PDCA & Tools

METHODOLOGIES & METHODOLOGIES & TOOLS FOR QUALITY TOOLS FOR QUALITY

MANAGEMENTMANAGEMENTPresented Presented

ON QUALITY DAYON QUALITY DAYByBy

Dr. Aquil Ahmed KhanDr. Aquil Ahmed KhanTQM-ACHTQM-ACH

This Means:This Means:

Steadily improving each person’s ability to:Steadily improving each person’s ability to:

Recognize and define important problems Recognize and define important problems PP Solve them Solve them

DD Learn from problem solvingLearn from problem solving CC Share the learning with others Share the learning with others AA

What is problem?What is problem?

Problem solving philosophyProblem solving philosophy

MethodologyMethodology

PDCA-CQIPDCA-CQI DMAIC (duh-may-ick)DMAIC (duh-may-ick) DMADVDMADV

04/13/2304/13/23 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 66


• PDCA-CQIPDCA-CQI• DMAIC (duh-may-ick)DMAIC (duh-may-ick)• DMADVDMADV

• CQI was originally developed by Walter Shewhart, and is CQI was originally developed by Walter Shewhart, and is often referred to as the "Shewhart Cycle". It was taken up often referred to as the "Shewhart Cycle". It was taken up and promoted effectively from the 1950s by the famous and promoted effectively from the 1950s by the famous Quality Management authority Quality Management authority W. Edwards Deming, and is , and is consequently known by many as "the Deming Wheel".consequently known by many as "the Deming Wheel".

PLANPlan carefully what is to be

done

Phase 1 - Identify the Opportunity

Phase 2 - Analyze the Current Process

Phase 3 - Develop the Optimal Solution

DOCarry out the plan

(do it)

Phase 4 - Implement ChangesCHECK

Check the Results.Did the plan work as intended or were the results different?

Phase 5 - Study the Results

ACTAct on the results by

identifying what worked as planned and what didn't.

Phase 6 - Standardize the Solution

Phase 7 - Plan for the Future


• PDCA-CQIPDCA-CQI

• DMAICDMAIC (duh-may-ick) (duh-may-ick)• DMADVDMADV

DMAICDMAIC is an acronym for five (5) interconnected is an acronym for five (5) interconnected phases: Define, Measure, Analyze, Improve and phases: Define, Measure, Analyze, Improve and Control. It refers to a data-driven quality strategy Control. It refers to a data-driven quality strategy for improving processes.for improving processes.

MethodologyMethodology• PDCA-CQIPDCA-CQI• DMAIC (duh-may-ick)DMAIC (duh-may-ick)

• DMADV DMADV

DMADVDMADV consists of five (5) inteconnected phases: Define, consists of five (5) inteconnected phases: Define, Measure, Analyze, Design and Verify. It is a data-driven Measure, Analyze, Design and Verify. It is a data-driven quality strategy for designing products and processes, It is quality strategy for designing products and processes, It is also an integral part of a Six Sigma Quality Initiative.also an integral part of a Six Sigma Quality Initiative.

IntroductionIntroduction

In the following we will Examine the In the following we will Examine the Techniques and Tools that Support Techniques and Tools that Support Quality Management within a Quality Management within a company. There are for the company. There are for the 7 Basic 7 Basic ToolsTools which we are going to define. which we are going to define. Generally they can be subdivided into:Generally they can be subdivided into:

• mathematical statistical Toolsmathematical statistical Tools• logical toolslogical tools


7 Basic Quality Control Tools7 Basic Quality Control Tools

The concept behind the seven basic tools came The concept behind the seven basic tools came from Kaoru Ishikawa, a renowned quality expert from Kaoru Ishikawa, a renowned quality expert from Japan. According to Ishikawa, 95% of from Japan. According to Ishikawa, 95% of quality-related problems can be resolved with quality-related problems can be resolved with these basic tools. The key to successful these basic tools. The key to successful problem resolution is the ability to identify the problem resolution is the ability to identify the problem, use the appropriate tools based on the problem, use the appropriate tools based on the nature of the problem, and communicate the nature of the problem, and communicate the solution quickly to others. Inexperienced solution quickly to others. Inexperienced personnel might do best by starting with the personnel might do best by starting with the Pareto chart and the cause and effect diagram Pareto chart and the cause and effect diagram before tackling the use of the other tools. Those before tackling the use of the other tools. Those two tools are used most widely by quality two tools are used most widely by quality improvement teams.improvement teams.

7 Basic Quality Control Tools7 Basic Quality Control Tools

Basic Quality control tools

1. Cause and effect diagram

2. Control Charts

3. Check sheets

4. Histograms

5. Pareto charts

6. Scatter Diagram

7. Flow Charts

a. Deployment flow charts

b. Linear or activity flow charts

HistogramsHistograms

What is it?What is it? A Histogram is a bar graph A Histogram is a bar graph usually used to present frequency datausually used to present frequency data

How does it Work?How does it Work? Define Categories for DataDefine Categories for Data Collect Data, sort them into the categoriesCollect Data, sort them into the categories Count the Data for each categoryCount the Data for each category Draw the Diagram. each category finds its place on Draw the Diagram. each category finds its place on

the x-Axis.the x-Axis. The bars will be as high as the value for the categoryThe bars will be as high as the value for the category

What is its use?What is its use? Histograms provide an easy way to evaluate the Histograms provide an easy way to evaluate the

distribution of Data over different categoriesdistribution of Data over different categories


LSL USL

Pareto ChartsPareto Charts

What is it?What is it? A Pareto Chart is a Histogram A Pareto Chart is a Histogram + a cumulative line + a cumulative line

How does it Work?How does it Work? Similar like a HistogramSimilar like a Histogram First define categories, collect Data and sort them into First define categories, collect Data and sort them into

the Categories. Count the occurrences for each category.the Categories. Count the occurrences for each category. Now rank the categories starting with highest value.Now rank the categories starting with highest value. Draw cumulative points above all the bars and connect Draw cumulative points above all the bars and connect

them into a line. them into a line.

What is its use?What is its use? Pareto Charts are used to apply the 80/20 rule of Pareto Charts are used to apply the 80/20 rule of Joseph Juran Joseph Juran

which states that 80% of the problems are the result of 20% of the problems. A Pareto which states that 80% of the problems are the result of 20% of the problems. A Pareto Chart can be used to identify that 20% route causes of problem.Chart can be used to identify that 20% route causes of problem.


Type

X

Pareto ChartsPareto Charts

04/13/2304/13/23 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 1717Types of defects

Per

cen

tag

es o

f de

fect

s fo

und

100%

50%

Run ChartsRun Charts

What is it?What is it? Run Charts are representing changeRun Charts are representing change in measurement over a sequence or timein measurement over a sequence or time

How does it Work?How does it Work? Gather DataGather Data Organize DataOrganize Data

Measurements (y) must be confronted with time or Measurements (y) must be confronted with time or sequence of the events.sequence of the events.

Chart DataChart Data Interpreting DataInterpreting Data

What is its use?What is its use? Determining Cyclic Events and there average characterDetermining Cyclic Events and there average character


Time

Mea

sure

men

t

Scatter DiagramsScatter Diagrams

What is it? What is it? Statistical tool showing a trend in a series of values.Statistical tool showing a trend in a series of values.

How does it Work?How does it Work? Gain values seriesGain values series Draw graph with value pointsDraw graph with value points Draw trend line: m*x+aDraw trend line: m*x+a

Calculate m valueCalculate m value Calculate a valueCalculate a value Calculate points for trend line.Calculate points for trend line.

What is its use?What is its use? Demonstrating correlations between values and showing Demonstrating correlations between values and showing

trends for value changes.trends for value changes.


Y

X

Control ChartsControl Charts

What is it? What is it? Statistical tool, showing whetherStatistical tool, showing whether A process is in control or notA process is in control or not

How does it Work?How does it Work? Define Upper limit, lower limit and medium valueDefine Upper limit, lower limit and medium value Draw Chart.Draw Chart. Gather values and draw them into chartGather values and draw them into chart

What is its use?What is its use? Taking samples of a process and detect possibility of process Taking samples of a process and detect possibility of process

being out of controlbeing out of control


Y

X

Upper limit

Lower limit

Average/Spec

Flow ChartsFlow Charts

What is it?What is it? Way of representing a Procedure Way of representing a Procedure using simple symbols and arrowsusing simple symbols and arrows A Flowcharts shows the activities in a process and the relationships between A Flowcharts shows the activities in a process and the relationships between

them. Operations and Decisions can be represented them. Operations and Decisions can be represented

How does it Work?How does it Work? Determine what Process or Procedure you want to Determine what Process or Procedure you want to

represent.represent. Start at a certain point and go then step by step using Start at a certain point and go then step by step using

circles or rectangles for operations or other elements, circles or rectangles for operations or other elements, diamonds for decisions, arrows show the flow and the diamonds for decisions, arrows show the flow and the direction.direction.

Document the elements with titles. Let it close with Document the elements with titles. Let it close with an ending point.an ending point.

What is its use?What is its use? A Flow chart lets a process or procedure be A Flow chart lets a process or procedure be

understood easily it also demonstrate the understood easily it also demonstrate the relationships between the elements.relationships between the elements.


Input WithinSpec?Process Output

adjust

Yes

No

Cause and Effect DiagramsCause and Effect Diagrams

What is it?What is it? It’s a diagram that demonstrates It’s a diagram that demonstrates the relationship between Effects the relationship between Effects and the categories of their causesand the categories of their causes The Arrangement of the Diagram lets it look like a The Arrangement of the Diagram lets it look like a

fishbone it is therefor also called fish-bone diagramfishbone it is therefor also called fish-bone diagram

How does it Work?How does it Work? Determine the Effect or Problem you would like to Determine the Effect or Problem you would like to

examineexamine Categorize the possible causesCategorize the possible causes find subcategoriesfind subcategories Describe the possible causesDescribe the possible causes

What is its use?What is its use?04/13/2304/13/23 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 2222

effect

Cause bCause a

Cause dCause c

7 Management and Planning Tools 7 Management and Planning Tools

You will learn the essentials of this You will learn the essentials of this toolset to form a powerful and toolset to form a powerful and rational system and gain full support rational system and gain full support for complex decision making, identify for complex decision making, identify key issues and causes of persistent key issues and causes of persistent problems. It will show you ways to problems. It will show you ways to involve teams for continuous involve teams for continuous improvements, performance analysis improvements, performance analysis and problem solving.and problem solving.

7 Management and Planning 7 Management and Planning ToolsTools

Management and Planning Tools

1. Activity network diagram

2. Affinity Diagram

3. Interrelationship diagram

4. Prioritization matrix

5. Process decision Program chart

6. Tree diagram

7. Matrix Diagram

PDCA & Tools

Health & Medicine

Transcript of PDCA & Tools