PDCA & Tools
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This document discusses various methodologies and tools for quality management. It describes tools like PDCA-CQI, DMAIC, and DMADV which are used for quality improvement. It also explains the seven basic quality control tools including histograms, Pareto charts, control charts, flow charts and cause-and-effect diagrams. These tools help identify and solve problems, improve processes, and ensure quality management.
PDCA & Tools
- 1. METHODOLOGIES &METHODOLOGIES & TOOLS FOR QUALITYTOOLS FOR QUALITY MANAGEMENTMANAGEMENT PresentedPresented ON QUALITY DAYON QUALITY DAY ByBy Dr. Aquil Ahmed KhanDr. Aquil Ahmed Khan TQM-ACHTQM-ACH
- 2. This Means:This Means: Steadily improving each person’s ability to:Steadily improving each person’s ability to: Recognize and define important problemsRecognize and define important problems PP Solve themSolve them DD Learn from problem solvingLearn from problem solving CC Share the learning with othersShare the learning with others AA
- 3. What is problem?What is problem?
- 4. Problem solving philosophyProblem solving philosophy
- 5. MethodologyMethodology PDCA-CQIPDCA-CQI DMAIC (duh-may-ick)DMAIC (duh-may-ick) DMADVDMADV
- 6. 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 66
- 7. MethodologyMethodology • PDCA-CQIPDCA-CQI • DMAIC (duh-may-ick)DMAIC (duh-may-ick) • DMADVDMADV • CQI was originally developed by Walter Shewhart, and isCQI was originally developed by Walter Shewhart, and is often referred to as the "Shewhart Cycle". It was taken upoften referred to as the "Shewhart Cycle". It was taken up and promoted effectively from the 1950s by the famousand promoted effectively from the 1950s by the famous Quality Management authorityQuality Management authority W. Edwards DemingW. Edwards Deming, and is, and is consequently known by many as "the Deming Wheel".consequently known by many as "the Deming Wheel".
- 8. 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 88
- 9. PLAN Plan carefully what is to be done Phase 1 - Identify the Opportunity Phase 2 - Analyze the Current Process Phase 3 - Develop the Optimal Solution DO Carry out the plan (do it) Phase 4 - Implement Changes CHECK Check the Results. Did the plan work as intended or were the results different? Phase 5 - Study the Results ACT Act on the results by identifying what worked as planned and what didn't. Phase 6 - Standardize the Solution
- 10. MethodologyMethodology • PDCA-CQIPDCA-CQI • DMAICDMAIC (duh-may-ick)(duh-may-ick) • DMADVDMADV DMAICDMAIC is an acronym for five (5) interconnectedis an acronym for five (5) interconnected phases: Define, Measure, Analyze, Improve andphases: Define, Measure, Analyze, Improve and Control. It refers to a data-driven quality strategyControl. It refers to a data-driven quality strategy for improving processes.for improving processes.
- 11. MethodologyMethodology • PDCA-CQIPDCA-CQI • DMAIC (duh-may-ick)DMAIC (duh-may-ick) • DMADVDMADV DMADVDMADV consists of five (5) inteconnected phases: Define,consists of five (5) inteconnected phases: Define, Measure, Analyze, Design and Verify. It is a data-drivenMeasure, Analyze, Design and Verify. It is a data-driven quality strategy for designing products and processes, It isquality 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.
- 12. IntroductionIntroduction In the following we will Examine theIn the following we will Examine the Techniques and Tools that SupportTechniques and Tools that Support Quality Management within aQuality Management within a company. There are for thecompany. There are for the 7 Basic7 Basic ToolsTools which we are going to define.which we are going to define. Generally they can be subdividedGenerally they can be subdivided into:into: • mathematical statistical Toolsmathematical statistical Tools • logical toolslogical tools04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 1212
- 13. 7 Basic Quality Control Tools7 Basic Quality Control Tools The concept behind the seven basic tools cameThe concept behind the seven basic tools came from Kaoru Ishikawa, a renowned qualityfrom Kaoru Ishikawa, a renowned quality expert from Japan. According to Ishikawa, 95%expert from Japan. According to Ishikawa, 95% of quality-related problems can be resolvedof quality-related problems can be resolved with these basic tools. The key to successfulwith these basic tools. The key to successful problem resolution is the ability to identify theproblem resolution is the ability to identify the problem, use the appropriate tools based onproblem, use the appropriate tools based on the nature of the problem, and communicatethe nature of the problem, and communicate the solution quickly to others. Inexperiencedthe solution quickly to others. Inexperienced personnel might do best by starting with thepersonnel might do best by starting with the Pareto chart and the cause and effect diagramPareto chart and the cause and effect diagram before tackling the use of the other tools. Thosebefore tackling the use of the other tools. Those two tools are used most widely by qualitytwo tools are used most widely by quality improvement teams.improvement teams.
- 14. 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
- 15. HistogramsHistograms What is it?What is it? A Histogram is a bar graphA 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 onDraw 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 theHistograms provide an easy way to evaluate the distribution of Data over different categoriesdistribution of Data over different categories 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 1515 LSL USL
- 16. Pareto ChartsPareto Charts What is it?What is it? A Pareto Chart is a HistogramA 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 intoFirst 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 connectDraw 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 ofPareto Charts are used to apply the 80/20 rule of JosephJoseph Juran which states that 80% of the problems are the result of 20% of the problems. AJuran 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.Pareto Chart can be used to identify that 20% route causes of problem. 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 1616 Type X
- 17. Pareto ChartsPareto Charts 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 1717Types of defects Percentagesofdefectsfound 100% 50%
- 18. 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 orMeasurements (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 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 1818 Time Measurement
- 19. 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 showingDemonstrating correlations between values and showing trends for value changes.trends for value changes. 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 1919 Y X
- 20. 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 processTaking samples of a process and detect possibility of process being out of controlbeing out of control 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 2020 Y X Upper limit Lower limit Average/Spec
- 21. Flow ChartsFlow Charts What is it?What is it? Way of representing a ProcedureWay of representing a Procedure using simple symbols and arrowsusing simple symbols and arrows A Flowcharts shows the activities in a process and the relationships betweenA Flowcharts shows the activities in a process and the relationships between them. Operations and Decisions can be representedthem. Operations and Decisions can be represented How does it Work?How does it Work? Determine what Process or Procedure you want toDetermine what Process or Procedure you want to represent.represent. Start at a certain point and go then step by stepStart at a certain point and go then step by step using circles or rectangles for operations or otherusing circles or rectangles for operations or other elements, diamonds for decisions, arrows show theelements, diamonds for decisions, arrows show the flow and the direction.flow and the direction. Document the elements with titles. Let it close withDocument 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 beA Flow chart lets a process or procedure be understood easily it also demonstrate theunderstood easily it also demonstrate the relationships between the elements.relationships between the elements. 04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 2121 Input Within Spec? Process Output adjust Yes No
- 22. Cause and Effect DiagramsCause and Effect Diagrams What is it?What is it? It’s a diagram that demonstratesIt’s a diagram that demonstrates the relationship between Effectsthe relationship between Effects and the categories of their causesand the categories of their causes The Arrangement of the Diagram lets it look like aThe 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 toDetermine 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?04/30/1404/30/14 Dr. Ashfaq Ahmed BhuttoDr. Ashfaq Ahmed Bhutto 2222 effect Cause bCause a Cause dCause c
- 23. 7 Management and Planning Tools7 Management and Planning Tools You will learn the essentials of thisYou will learn the essentials of this toolset to form a powerful andtoolset to form a powerful and rational system and gain full supportrational system and gain full support for complex decision making, identifyfor complex decision making, identify key issues and causes of persistentkey issues and causes of persistent problems. It will show you ways toproblems. It will show you ways to involve teams for continuousinvolve teams for continuous improvements, performance analysisimprovements, performance analysis and problem solving.and problem solving.
- 24. 7 Management and Planning7 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