TQM, Unit 4, VTU Syallabus

Continuous Improvements

By Prof. Raghavendran V

By. Prof. Raghavendran V 2

Proactive Improvements



There are some improvements that they wont use hard data but rely on subjective information. Application of these tools has proven useful in process improvement, cost reduction, policy making & deployment and New-Product Development.



The tools are very simple, it is effective and it can be key to finding the root cause of a problem in specific terms and then ask why.

You may have to ask why 2 or more times to obtain root cause of the problem.


Management Tools & Techniques

There are 9 different techniques involved and also called as “Management tools Technique”. There are listed as follows:

1. Forced Field Analysis2. Nominal Group Technique3. Affinity Diagram4. Interrelationship Digraph5. Tree Diagram6. Matrix Diagram7. Prioritization Matrices8. Process Decision Program Chart(PDPC)9. Activity Network Diagram


Forced Field Technique

This analysis is used to identify the force & factors that may influence the problem or goal.

It helps an organization to better understand promoting & inhibiting forces so that the positives can be reinforced & the negatives can be reduced.

The procedure is define the Objective, determine the criteria for evaluating effectiveness of action


Forced Field Technique

For Illustration:Objective: Stop Smoking

The Benefit are the determination of the positives and negatives, encouraging people to prioritize the competing forces and identify root causes.

Promoting Forces to stop smoking

Inhibiting forces to cant stop Smoking

Poor Health Habit

Smelly Clothing Addiction

Cost Taste

Impact on others Advertisement

Setting an Example Stress


Nominal Group Technique

This provides for issue/idea input from everyone on the team and for effective decisions.

For Example: Indian cricket team decides which problem to work on. All players write down on the papers the problems they think is most important.

Ranking is consider to evaluate the problem. The highest number is consider as most important problem.


Affinity Diagram

This diagram allows the team to creatively generate large number of issues/ideas and logically group them for problem understanding and possible breakthrough solutions.

The procedure is to state the issues in a full sentences, brain storm.

(large group must be divided into small groups with appropriate headings)


Affinity Diagram

For Illustration for scrambled idea:

What are issues involved in losing the world cup for

England

Not enough experien

ce playersSpin

Tracks

Big Grounds

No form players

No seriousness in playing

Ambience of the crowd

Fear of Terrorism

Fatigue Pitch


Affinity Diagram

For Illustration for Ordered idea:What are issues involved in

losing the world cup for England

Not enough experience players

Spin Tracks

Big Grounds

No form players

No seriousness in playing

Ambience of the crowd

Fear of Terrorism

Fatigue Pitch

About Technical aspects

About Players

About Public Factors


Interrelationship Diagraph(ID)

The Interrelationship Diagraph clarifies the inter relationship of many factors of a complex situation. It allows to team to classify the cause & effect relationships among the all the factors.

The procedure is complicated & as follows1. The team should agree on the issue or

problem statement.2. All the ideas or issues must be laid out



3. Start with first issue & evaluate with the other issue using cause-effect relationship.

4. The second iteration is to compare second issue with other issue and followed by.

5. The entire diagram should be reviewed where necessary. It is good idea to obtain information from others people Upstream or Downstream.

6. The diagram is completed by tallying the incoming & outgoing arrows and placing this information below the box.



Benefits of Interrelationship Diagraph(ID) It allows a team to identify root causes

from subjective data systematically.Cause and effect relationshipsEncourage members to think in

multidirectionalDevelops team harmony and

effectiveness.


Tree Diagram

This tool is used to reduced any broad objective into increasing levels in detail in order to achieve objective.

Procedure to choose action oriented objective statement.

Secondly, brainstorming, choose the major headings

Thirdly, generate the next level analyzing the major heading.


Matrix Diagram

Here diagram allows individuals or teams to identify, analyze and rate the relationship among two or more variable.

Data are presented in table form and can be objective or subjective, which can be given symbols with or without numerical values.

There are different formats 2 or variablesL-shaped (2V), T or C or Y-shaped(3V) and X

Shaped (4V).


For Illustration:

o AlwaysFrequently Occasionally

Tool/ Use Creativity Analysis Consensus

Action

Affinity o o

ID o

Tree Diagram

Prioritization Matrix

o

Matrix Diagram


Prioritization Matrices

These tools prioritize issues, tasks, characteristics, and based on weighted criteria using combination of tree and matrix diagram techniques.

Prioritization matrices are designed to reduce the teams options rationally before detailed implementation planning occurs.


Construction of Prioritization Matrices

Construct an L-shaped matrix combing the options

Determine implementation criteria Nominal Group technique.

Prioritize the criteria using NGT, each member weights the criteria so that total weights equal to 1.00

Rank order the options in terms of importance by each criterion

Compute the option importance score


Process Decision Program Chart

Programs to achieve particular objectives do not always go according to plan, and unexpected developments may have serious consequences. The PDPC avoids surprises and identifies possible countermeasures.


PDPC

Plan successful conferences

Registration Presentations Facilities

Audio/Visual Fails

Speakers Late Too Long

Have Substitute

Have Backup Use Time

KeeperUse AV Person


Activity Network Diagram

This tool goes by a number of different names and deviations, such as program evaluation and review technique, Critical Path Method, arrow diagram and activity on node.

It allows team to schedule a project efficiently.


1) The team brainstorm/document all the tasks to complete project.

2) The first task is always started from extreme left.

3) Any tasks that can be done simultaneously.4) Repeat step 2 & 3 until all tasks are placed5) Number each task & draw connecting

arrows. Determine the completion time and post it in the lower left box. Completion times recorded in hours/days/weeks

6) Determine the critical path by completing the four remaining boxes in each task. These boxes are Earliest start time(ES), Earliest Finish(EF), Latest Start(LS) and latest Finish (LF).


Reactive Improvements


Reactive Improvements is also known as Statistical Process Control. This is one of the best technical tools for improving product and service quality. There are seven basic technique and they are:

1. Pareto diagram2. Process flow diagram3. Cause and effect diagram4. Check sheets5. Graphs- Histogram, Line graphs, Pie

charts6. Scatter diagram7. Control Charts

Some what Statistical


Pareto Diagram

Alfred Pareto conducted extensive studies of the distribution of wealth in Europe.

Pareto diagram is a graph of that ranks data classification in descending order of their numerical value of their frequency of occurrence from left to right in accordance with the variables.

Variables are problems, complaints, causes, type of non conformities.


Pareto Diagram

Pareto Diagram Concepts:

Category of data0

5

10

15

20

25

30

35

40

45

50

Series 1Series 2Series 3Series 4


Construction of Pareto diagram

Determine the method of classifying the data (Problem, cause, non conformity and so forth)

Decide if rupees, frequency or both are to be used to rank the characteristics.

Collect data for an appropriate time interval or use historical data.

Summarize the data and rank order categories from largest to smallest.

Construct the diagram and find the vital few.


Solve the problem: In an recent 1st internal assessment

conducted for 7th mechanical students, the following result declared for 48 students

0-14 marks: 31 Students15-20 marks: 13 Students21-25 marks: 04 Students.Categorize them using Pareto Diagram.


Pareto Diagram

Students marks0

5

10

15

20

25

30

3531

13

4

0-1415-2021-25

65%

27%08%


Process Flow Diagram

It shows different activities of a process operation, for a product or services as it moves through the various processing operations.

The diagram makes it easy to visualize the entire system, identify potential trouble spots and locate control activities.


Process Flow Diagram

For Illustration: let us consider vehicle parking operation in a bus terminus.

Customer gets the tkt for Parking

Customers parks the car

Customers comes back to parking lot to leave

Customers drives the car to exit

Cashier System

Customer Drives the car

Receive tkt from the customer

Stamp the exit time on ticket

Read difference time and collect the time

Put the tkt in Storage Bin

End of the day complete report

Owner of the parking lot gets the accounting report


Cause and Effect Diagram

A C&E diagram is a picture composed of lines and symbols designed to represent meaningful relationship between effect and causes.

It was developed by Dr. Kaoru Ishikawa 1943 and it is referred as fishbone diagram because of it shape.


Cause and Effect Diagram

Quality Characteristics

People

Materials Work Methods

Environment Equipment Measurement

Causes

Effect


Check Sheets

The main purpose of check sheets is to ensure that the data is collected carefully and accurately by operating personnel.

Data should be collected in such a way that it can quickly and easily used and analyzed.

For Illustration: Check sheet for paint nonconformities


Check Sheets

Check SheetProduct: Bicycle 32 Number inspected:

2222Nonconformity Type Check

Total

Blister 21

Light Spray 38

Drips 22

Overspray 11

Runs 47

Others 5

Total 144

Number

Non Conforming113


Histogram

Arguably the first ‘Statistical’ technique.It describe the variation in the process.The histogram graphically estimates the

process capability.For any histogram there will graphical and

analytical techniques for summarization.

Graphical technique is a plot or picture of a frequency distribution, which is a summarization of how the data points occur within each subdivision of observed values.


Histogram

Analytical technique, summarize data by computing measure of the central tendency (Average, Median, Mode)and measure of the dispersion ( Range and standard Deviation).

Illustration for Ungrouped data:Number of daily accounting errors.

0 1 3 0 1 0 1 0

1 5 4 1 2 1 2 0

1 0 2 0 0 2 0 1

2 1 1 1 2 1 1

0 4 1 3 1 1 1

1 3 4 0 0 0 0

1 3 0 1 2 2 3


Tally of number of daily accounting errors

Number Nonconforming

Tabulation Frequency

0 15

1 20

2 8

3 5

4 3

5 1


Histogram

Illustration for Grouped data:

Temperature0

5

10

15

20

25

30

35

40

24

34

22Series 1Series 2Series 3

Cell

Interval

Boundary

Mid Point

Frequency


Histogram

There are 6 different types of histogramAnd they are 1. Symmetrical2. Skewed right3. Skewed left4. Peaked5. Flat6. Bimodal


Scatter Diagram

This is simplest way to determine, if a C&E relationship exists between two variables.

For Illustrations: in a relationship between automotive speed and mileage.

As speed increases, mileage decreases.Automotive Speed is plotted on the axis and

is the independent variable.Gas mileage is plotted on y axis and this is

dependent variable.


Scatter Diagram

20 30 40 50 60 70 80 9005

1015202530354045

Y-Values

Y-Values

Speed –Mi/hour

Mileage/ltr


Scatter Diagram

Other examples for relationship are:Cutting speed and tool lifeTemperature and Lipstick hardnessTraining and errorsBreakdowns and equipment age


Control Charts

A control chart is a graphical representation of collected information and common tool used in industries in controlling the quality of products or quality characteristics.

It is an aid for analyzing the quality in repetitive process.

It is developed by Dr. W.A Shewhart


Control Charts

Control charts is classified into types and they are:

1. Variable (Continuous Data)2. Discrete Data (Discontinuous Data)

Variable: Data which can take any value depending on the accuracy of the measuring instrument is called continuous data.

For Ex: Weight of Object can be 1.2 or 1.23 or 1.234 Kg Depends on the accuracy of the instrument.


Discrete: Data which can take only definite is called discrete data. The values are whole number.

It will be only whole number. For ex: Number of wickets took by bowler.


Variables

It is common phenomenon, in nature and also in the product produced in industry. There will be lot of variations on so many factors in a twin children.

It is impossible to produce identical parts. Henceforth, tolerance limits came in picture. Variations are due to 2 causes:

1. Variation due to chance causes2. Variation due to assignable causes.


Variables

1. Variation due to chance causesThe variations due to sheer chance. This is

not permanent factor for variation.For Ex: Voltage Variation, Vibrations on

Machine tool.( It is difficult to avoid the variation)

2. Variation due to assignable causesVariations caused by assigned job. These

are easily traceable.For Ex: Difference among the M/c’s, Men,

materials


Variable

Based on data, we have:

1. Control Charts for Continuous Data or Variable

2. Control Charts for Discrete Data or Attributes


Control Charts for Continuous Data or Variable

The data collected for control charts for variable will be measured in two types and they are:

Mean and Range charts also called R Charts

Mean and Standard Deviation also called Charts.

Mean is most common method of measure of central tendency.

R and are most common method to measure of dispersion.


Mean and Range charts

Procedure for drawing Charts:1. Collect good number of samples of

constant sample size ‘n’ at random at different intervals of time.

2. Measure all the quality characteristics of all which is to be controlled of all the pieces in the sample and of all the samples and record the same in tables.

3. Find the mean of the all the samples.4. Find the mean of the mean .



5. Find the range of the samples6. Find the mean of the range of all

samples.7. Compute the trial control limits or 3

control limits or control for X and R as follows:

Control limits for X chart:CLX= X± 3 X = X ± 3A2R



Control for R Chart:UCLR=D4R

LCLR=D3R

Where A2, D3, D4 are factors obtained from Table B, factors for controlling limits.

8. Draw X and R Charts

TQM, Unit 4, VTU Syallabus

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Transcript of TQM, Unit 4, VTU Syallabus