Session-11 problem

8/7/2019 Session-11 problem

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TOTALTOTAL

QUALITYQUALITYMANAGEMENTMANAGEMENT

By:By:Zahid HussainZahid HussainQuality TrainerQuality Trainer

MSMS--Total Quality ManagementTotal Quality ManagementIRCA Lead Auditor ISOIRCA Lead Auditor ISO--90019001--20002000

B.Sc Engineering (Chemical)B.Sc Engineering (Chemical)PCBAPCBAUCPUCP

SESSION 11


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ProblemProblem


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ProblemProblem

Most people rush to find solution before knowing the real

problem.

Problemisa chance foryouto dobest. Itisanopportunity forimprovement.

Most people spend more time and energy going around

problems than in trying to solve them. (Henry Ford)

A problemisthe differencebetweentheactualstateand desired state.

Problemsolving isatool,askilland a process.


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Typesof ProblemsTypesof Problems

1. Process Design Problem (Developmentof newprocessand revisionof existing process, Technologyadvancementsystemobsolete,userneed)

2. Product Design Problem (Developmentof newproductand revisionof existing product, customerneed notunderstood,or poor performance )

3. Compliance Problem (Non compliancewith Standard)

4. Unstructured Problem (Duetono Standard Documentation)

5. Efficiency Problem (Systemunacceptabilitybyowner dueto

high cost,maybe Customersatisfied)


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Keytosuccessful problemresolution.Keytosuccessful problemresolution.

- Abilitytoidentifythe problem.

- Usetheappropriatetoolsbased onthenatureof the

problem.- Make decisionon factualapproach- Problem processingtime

Ethicalissues.Ethicalissues.

-- Never hide facts - Speakthetruth.

- Be fair- In caseof anymistake,acceptthat.

- Nevertrytoshiftresponsibilitytosomeoneelse.

- Maintainthe credibility.

SolutionSolution


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Identify

Problem

1.Gather Relevant

Data

2.Detailed Problem

Analysis

4.Consider all

Possible

Root Causes

3.Root cause

Investigation

5.Take Corrective /

Preventive Action(s)

6.Evaluate

outcome

Problem

Fixed

No root cause found

Rootcause (s)

found

Ineffective Corrective/ Preventive Action

Redefine the Problem

Effective Corrective/ Preventive Action

Redefine the Problem

In situations of conflict always rememberSTARSTOP

THINK

ANALYSE

RESPOND

SolutionSolution


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Problem Solving ToolsProblem Solving Tools

The concept behind theThe concept behind the seven basic tools camecamefrom Kaoru Ishikawa.from Kaoru Ishikawa.

According to Ishikawa, 95% of qualityAccording to Ishikawa, 95% of quality--relatedrelated

problems can be resolved with these basic tools.problems can be resolved with these basic tools.

1.1. FLOWCHARTSFLOWCHARTS

2.2. CHECK SHEETSCHECK SHEETS

3.3. PARETO DIAGRAMSPARETO DIAGRAMS4.4. HISTOGRAMSHISTOGRAMS

5. CAUSE AND EFFECT DIAGRAMS

6.6. SCATTER DIAGRAMSSCATTER DIAGRAMS

7.7. CONTROL CHARTSCONTROL CHARTS


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- Shows the flow of products or services as it moves through

various processing operations.- Easy to visualize entire system, to identify potential troublespots to locate control activities.-Improvements can be accomplished by changing, reducing,combining or eliminating steps.

-Sample

FLOW CHARTFLOW CHART

SEVEN BASIC TOOLSSEVEN BASIC TOOLS


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CHECK SHEETSCHECK SHEETS

1. Data is collected carefully and accurately.

2. Data can be quickly used and analyzed.

3. Sample ChecklistsSample Check Sheet -1

Sample Check Sheet -2

Sample Check Sheet -3



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HISTOGRAMSHISTOGRAMS

-- Data variation difficult to see in table (An easy way to see theData variation difficult to see in table (An easy way to see thedistribution of the data, its average, and variability) such asdistribution of the data, its average, and variability) such asdaily billing error in bank,daily billing error in bank,

--Relationship with other parameters such as billing error withRelationship with other parameters such as billing error withtime, with person etc.time, with person etc.


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PARETO DIAGRAMSPARETO DIAGRAMS. AlfredoPareto(unequalwealth distribution. AlfredoPareto(unequalwealth distribution-- fewwith lotof moneyandfewwith lotof moneyand

manywith littlemoney)manywith littlemoney). Juranrecognized the conceptasuniversal. Juranrecognized the conceptasuniversal (concept(conceptof vital fewand usefulmany)of vital fewand usefulmany)

. Mostquality problemsresult fromasmallnumberof. Mostquality problemsresult fromasmallnumberofcauses.causes.. 80. 80--20 rule :20 rule : 80 % of problemsare caused by 20 % of80 % of problemsare caused by 20 % ofthe potentialsources.the potentialsources..Pareto diagramisused toidentifythemostsignificant.Pareto diagramisused toidentifythemostsignificantproblemstobe corrected first.problemstobe corrected first.

.Pareto diagramisused toidentifythemostsignificantproblemstobe corrected first.

CountPareto (50 vs. 3 occurrence- willtackle50 occurrence first)CostPareto(50 vs 3 occurrence50 causing 10 $, 3 causing 150$,tackle 3

occurrence first)



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PARETO DIAGRAMSPARETO DIAGRAMS. A few customers. A few customers

account for majorityaccount for majority

of sales.of sales.

. A few processes. A few processesaccounts for the bulk ofaccounts for the bulk of

the scrap or rework.the scrap or rework.

. A few suppliers account. A few suppliers account

for the majority offor the majority ofrejected parts.rejected parts.

A few items accounts forA few items accounts for

the bulk of thethe bulk of the

inventory cost.inventory cost.

Vital few

Useful Many



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Purpose of C & E Analysis To identify the cause, factors or sources of variation lead to specific

event, result or defect in a process or product.

Fishbone diagram : It Shows Causes and Effect

A toll to be used with

- Brainstorming (broaden and focus your thinking)- 5 Whys (why and why else until to come up with possible root causes.

Example:Cause: Improper handling

Why -- Fail to wear glovesWhy -- Stock not available

Why -- inventory issue

Why -- QSP not documented

Improper handling vs QSP not available

CAUSE AND EFFECT DIAGRAMS


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CAUSE AND EFFECT DIAGRAMS(displaysall contributing factorsand theirrelationships))


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CAUSE AND EFFECT DIAGRAMS(displaysall contributing factorsand theirrelationships))

MATERIAL

ENVIRONMENTEQUIPMENT

METHOD

Cheap

Solvent

Contaminated

Dirt

Toothin

Toothick

Bad bristle

DirtyBrush

AirPollution

Temperature

Humidity

Acid rain

HousePaintPeeling

EffectCause

NoInstructions

Paintoverdirt

1

4

32

Wrongtype

5


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SCATTER DIAGRAMSSCATTER DIAGRAMS

Relationship betweentwovariables.Relationship betweentwovariables.

CONTROL CHARTSCONTROL CHARTS

Method of presentationand analysisof

data UCL, LCL,


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Exercise

Cause and effect of Peeling of House Paints

Cause and effect of Expanding Terrorism

Cause and effect of Wrong Delivery

Cause and effect of Poor Productivity

Cause and effect of Poor Material

Cause and effect of Poor Performance


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QUESTIONSQUESTIONS

Session-11 problem

Documents

Transcript of Session-11 problem