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QUALITY
Quality of a product is good when the product is able to
satisfy the needs of the consumer. So quality is defined
as customer satisfaction, or fulfilling customer
expectations.
Ethical Characteristics
(Courtesy of sales persons, Honesty of service, Promptness of service, Timely delivery of product
at the promised date)
Miscellaneous Characteristics
(Environmental Norms of Regulatory Bodies, Ergonomic considerations, Availability of Service Stations etc.)
FREEDOM FROM DEFECIENCIES
Freedom from deficiencies mean that the product should be free from defects, errors or problems.
DEFECT is a departure of a quality characteristic from its intended level or state that occurs with a
severity sufficient to cause an associated product or service not to satisfy intended normal or
reasonably foreseeable usage requirements.
(ANSI/ASQC Standard A3-1987)
DEFECTS or Product Deficiencies can take such forms as: FIELD FAILURES, FACTORY SCRAP and
REWORK, LATE DELIVERIES, ERRORS IN INVOICES etc. Each of these cause trouble to the customers
and hence Customer Dissatisfaction.
Customer Dissatisfaction can be in the form of COMPLAINTS, RETURNS and CLAIMS etc.
If the extent of Dissatisfaction is very high or the response by the manufacturer to the
dissatisfaction is inadequate, external customers may stop buying the product and go elsewhere.
This will lead to lower sales, higher costs and lower productivity. In case of internal customers,
dissatisfaction will lead to lack of cooperation between the departments, mutual blame and poor
morale.
Stages/ Phases of Building Quality
(Elements of Quality)
To incorporate quality into a product, there are three essential
elements:
Quality of Conformance phase ensures that the manufactured product or the service
rendered meets the standards set in the Design Phase (QOD). This phase is concerned
with determining, how well the manufactured product conforms to the original design
requirements.
QOC involves designing the tools, equipment and operations such that the product
will meet the design specifications. If such a system of production can be achieved, the
conformance phase will be capable of meeting the requirements set during the first
phase. If not, the design phase will be affected and the design of the product will have
to be changed.
The next activity would be to control the quality right from procurement of material
to production, shipment, and storage of finished goods. This activity of Quality
Control consists of three main activities viz. defect finding, defect prevention, and
defect analysis and rectification.
QUALITY OF CONFORMANCE
This phase helps in clarifying the quality responsibilities of the workers
and supervisors.
Concerned with how well the product functions or service performs when in
use.
Measures the degree to which the product or service satisfies the customer.
QOP is a function of both Quality of Design and Quality of Conformance. When product is
put to use, performance of the product depends both on Product Features available (QOD)
and Freedom from Deficiencies (QOC). It can be the best design but poor quality control will
cause poor performance. Conversely the best quality control can not make the product
function to satisfaction if the design is not proper.
Ishikawas Quality Tools/ The Seven Basic Quality Tools
Dr Karou Ishikawa put forward seven basic visual tools of quality so that even
an average person (with little formal training in statistics) could analyze and
interpret data/troubleshooting issues related to quality. These tools are used
world wide by companies, managers, and employees at all levels.
i. Histograms
ii. Pareto Charts
iii. Cause and Effect Diagrams
iv. Run Charts
v. Scatter Diagrams
vi. Flow Diagrams
vii. Control Charts
Suggested Mean
5 10 15 20 25 Length
HISTOGRAM
2. PARETO ANALYSIS
Vilfredo Pareto (1848-1923), an Italian economist stated 20% of the population has
80% of the wealth. Juran used the term vital few, trivial many. He noted that
20% of the quality problems caused 80% of the monetary loss. The 80/20 rule
states that approximately 80% of the problems are created by approximately 20%
of the causes.
A Pareto chart is usually used to identify the principle drivers to a problem. Pareto
charts are used to identify and prioritize problems to be solved. Pareto Charts are
used when products are suffering from different defects but only a few account for
most of the defects present, or different defects incur different costs. The
manufacturer could concentrate on reducing the defects which make up a bigger
percentage of all the defects or focus on eliminating the defect that causes monetary
loss.
A check sheet is used to count how often a particular item occurs usually as a cause
to a problem. The items are then charted by the percentage of the occurrences in
decreasing order. They are actually histograms aided by the 80/20 rule adapted by
Joseph Juran. The resulting chart shows which items have the most influence on the
problem. This goes along with the 80-20 rule.
3. RUN CHARTS (TIME SERIES PLOT)
Run charts examine the behavior of a variable over time. These charts are
the basis for Control Charts.
An example of using a Run Chart: An organizations desire is to have their product
arrive to their customers on time, but they have noticed that it doesnt take the
same amount of time each day of the week. They decided to monitor the amount
of time it takes to deliver their product over the next few weeks.
4. SCATTER DIAGRAMS
Scatter Diagrams depict the relationship between paired data (i.e. two process
parameters).
Scatter Diagrams are used to study and identify the possible relationship between the changes
observed in two different sets of variables.
i. First, collect two pieces of data and create a summary table of the data.
ii. Draw a diagram labeling the horizontal and vertical axes.
iii. It is common that the cause variable be labeled on the X axis and the effect
variable be labeled on the Y axis.
iv. Plot the data pairs on the diagram.
v. Interpret the scatter diagram for direction and strength.
An Example of use of Scatter Diagram: A scatter diagram can be used to identify the
relationship between the production speed of an operation and the number of
defective parts made. Displaying the direction of the relationship will determine
whether increasing the assembly line speed will increase or decrease the number of
defective parts made. Also, the strength of the relationship between the assembly line
speed and the number of defective parts produced is determined.
SCATTER DIAGRAMS
A cluster of points resembling a straight line indicates the strongest correlation between
the variables. In this graph, there is a strong positive correlation between Variable 1
and Variable 2.
5. FLOW CHARTS/FLOW DIAGRAM
Flow Charts Defined
A flow chart is a pictorial representation showing all of the steps of a process. It is a
graphical description of how work is done.
No
FLOW CHARTS / FLOW DIAGRAM
FLOWCHART
An Example: Statistical Process Control Steps
Produce Good
Start
Provide Service
No
Assign.
Take Sample Causes?
Yes
Inspect Sample Stop Process
Create
Find Out Why
Control Chart
5*. Process Chart Symbols
Operations
Inspection
Transportation
Delay
Storage
Location: Kullu Mountain
Process Chart
Date: 03-09-08 Process: Apple Sauce
Description
Distance
Operation
Transport
Storage
(min)
(feet)
Time
Inspect
of
Delay
Step
process
4 Move to storage 50 ft
6 Move to peeler 20 ft
9 Place in conveyor 5
Quality Problem
(Backbone or Spine) (Problem Statement)
(Fish Head)
STEPS TO CONSTRUCT C&E DIAGRAM
2. In this step, a brainstorming session of the group
members is held to identify the broad areas of the
problem i.e. the major categories of the causes are
identified. Generally these Broad Areas/ Major
Categories are:
Main Bones
Problem
Statement
Backbone or Spine
Fish Head
Problem
Statement related
to Manufacturing
Industry
METHOD MATERIAL
MEN MACHINERY
Problem
Statement related
to Service
Industry
PROCEDURES POLICIES
STEPS TO CONSTRUCT C&E DIAGRAM
3. In this step, again a brainstorming session of the group
members is held to identify the causes/ issues under each problem
area/ major categories of cause. For this, under each category, look
for the things that have changed, deviations from norms or patterns.
For each problem area, ask, why does it happen? List the responses
as branches off the main bones i.e. major causes. The causes
identified for each main cause is called Level 1 cause. Similarly Level
1 causes are found for each main cause.
In the next stage, for each level 1 cause, find the possible sub-causes
which would be called Level 2 causes. For each level 2 cause, find
the possible sub-causes which would be called Level 3 causes. One
can go up to Level 4 or 5.
Level 3
Level 1 Cause
Level 1 Cause
Supporting
Ideas Why
students
earn poor
grades?
AVGP
decreased
to 6.0
Equipment Personnel
Procedure
Cause-and-Effect Chart
4. In this step, the different causes are quantified i.e. data
is collected to show that the causes being shown on
the diagram are real. The quantification is represented
with the help of Pareto or any other tool, to fix the
priority in which different causes would be eliminated.