Quality Time Line

„ Pre-Industrial Revolution – Quality

controlled by individual craftsmen who
were involved in all aspects of product.

„ 1875
– Mass production and the notion of division
of labor
– F.W. Taylor’s principles of scientific
management

G. Baker, Department of Statistics

University of South Carolina; Slide 1

Quality Time Line

„ 1925
– Walter Shewhart of Bell Labs introduces
statistical process control

„ 1930
– Dodge and Romig of Bell Labs introduce
acceptance sampling methods

G. Baker, Department of Statistics

University of South Carolina; Slide 2

Quality Time Line

„ 1945 – American Society for Quality Control

„ 1950
– W. Edwards Deming develops a statistically based
approach to continuous quality improvement
– Deming does not get the attention of US
management, but is readily accepted in Japan

„ 1951
– Joseph M. Juran publishes his Quality Control
Handbook, still in use as a reference many
editions later G. Baker, Department of Statistics
University of South Carolina; Slide 3

1
 Quality Time Line
„ 1980
– US management begins to accept Deming’s
approach to continuous improvement
– Taguchi’s approach to product design,
while initially ignored in Japan, is embraced
by Ford Motor Company

„ 1990
– TQM – Total Quality Management
– QFD – Quality Function Deployment
– Six Sigma
G. Baker, Department of Statistics
University of South Carolina; Slide 4

Quality Management in the US

1930-1970
Product Control is the Approach:
‰ Use of statistical sampling of process
output to determine ppm.
„ Acceptance sampling
Quality Department is the Watchdog
„ Separation of Quality and Production
Departments
Problem solving consists mainly of
Firefighting.
G. Baker, Department of Statistics
University of South Carolina; Slide 5

Quality Management in the US

1980’s
„ American manufacturers strive to regain
competitive position.

„ Startto use statistical process control to

understand process variation and reduce
it.

„ Importance of root causes is recognized.

G. Baker, Department of Statistics
University of South Carolina; Slide 6

2
 Quality Management in the US
Quality Effort by Activity

Japanese Companies
Percent Involvement

Job 1

US Companies

Prod Devel Design Manufact Prob Solve

LP Sullivan, “The Seven Stages of Company-

G. Baker, Department of Statistics
Wide Quality Control”, Quality Progress, 5/86 University of South Carolina; Slide 7

Quality Management in the US

1990’s
„ Quality is everyone’s responsibility
– TQM - Push quality issue upstream to
marketing, product design, engineering,
production, etc.
– Quality Function Deployment – translate
needs of customer’s into products
– Six Sigma - disciplined, data-driven
approach and methodology for
eliminating defects in any process.
G. Baker, Department of Statistics
University of South Carolina; Slide 8

Frederick Winslow Taylor

1884: became an executive
at the Midville Steel
company
1898: began to work for the
Bethlehem Iron Company
1903: devised the concept
for the Assembly Line
1911: introduced Scientific
Management, including time
1856 - 1915
studies, work standards and
wage incentives.
G. Baker, Department of Statistics
University of South Carolina; Slide 9

3
 Walter Shewhart
1925 – started at Bell
Labs.

1931 – first addresses the

use of control charts as a
means of detecting and
eliminating sources of
variation that are not
inherent to the process in
Economic Control of
Quality of Manufactured
Product.
1891 - 1967 G. Baker, Department of Statistics
University of South Carolina; Slide 10

Walter Shewhart
„ Shewhart’s control chart principles
– Process measurements are
consistently taken over time
– Data plots over time aid in
converting numbers into information
– Distinction between on-going
variations and episodic variations
support decisions about correction
and improvement of processes
G. Baker, Department of Statistics
University of South Carolina; Slide 11

H.F. Dodge and H.G. ROMIG

H.G. Romig H. G.F.Baker,

Dodge
Department of Statistics
University of South Carolina; Slide 12

4
 H.F. Dodge and H.G. ROMIG
„ At Bell Labs same time as Shewhart

„ Acceptance Sampling
– System of lot by lot inspection of in-
process and finished goods
– AQL (acceptable quality level) is a by
product
ƒ Target level of defective material

G. Baker, Department of Statistics

University of South Carolina; Slide 13

W. Edwards Deming

Out of the Crisis,

1982

The New Economics,

1994

1900 - 1993 G. Baker, Department of Statistics

University of South Carolina; Slide 14

W. Edwards Deming
„ Eminent American Statistician in the 1930’s
and 1940’s
„ Brought statistical thinking and methods to
Japan after WWII; to the US in the 1970’s
„ How to put quality improvement on an
institutional basis rather than a department
basis
„ Obligations and responsibilities of
management spelled out in his “14 Points”.

G. Baker, Department of Statistics

University of South Carolina; Slide 15

5
W. Edwards Deming – 14 Points
(1) Create constancy of purpose for the
improvement of product or service
(2) Adopt the new philosophy
(3) Cease dependence on mass inspection
(4) End the practice of awarding business on
the basis of price tag
(5) Improve constantly
(6) Institute more thorough training
(7) Institute leadership
G. Baker, Department of Statistics
University of South Carolina; Slide 16

W. Edwards Deming – 14 Points

(8) Drive out fear
(9) Break down barriers between
departments
(10) Eliminate slogans and targets
(11) Eliminate work standards
(12)Remove the barriers that rob employees
of their right to pride in workmanship
(13) Institute programs of education and
self-improvement
(14) Put everybody to work to accomplish
the transformation G. Baker, Department of Statistics
University of South Carolina; Slide 17

Plan-Do-Check-Act Cycle
„ Discipline used in process study

Plan for a
Act – change
implement needed to
change if improve
appropriate process

Check impacts Do – test

of proposed change on small
change scale, collect
data

G. Baker, Department of Statistics

University of South Carolina; Slide 18

6
 G. Taguchi
Rather than detecting
defects, let’s design
quality into the product
right from the beginning
(“an ounce of
prevention…”)

Design a
product/process the
performance of which is
insensitive to noise
1924 -
G. Baker, Department of Statistics
University of South Carolina; Slide 19

Traditional View of Loss

Quality Loss

Quality Characteristic
G. Baker, Department of Statistics
University of South Carolina; Slide 20

Taguchi’s Loss Function

Quality Loss

Quality Characteristic
G. Baker, Department of Statistics
University of South Carolina; Slide 21

7
Joseph M. Juran

Main contributions in
the area of Quality
Management.

Initially published
his Quality Control
Handbook in 1951

G. Baker, Department of Statistics

University of South Carolina; Slide 22