Quality Circle and 8 D Methodology

Dr. Mohamed Riyazh Khan - DoMS

Walter A. Shewhart

Walter A. Shewhart could be considered the "Father of Quality." This title is most often associated with W. Edwards Deming, but Deming learned "at the feet" of Shewhart.

Shewhart laid the first seed of the quality movement with his book "Economic Control of Quality of Manufactured Product."

This book introduced the concept of Statistical Process Control. SPC has become the cornerstone for process control in industry.

Walter A. Shewhart

An idea that is commonly credited to Deming, but in actuality belongs to Shewhart is the PDCA (or PDSA) cycle of management.

This is the Plan-Do-Check (or Study)-Act cycle that should be used for all management projects.

Plan what you want to do, do it, study the results, make corrections, and then plan for the improvements (starting the cycle again).

Walter A. Shewhart

The Shewhart Cycle - The Deming Wheel - Plan-Do-Check-Act

Walter A. Shewhart

PLAN  Establish the objectives and processes necessary to deliver results in accordance with the specifications.

DO  Implement the processes.

CHECK  Monitor and evaluate the processes and results against objectives and Specifications and report the outcome.

ACT  Apply actions to the outcome for necessary improvement. This means reviewing all steps (Plan, Do, Check, Act) and modifying the process to improve it before its next implementation.

Shigeo

Shigeo Shingo's life-long work has contributed to the well being of everyone in the world. Shigeo Shingo along with Taiichi Ohno, Kaoru Ishikawa and others has helped to revolutionize the way we manufacture goods.

His improvement principles vastly reduce the cost of manufacturing - which means more products to more people. They make the manufacturing process more responsive while opening the way to new and innovative products with less defects and better quality.

Shigeo

He is one of the pioneers of change management. He brought about many new concepts such as ZD (Zero Defects), shifting use of statistics for acceptance or rejection from SQC (Statistical Quality Control) to SPC (Statistical Process Control),SMED (Single Minute Exchange of Dies), POKA-YOKE (mistake proofing),Defining Processes & Operations in two-dimensions of VA (Value Addition) and non-VA, etc.

IncreaseMotivationCreate the

will to workImprove

communication

Create problem solving

capability

Build an attitude

of problem prevention

QUALITY CIRCLE

Inspire Employees

to come together

Team work

Create positive work

attitude in employees

Develop knowledge

and skill

Develop safety

awareness

Reduce job

errors

Develop harmonious supervisor employees relationship

SteeringCommittee

COORDINATOR

STRUCTURE OF QUALITY CIRCLES IN AN INDUSTRY

TOP MANAGEMENT

• Chairman and managing director, directors, chief executives, general managers and other top executives

• Lends total support to the philosophy and activities of QC

• Motivates by meeting circle leaders and members occasionally.

• Incorporates QC promotion as one of the company's broad objective.

STEERING COMMITTEE

• Comprises of representatives of all major functions

• Responsible for establishing objectives and resources • Meets regularly once in two months with facilitators as

invitees

• Provide guidance and direction

• Gives thrust by promoting qc as a way of life

FACILITATOR

• Responsible for the successful operation of the circles on his area

• Trains members by assisting leaders

• Solves interface problems between circles

• Demonstrates support of the management

• Works closely with steering committee

• Maintains activity level records of circles

• Reports to the steering committee

• Takes timely corrective action to revitalize inactive circles.

LEADER

• Chosen by members

• Guides, trains members

• Involves every member in circle activities

• Prepares agenda and conducts meetings regularly and effectively and ensures discipline and decorum.

• Chalks out action plan

Members

• Voluntary group of people coming from the same work area

• Meet regularly (One hour in week) and actively participate in circle meetings

• Identify, analyses and recommend solutions to work related problems

• Assist leader

•8D is a problem-solving methodology for product and process improvement.

•It is structured into eight disciplines, emphasizing team synergy.

•The team as whole is better and smarter than the quality sum of the individuals.

•Each discipline is supported by a checklist of assessment questions, such as “what is wrong with what”, “what, when, where, how much”.

8D METHODOLOGY

1. Use Team ApproachEstablish a small group of people with the knowledge, time, authority and skill to solve the problem and implement corrective actions. The group must select a team leader.

2. Describe the ProblemDescribe the problem in measurable terms. Specify the internal or external customer problem by describing it in specific terms.

8D METHODOLOGY

3. Implement and Verify Short-Term Corrective ActionsDefine and implement those intermediate actions that will protect the customer from the problem until permanent corrective action is implemented. Verify with data the effectiveness of these actions.

4. Define end Verify Root CausesIdentify all potential causes which could explain why the problem occurred. Test each potential cause against the problem description and data. Identify alternative corrective actions to eliminate root cause.

8D METHODOLOGY

5. Verify Corrective ActionsConfirm that the selected corrective actions will resolve the problem for the customer and will not cause undesirable side effects. Define other actions, if necessary, based on potential severity of problem.

6. Implement Permanent Corrective ActionsDefine and implement the permanent corrective actions needed. Choose on-going controls to insure the root cause is eliminated. Once in production, monitor the long-term effects and implement additional controls as necessary.

8D METHODOLOGY

7. Prevent RecurrenceModify specifications, update training, review work flow, improve practices and procedures to prevent recurrence of this and all similar problems.

8. Congratulate Your TeamRecognize the collective efforts of your team. Publicize your achievement. Share your knowledge and learning.

8D METHODOLOGY