142 Spring 2014 Wk 07a

download 142 Spring 2014 Wk 07a

of 17

Transcript of 142 Spring 2014 Wk 07a

  • 8/11/2019 142 Spring 2014 Wk 07a

    1/17

    Total Quality Management

    BUS 3142

    Tools of QualityMarch, 2014

  • 8/11/2019 142 Spring 2014 Wk 07a

    2/17

    Page 2

    2

    Ishikawas Basic Seven (7) Tools of Quality

    Process Maps

    Check Sheets

    Histograms

    Scatter Plots

    Control Charts

    Cause & Effect (Fishbone) Diagrams

    Pareto Analysis

  • 8/11/2019 142 Spring 2014 Wk 07a

    3/17

    Page 3

    3

    Logical Order of the Seven Basic Tools

    Foster, Quality Management, Fifth Edition, Prentice Hall

  • 8/11/2019 142 Spring 2014 Wk 07a

    4/17

    Page 4

    4

    Process map

    Specific symbols for specific definitionsProcessing

    Decision

    Input / Output

    Start / Stop

    Flow Line

    Page Connector

    Create a flow chart , from beginning to end

  • 8/11/2019 142 Spring 2014 Wk 07a

    5/17

    Page 5

    5

    Steps in creating process maps

    Communicate the purpose to impacted individuals

    Observe behavior

    Interview participants and stakeholdrrs

    Review reports and outputs

    Draw the flow chart using the symbols

    Evaluate Value Added (VA) and Non Value Added (NVA) activities

    Review multiple times to ensure accuracy and buy-in

    Use the map to streamline and simplify the

    process, including eliminating NVA steps

    Use the map for the Vision of the improved

    Future Process

  • 8/11/2019 142 Spring 2014 Wk 07a

    6/17

    Page 6

    6

    High Level Supply Chain Flow

    Product

    Planning

    Demand

    Planning

    Material

    Planning

    Master

    Production

    Scheduling

    ProductionDelivery

    & Service

  • 8/11/2019 142 Spring 2014 Wk 07a

    7/17Page 7 7

    Forecast Process (SampleCross-Functional Swim Lane)

    Acc ount Managem ent

    Production Planning

    Sales

    Demand Planner

    Sales Ops

    Manugistics

    Fulfillment

    "Wednesday"

    JudgedForecast

    ReconciledForecast

    RevenueIncreases

    "Friday"

    DemandSignal&

    ExceptionReport

    Build Plan "Thursday"

    "Tuesday"

    Commited Buffer

    BuildP

    lan

    No

    Yes

    MaterialJudgementNotification

    ForecastRevisions

    No

    Forecast

    Revisions

    Yes

    No

    Yes

    No

    Pull Forecast fromManugistics

    Judge Forecast

    Reconcile with AM& Sales

    Reconcile wilthRevenue Plan

    EscalateJudgements

    Revenue IncreaseCommit

    Create Build Plan Reconcile ExcessInventory

    Customer Commit

    Publish Build Plan

    Publish Demand signal &Exception ReportStart Demand

    Reconciliation

    Demand /Supply

    Reconciled

    JudgementAcceptable?

    SupplyAdequate?

    EscalateSupply

    Requiremen

    Revenue IncreaseCommit**

    Publish 13wk DSIposition / Heat Map

    Allocate Productby Customer

    RevenueRisk/

    Sales Forecast

    Revenue Plan

    Enter OEMForecast at Part #

    Level

    Regional OEMsplits report -

    Standard Tabs

    Allocate StandardProducts by

    Region

    StandardTabs

    Enter OEMForecast at Model

    Level

    Sales Forecast

    Revenue Plan

  • 8/11/2019 142 Spring 2014 Wk 07a

    8/17Page 8 8

    Check Sheets - for DATA GATHERING

    After common defects are identified, operators andmachines track how often they occur

    Setup routine not followed

    Missing equipment

    Machine breakdown

    Parts shortage

    Etc

    A table is created to track the defects over time (hours /shifts / days / weeks)

    The data from the check sheets are then used to populatehistograms and Pareto charts

  • 8/11/2019 142 Spring 2014 Wk 07a

    9/17Page 9 9

    Check Sheet Example

  • 8/11/2019 142 Spring 2014 Wk 07a

    10/17Page 10 10

    Histogram

  • 8/11/2019 142 Spring 2014 Wk 07a

    11/17Page 11 1111

    Work ExampleHistogram

    Median Drive

    Age at Invoice

    Average Drive

    Age at Invoice

    Median: 18 days

    Average: 25 days

    Mode: 1 day

    80% of units invoiced under 36 days of age

  • 8/11/2019 142 Spring 2014 Wk 07a

    12/17Page 12 12

    Scatter Diagrams

    Fi hb Ch

  • 8/11/2019 142 Spring 2014 Wk 07a

    13/17

    Page 13 13

    Fishbone Chart

    U H t b ild th h d P i tb h t i t it

  • 8/11/2019 142 Spring 2014 Wk 07a

    14/17

    Page 14 14

    Use a Hammer to build the house and a Paintbrush to paint it

    Quality Tool Purpose

    Process Maps Establishing Baselines

    Learning / Understanding the Basic Process

    Identifying Data Requirements (Volumes, times, resources, systems, etc)

    Encourage feedback and ownership

    Communicate Future State Vis ion

    Check Sheets Gather data according to predetermined categories

    Timely

    Lead to Process Control & Improvement

    Histograms Summarized representation (totals) of categorized data

    Can be a visual representation of key statistics (Mean, Median, Mode)

    Can represent specific distributions (Normal, Poisson, other)

    Pareto Analyses Histogram, sorted saccording to frequency of occurences

    Scatter Plots Detailed representation (events / results) of categorized data

    Control Charts Real time data gathering and analysis

    Key for sustained productivity and cost management (later chapters)

    Cause & Effect (Fishbone)Separates Problems from Symptoms (Is your problem that you have no money or

    that you spend too much?)

    Experts list key categories for further drill down and anlysis

    Can be as detailed or general as necessary (team to decide)

    Encourages teamwork and grup problem-solving

    N T l f Q lit B l d S d

  • 8/11/2019 142 Spring 2014 Wk 07a

    15/17

    Page 15 1510- 15

    Strategic Quality PlanningThe Too ls of Qual i tyOther Tools for Performance Measurement

    New Tool of Quality: Balanced Scorecard

    Designed to prevent over-emphasis on one objective or theme over

    others

    A control mechanism to monitor that optimizing one factor does notsub-optimize the whole enterprise

    Adapted from Foster, Quality Management, Fifth Edition, Prentice Hall

    N T l f Q lit D hb d

  • 8/11/2019 142 Spring 2014 Wk 07a

    16/17

    Page 16 1610- 16

    Strategic Quality PlanningThe Too ls of Qual i tyOther Tools for Performance Measurement

    New Tool of Quality: Dashboard

    Adapted from Foster, Quality Management, Fifth Edition, Prentice Hall

    Easy to see

    Best when tied to most critical metrics and performance levers

    Requires little, to no, interpretation

    K P i t di T l

  • 8/11/2019 142 Spring 2014 Wk 07a

    17/17

    Page 17 17

    Key Points regarding Tools

    Know if you are looking at time and trend data or at static /populationdata

    Process Maps are static

    Check sheets can be both

    Histograms, Scatter Plots, Pareto Charts are for populations

    Control Charts / SPC look at time and trend

    Data gathering and analysis enables a more effective Plan-Do-Check-Act cycle

    The data TELL you something! Act on what the data tell you

    Root Cause identification

    Separating Causes from Effects (5 Whys)

    Planning and Implementing improved performance and Results

    Refine the Measurement System so that focus is on facts andcollaborative problem solvingnot blame or spin

    Precision vs. Enough (Diminishing Returns)