description 1 2 3 4 5 6 7 8 9 T1 Poor coordination and
communication25
2 No review on test run 22
3 Insufficient information
28
4 Errors in report 39
5 Inaccuracy of report 37
Total 34 17 19 10 12 29 7 13 10 151Observed by:Frequency: Daily
Checksheet on: Generation of Final Report Date: 13TH JAN 09Location: IKRAM PAVES (Case study)
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CAUSE AND EFFECT DIAGRAM
• The Cause and Effect diagram helps us to find out all possible causes, to sort them out, and to organise their inter-relationship. Typically, the causes are brainstormed in a free-flowing session.
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CAUSE AND EFFECT DIAGRAM
MAN
METHODMACHINE
MATERIAL
Lack Manpower
Error in Report
Generation
Lack of training
Tight Dateline
Time wasted
Data entry error
Insufficient skill
Paper wastage (Cost)
Graphics module not on
line
No reference materials
(Guide book)
Unable to cater complex
reports
No proper evaluation of equipment (vendor)
Take over of vendor
No user requirement
No proper planning
No review during testing
Redundant work
Two individuals processing same data
Manual to computer format
Shipping delay
Holiday season
No inter dept communication
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PARETO DIAGRAM
• A Pareto diagram is constructed to show the relative importance of different categories in a process. The vital few is separated from the trivial many. This will ensure that focus is made on the what is important.
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PARETO DIAGRAM
Observed by:Frequency: Daily
100151Total
100.014.622No review on test run5
85.416.625Poor communication & coordination4
68.818.528Insufficient information3
50.324.537Inaccuracy in report2
25.825.839Errors in report1
Cum %
%TOTDescription
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PARETO DIAGRAMPARETO DIAGRAM
020406080
100120140160
Errors in report Inaccuracy in report InsufficientInformation
Poor communoation No Review
100%
0
50%
25.8%
75%
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HISTOGRAM
• A histogram is used to summarise the frequency of occurrence of something from a sample of data. The shape of distribution is displayed and descriptive statistics can be calculated.
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HISTOGRAM
0
10
20
30
40
50
60
70
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CONTROL CHART• A control chart has a
center line corresponding to the average quality at which the process should perform. An out of control situation and other unnatural patterns can be detected from the chart
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CONTROL CHART
05101520253035404550
UCL
LCL
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SCATTER DIAGRAM
• A scatter diagram is a special type of graph which shows the relationship between two variables. If there is an empirical relationship between the two variables it can be easily seen.
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SCATTER DIAGRAM
0
5
10
15
20
25
0 2 4 6 8 10 12 14 16
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STRATIFICATION
• Stratification is the technique of analysing data by separating it into several groups with similar characteristics. The data must be stratified by group to better understand the differences
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STRATIFICATION
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