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ENGINEERING MANAGEMENT

QUALITY IMPROVEMENT IN TECHNICAL CONCERNS


FAHAD MAHMUD MIRZA
11/12/10 1
 Quality Improvement falls in the major subject of Quality
Control and Management…

Quality Improvement:

“Systematic approach to reduction or elimination of

waste, work-back flow, rework, and losses in
production process”

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Quality has to be caused, not controlled…

-Phil Crosby

PRO
LOG ENGINEERING MANAGEMENT

7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
UE
Fahad Mahmud Mirza 11/12/10 2
 Quality & Productivity Improvement

While companies have adopted different methods to control

design and manufacturing outcomes, the intent is always the
same: quality improvement.

Quality improvement efforts work best when problems are

addressed systematically using a consistent and analytic
approach; the methodology shouldn't change just because
the problem changes. Keeping the steps to problem-solving
simple allows workers to learn the process and how to use
the tools effectively.

//////////////////////////////////////////////////////////////

Quality is never an accident,

It is always the result of intelligent effort...

PRO
LOG ENGINEERING MANAGEMENT

-John Ruskin
7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
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Fahad Mahmud Mirza 11/12/10 3
 Quality Improvement Requirements

• Organizational commitment

• Communicating the commitment

• Organizational culture

//////////////////////////////////////////////////////////////

Quality means
doing it Right when no one is looking...

PRO
LOG ENGINEERING MANAGEMENT

-Henry Ford
7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
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Fahad Mahmud Mirza 11/12/10 4
 Quality Management

Application of a system to manage a process consisting of

structure, responsibilities, and procedures that achieves the
quality desired

Quality Plan

A document that describes the standards, practices,

resources and processes specific to producing quality

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Quality is not an act,

It is a habit…

PRO
LOG ENGINEERING MANAGEMENT

-Aristotle
7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
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Fahad Mahmud Mirza 11/12/10 5
 Quality Assurance

All the planned and systematic activities implemented within

the quality system that can be demonstrated to provide
confidence that a product or service will
fulfill requirements for quality

Quality Tool

An instrument or technique to support or improve the

activities of process management and improvement to meet
the characteristics of quality

//////////////////////////////////////////////////////////////

Professionalism means
consistency of Quality…

PRO
LOG ENGINEERING MANAGEMENT

-Frank Tyger
7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
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Fahad Mahmud Mirza 11/12/10 6
 Quality Improvement Methods-

ISO 9004:2000 Guidelines for performance improvement

ISO 15504-4: 2005 Process assessment
QFD — Quality Function Deployment
Kaizen — change for the better; the continual improvement
Six Sigma — 6σ, methods such as Statistical Process Control
PDCA — Plan-Do-Check-Act cycle for quality control purposes
Taguchi Methods — Quality loss function and Target specifications
TQM — Total Quality Management
TRIZ — Theory of Inventive Problem Solving
BPR — Business Process Re-Engineering
IMP Quality Circle — People oriented group approach to improvement
ROV 7QC — Also known as SQC (Seven Quality Control Tools)
EME
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MET
HOD ENGINEERING MANAGEMENT

7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
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Fahad Mahmud Mirza 11/12/10 7
 Easy to implement and follow up, the most commonly used and
well-known quality process is the Plan-Do-Check-Act (PDCA)
cycle
P  Plan:
Define a problem or opportunity
Analyze the situation and Develop a implementation Plan

D Do:
Implement corrective actions
Document procedures and observations
Using data-gathering tools to collect information

C Check:
Analyze information
Monitor trends
Compare obtained results with expected results

A Act:
Expected results: Do Nothing!
Not-Expected results: Repeat PDCA cycle
PDC
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Document the process and revised plan

A- QC
MO ENGINEERING MANAGEMENT


QUALITY IMPROVEMENT IN TECHNICAL CONCERNS

DEL
Fahad Mahmud Mirza 11/12/10 8
 Process and the Sub-Process

//////////////////////////////////////////////////////////////

Quality is free, but only to those

PDC who are willing to pay heavily for it…

A-
MO ENGINEERING MANAGEMENT

-Philip Crosby
7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
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Fahad Mahmud Mirza 11/12/10 9
 One of many methods to ease the quality improvement
process was introduced by Kaoru Ishikawa

It was called Seven Tools of Quality.

Ishikawa believed that 95% of a company’s problems can be

7
solved using these seven tools

BASI The tools are designed for simplicity so average person can
C have less complicated statistical analysis
TOO
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QUA ENGINEERING MANAGEMENT
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7 QC
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Fahad Mahmud Mirza 11/12/10 10
 Seven Tools of Quality Improvement

7
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Fahad Mahmud Mirza 11/12/10 11
 Flow Chart

1.Flow charts describe sequence of activities graphically in

accomplishing a task.
2.
3.It must reflect the actual process rather than what the
process owner wants it to be.
4.
5.By generating flow charts, process owner can understand
the process and working relationship between people and

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organization will be clarified.
6.
7.Furthermore, flow charts will show the duplicated effort and
BASI other non value added steps.
8.
C 9.So process owner can identify the target specific steps in
TOO order to make continuous improvement.

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7 QC
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Fahad Mahmud Mirza 11/12/10 12
 Flow Chart

DOCK
PAINT AND
AESTHETICS
RECIEVE

INSPECTION

7
BASI FINAL TEST ASSEMBLY

C
TOO
LS SHIPPING SUB-

7
INSPECTION
AND TESTING OPERATIONS
OF DOCK
QC
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QUALITY IMPROVEMENT IN TECHNICAL CONCERNS

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Fahad Mahmud Mirza 11/12/10 13
 Cause & Effect Diagrams

1.Cause and effect diagrams are also called Ishikawa

diagrams or fishbone diagrams.
2.
3.These diagrams show a relationship between the effect of
the problem and the causes.
4.
5.Although cause and effect diagrams can be developed by
individual, but it is better to be brainstormed by a team.

7
6.
7.To help in identifying the causes, people used to take 5
potential factors which are man, machine, material,
BASI method, and environment as the guidance.
8.
C 9.Cause and effect diagrams consist of 2 sides. The right
TOO side lists the effect or the problem, while the left side lists
the causes of the problem.
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7 QC
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Fahad Mahmud Mirza 11/12/10 14
 Cause & Effect Diagram

MATERIALS METHODS PEOPLE

7 RESULT

BASI
C
MEASUREMENTS MACHINES DESIGNS
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 Check Sheets

1.Check sheets are the paper forms for collecting data in real
time easily and concisely.
2.
3.According to the data on check sheets, frequency or
pattern of the events, problems, defects, etc. can be
observed.
4.
5.These data are then used as input data for other seven

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quality tools such as histograms and Pareto diagrams.
6.
7.Furthermore, collected data on check sheets can be used
BASI as input to understand the real situation, analyze
occurring problem, control the process, make the
C decision, and develop planning.
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Fahad Mahmud Mirza 11/12/10 16
 Check Sheets

Defective Item Mon Tue Wed Thu Fri Total

9/3 10/3 11/3 12/3 13/3
Mold 5 3 6 3 4 21
Cracked
Fibers 2 0 5 1 0 8
Grit 4 2 3 5 0 14
7
BASI Pinholes 1 5 0 2 1 9
C Cracks 0 1 1 0 0 2
TOO Other 1 3 0 0 3 7
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OF Total 13 14
QUA ENGINEERING MANAGEMENT
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15 11 8 61
7 QC
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Fahad Mahmud Mirza 11/12/10 17
 Histogram Charts

1.Histograms are bar graphs that present the frequency

distribution of data.
2.
3.The horizontal axis represents the class interval of data while
the vertical axis represents the frequency of each class
interval.
4.
5.Not only for displaying data, histogram can also be used as a

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tool for summarizing and analyzing data.
6.
7.The particular values of histogram are:
BASI
• Summary graph of frequency distribution
C • Shows data in various ranges
TOO • Conveys symmetry

LS
OF
QUA ENGINEERING MANAGEMENT

7QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
LITY
Fahad Mahmud Mirza 11/12/10 18
 Histogram Charts

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QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
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Fahad Mahmud Mirza 11/12/10 19
 Scatter Diagrams

1.Scatter diagrams describe the correlation between 2 variables,

so it can be identified whether those 2 variables are related.
2.
3.After developing cause and affect diagrams, sometimes
people use scatter diagrams to determine objectively
whether the cause and the effect are related.
4.
5.By looking at a glance to the scatter diagrams, process owner

7
can analyze the positive/negative correlation of 2 variables.
When the trend line goes from the bottom left to the up right,
it means those 2 variables have positive correlation.
BASI Otherwise, if the trend line goes from the up left to the
bottom right, and then it means those 2 variables have
C negative correlation.
TOO 6.

LS
OF
QUA ENGINEERING MANAGEMENT

7QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
LITY
Fahad Mahmud Mirza 11/12/10 20
 Scatter Diagrams

7
BASI
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QUA ENGINEERING MANAGEMENT
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7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
LITY
Fahad Mahmud Mirza 11/12/10 21
 Control Charts

1.Control charts were invented by Walter A. Shewhart in 1920s.

2.
3.The maximum limit often called upper control limit and the
minimum limit often called lower control limit, while the
central line represents an estimate of the process mean.
4.
5.If the value is within control area, the process can be stated as
a controllable process.

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6.
7.The value outside control area indicates that the process is no
longer stable because of some variation causes. Thus, this
BASI process needs proper corrective actions to eliminate the
sources of variation.
C 8.
TOO
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QUA ENGINEERING MANAGEMENT

7QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
LITY
Fahad Mahmud Mirza 11/12/10 22
 Control Charts

Samples Observations Average

1 74.030 … … … 74.008 74.010
… …
15 73.988 … … … 74.002 74.008
Median : 74.001

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7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
LITY
Fahad Mahmud Mirza 11/12/10 23
 Pareto Charts

1.Pareto diagrams consist of bar graph and line graph that

describe the proportion of each problem cause toward the
overall cause.
2.
3.According to these quality tools, the major factor of the
problem can be identified. Thus, it helps process owner in
prioritizing the problem to be solved first.
4.

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5.As Dr. J. M. Juran said, 80% of the problems are caused by
20% of the potential sources.
6.
BASI 7.Not only to identify the major problem, pareto diagram can
also be used to analyze the improvement after solving some
C problems.
TOO 8.
9.Process owner can evaluate the process before and after
LS solving the problems.

OF
QUA ENGINEERING MANAGEMENT

7QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS
LITY
Fahad Mahmud Mirza 11/12/10 24
 Pareto Charts

100
90
80
70
60
50
40

7
30
20

BASI 10
0
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Fahad Mahmud Mirza 11/12/10 25
 Benefits

1.Many people in the industries are undoubtedly familiar with

many of these tools and know their application, advantages,
and limitations.
2.
3.However, this must ensured that these tools are in place and
being used to their full advantage as part of their quality
system procedures.
4.
5.Flowcharts and check sheets are most valuable in identifying
problems, whereas cause and effect diagrams, histograms,
scatter diagrams, and control charts are used for problem

CO 6.
analysis. Pareto diagrams are effective for both areas.

7.By properly using these tools, the problem-solving process

NC can be more efficient and more effective.

LU
SI ENGINEERING MANAGEMENT

7QC

ON QUALITY IMPROVEMENT IN TECHNICAL CONCERNS

Fahad Mahmud Mirza 11/12/10 26

 Persistence is the twin sister of excellence.
One is a matter of quality; the other, a matter of time…

Even though if quality cannot be defined,

you know what quality is

AN
YO

TH
U

ENGINEERING MANAGEMENT

7 QC
QUALITY IMPROVEMENT IN TECHNICAL CONCERNS

Fahad Mahmud Mirza 11/12/10 27