Concept of Quality Control

Concept of Quality Control
1.Viewpoints of Control
2. Viewpoints of Assurance
3. Viewpoints of Improvement
4. Statistical Approach
5. Viewpoints of Humanity
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by : AVG
1.1 PDCA Cycle
Fig 1.1
Necessity of PDCA: When an operation is carried out, many people may do the operation randomly and think their jobs are completed when everything is done. The way of job to just Do seems easy, however, it is actually very inefficient.
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1.1 PDCA Cycle
Because when an operation is carried out with an inadequate planning, the operation might be carried out with much time and man-hour increases as a result. It is important to minimize rework or duplication of Operations by making a Plan through the viewpoints such as Fact Control, Priority Principle and others. (Refer to Fig.1.2)
Fig 1.2
1.1 PDCA Cycle Also, quality of operations is improved by Check and Action to reflect results of operations. If the situation changes after a Plan is made, it is necessary to change implementation (Do) of the operation. However, if Check is not carried out, wasteful implementation continues without being noticed. For this reason, turning PDCA Cycle is the fundamental of all operations
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1.1 PDCA Cycle There is no sense in turning the PDCA Cycle !? Someone said: It is just conventional and nonsense.
If PDCA Cycle is proceeded/followed inappropriately, it becomes conventional.

Example of an inappropriate PDCA Cycle. automation rate of production line is 80% or more Is it OK because the achievement is 90%
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1.1 PDCA Cycle
What is the 80% automation rate for?

When 80% or more automation rate is decided as a goal to decrease number of man-hour, even the goal is accomplished, it makes no sense if the number of man-hour does not decrease.
PDCA must be proceeded to fulfill a purpose.
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1.1 PDCA Cycle

Why PDCA is not proceeded appropriately? The way of operation is incorrect (signal of mistake). The reason is not pursued thoroughly. The man-hour for Check and Action is insufficient. What is necessary to proceed PDCA? A purpose and a goal should be clarified. Start with an easy PDCA to built confidence. If PDCA is not proceeded. It cannot be decided whether an operation carried out at the present is correct or not.
1.1 PDCA Cycle
Summary Job has a goal of QCDSM (Quality, Cost, Due date, Safety and Moral). It is important to proceed P D in accordance with the goal. And also it is important to proceed C D absolutely to confirm how much the goal is achieved. It is a fundamental to turn PDCA cycle to achieve a good job.
1.2 Fact Control
- to explain using all the possible data on the basis of fact

What is Fact Control? Fact Control means to carry out jobs using all the possible fact rather than experience or intuition. Control by fact means to explain by data and to objectify subjective judgments.
1.2 Fact Control
Necessity of Fact Control Relying on KKD (Kei ken-experience, Kan-Intuition, Dokyo-Guts) can lead to big risks. Following are Examples: based on KKD, 1)material must cause strength deficiency of this part, but actually the cause was hardening temperature. 2) We were confident that experiences show there is no doubt that next project will be great success, but actually it was just wrong guess.
1.2 Fact Control
Follow the steps to figure out the fact,
[1] Observe actual things at actual places to figure out fact and phenomenon. [2] Decide which data are collected. [3] Clarify how to use data. It is incorrect to collect data without a plan. [4] Collect appropriate data Does sampled data reflect entire picture? Is measuring method appropriate? Is measurement accuracy appropriate? Is measuring instrument reliable? [5] Analyze data by scientific methods (such as QC method and others). [6] Consider and collect accurate information.
1.2 Fact Control
Someone said KKD is quicker and easier. (KEIKEN =Experience, KAN= Intuition, DOKYO= Gut feeling) Data collection takes time and troublesome.
If only KKD is employed: It is true in some case that KKD is quicker and easier. However, total man-hour will increase since lack or redo often takes place. This tendency is especially remarkable for inexperienced persons or even experienced persons when they work on new and inexperienced jobs.
Notes on data collection: Data collection seems time-consuming However, it saves time for trial and error by grasping the fact accurately. In addition, when data is collected, examine the items in advance and avoid collecting unnecessary data.
1.2 Fact Control
Since experience is definitely important, it is not correct to totally discard KKD. KKD is important at the stage such as extraction of problems, clarification of factors, developing of ideas and others. But, KKD is not so reliable as to solve all problems by KKD only. KKD is a special method which can be effected only by considerable experienced persons.
Summery
Nothing indicates the fact better than data.

Appropriate judgment can be made to grasp the phenomenon by the fact as data. In other words, Fact Control means to explain by data.
1.3 Emphasis on Process (Process Control)
Good processes bring Good Results. It is a way of thinking to controlling and improving an operation method to get Good results continuously
Ex-1: Sales division put up an advertisement for a product, and the sales doubled. Going by the success, went for extensive advertisement met no success. Process NG, Results Good Consideration was not given to the content and target reader segment. You can not always succeed.
Ex-2: A screw strength was found not meeting specification.
After reviewing the Design & Process, it was decided to change the material. Strength improved but --Process Good, Results NG
Still this gives an opportunity to investigate further, and chances of success next time is greatly increases.
Why not control by results!?
Someone said
Actually, results are important. Operation is not completed without a good result There is no problem because we have got a good result so far.
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Why not control by results!? It is true that results are important, but... One need to consider whether these Good Results can be reproduced. Even if the results are Bad, can we guarantee that next time also will be Bad and not Good.? On the other hand, if the process leading to Good Results and the sequence of operations are documented -one can always say with confidence next time same results can be obtained even when the process is carried out by another person.
When the results are Bad, by recognising where and went wrong, we can get Good results. Problems can be said treasures. It is A process connecting an operation method and important to check not only a result but also the consequence thereby will be a treasure. a process. The reason why Process Control is important. Bad effect of Result-oriented approach In a system to evaluate things depending on the result, potential things also could be abandoned. And, it is wasteful.
1.4 Standardisation
What is Standardization?
A standard is description which is used repeatedly and commonly to instruct how to make a product or how to proceed an operation. And standardisation is to establish and to utilize the standard.
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1.4 Standardisation
Example: suppose a process to wash a part for 10seconds, and washing time is different for each operator. If washing the part for more than 10 seconds makes no difference in the effect, 15-second washing is a waste. On the other hand, washing less than 10seconds would result in a problem of quality.
Therefore, a standardization of 10-second washing can minimize the variance.

1.4 Standardisation
Advantages of Standardization
Personal/individual unique techniques can be accumulated as companys Techniques. Technical capabilities can be advanced based on the accumulated techniques. Cost reduction and convenience can be advanced by improvement of parts and products compatibility and system consistency.
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1.4 Standardisation
Advantages of Standardization
Inter-department cooperation will be improved to standardize the way to work. Industrial accidents can be prevented by materializing equipment maintenance and accident prevention. Company can contribute to consumers and benefit of society by supplying products which are full of safety and reliability thanks to product specification and others.
Standardization makes no difference!!?-Someone said
Even if an operation is standardized, the standard is not used in fact.

Standardization makes 100 stupid persons (It discourages individual creativeness) operations can not standardised because operations are different each time in our shops
Standardization makes no difference!!?-Can we counter these viewpoints?
Consider to clarify necessary conditions of standardization

It can be carried out It is easily to understand It is easy to follow It will be improved
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Standardisation itself is not the Objective or Goal Thought that standardization cannot be used in fact or cannot be followed may be due to implementation of standardisation without Understanding/considering how it can be applied at the workplace. Operators convenience is not taken in to account. These types of standardization are not standardization we are aiming at.
Standardisation itself is not the Objective or Goal
Also, standardization itself is not the final goal, but must be improved continuously. From another point of view, satndardisation clarifies new problems. Therefore, standardization is carried out to develop technical capability and improvement, and it never results in making 100 stupid persons
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Standardisation itself is not the Objective or Goal Additionally, in the case of different operations each time we can standardise the thinking process. Idea can be used in similar processes and we can get clues to solve the problems. Summary Documentation is not the final step of standardization. The essentiality of standardization is to follow and utilize the standards, and it is important to improve the standards continuously.
1.5 Source Control
Source Control to control operations not

in downstream, but in upstream processes
What is Source Control? It is often said a bad thing must be eliminated at its source. To provide products and service which satisfy customers, it is necessary to go back to upstream processes to find a cause of problem and take measures to prevent detectives from transferring to downstream processes.
1.5 Source Control
Necessity of Source Control
o Prevention is better than Cure is an old saying. Similarly, it is necessary to prevent the mistake at the source is very important rather than defect sorting or reworking to salvage. o A dent or scratch on the car body during pressing operation can not be corrected completely in the subsequent process/es like painting. However well the car was designed, produced and marketed by the sales team can not find acceptance in the market.
1.5 Source Control
Necessity of Source Control If a critical defect is found in a part, o It may call for total re-call of the products from the field, and result in loss of customer trust. o Thus, a defect in upstream affects significantly to the downstream, and the source control is necessary to avoid waste of manpower or labour. So, what we should do for the source control? Key points of the source control are introduced below.
1.5 Source Control
Points of Source Control Mechanism and operational flows of development and quality assurance are to be systematized. Products are to be planned and designed from the users point of view. Operation is to be evaluated at each the next step. If the goal is not accomplished, do not proceed to step of process. Possible troubles are anticipated and to be prevented. A cause of a trouble is to be traced to upstream processes.
Source Control is ldeal !! ?

Someone said
We must take measures for defectives immediately. It is not the time for the source control. Preventing transfer to the following process is easier. Because it is a problem of source, designing or planning section should be responsible. It is true that immediate response is important, but---23 April 2013 by : AVG 32
Source Control is ldeal !! ?
If measures are not taken at the source, it can recur.
Defects in downstream processes affects more significantly.

Whole process can be improved when all departments participate in the source control.
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If measures are not taken at the source, it can recur.
Example: A painting defective was detected in a production line. Cause identified as DUST Handling of the defective product (outflow prevention) Carry out 4S(cleaning) of the periphery (Emergency measure) Investigate entry route of dust and take measures. (Source Control) Without source control, even 4S is carried out, there is a possibility of recurrence.
Defects in downstream processes Affects more significantly. ex: Critical defect is found in a part.
Action after Problem is noticed recall all products in market, Indemnity, abasement of reliance and others (possibility of financial crisis)
Action after shipping recall all products in market (extensive loss) Action in factory (response at manufacturing) Action in design (response at designing)
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change all products (considerable loss) Modification of drawings. (Small no. of man hours)
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1.5 Source Control
Whole process can be improved when all departments participate in the source control. Problems will decrease if even a downstream department points it out from the viewpoint of downstream and consequently, it makes benefit for the downstream process itself.
Summary When a problem happens, symptomatic action tends to be taken. However, it is not a real solution. If the source control is carried out to solve the same problem, you can spend smaller effort in general.
1.6 On-site checking approach
(Genchi Genbutsu)
What is On-site Checking Approach? It is an attitude to go to the source and to identify and analyze the facts objectively.
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Necessity of On-site checking Approach PDCA Cycle and Fact Control mentioned before would be useless if these activities are not based on true facts. For example, if data, measured a measuring equipment with considerable margin of error are analyzed with a prejudice that variation of the measured objects is large, not only correct information cannot be obtained but also time and cost are wasted.
No good company nor good quality can be realized without washing hands 3 times a day. Going to the source and observing the facts are not enough. Diagnosing (watching) using own hands is necessary for products with Quality that can satisfy customers.
Observing is the first step of On-site Checking Approach. However, it would be difficult to figure out the true cause by looking vaguely. How and what to observe ???
1.6 On-site checking approach (Genchi Genbutsu)
Viewpoint for Observation Compare (line up )actual items Look with five senses or even sixth senses (use of high-speed camera and others) Enlarge the objective (eyes/ears/nose/skin/feeling and others) See the movement in a slow speed. Disassemble, cut in section or destroy the object or the product. See the work site when the line is stopped. Carry out the operation by yourself and----so on.
On-site Checking Approach
Someone said
Is it really necessary ! ? ,. Is On-site Checking Approach necessary in this virtual era in which remote monitoring and remote operation are in practical use? I have no time to visit the actual place when Im busy at work. Strict On-site Checking Approach is the fundamental of manufacturing
On-site Checking Approach is necessary, especially in the virtual era. Machines produce products, but the machines are made by human. These machines are handled by human beings. Manufacturing is impossible without developing this human resources. Just considering is not enough, but trying to do by yourself using your hands and feet is important. Then only the Five senses will be developed through frequent repetition of this action.
On-site Checking Approach is necessary, especially when you are busy.
It is not by sitting at the table and considering for a long time but by touching and confirming actual things at the actual place that clarifies problems and helps to proceed with improvement efficiently. Kiichiro Toyota, the founder of Toyota Motor Corporation, once said Professional technicians and engineers are developed with increased flair for technology and ability to refine technology fostered by going to the actual place and confirming actual things.
Summary This is the TOYOTA principle. This attitude and value concept to give attention to facts and to objectively observe things as they are is the biggest stepping stone of Success. On-site Checking Approach, is being observed by each of the TOYOTA group companies as a tradition as well as its source of power.
2.Viewpoint of Assurance
2.1 Quality First Policy
Quality First Policy
to try to ensure profit by supremacy in quality .

What is Quality First Policy? Quality First Policy is an idea to place top priority on quality, satisfying requirements of cost and due date. Here, quality means not only those of product and service, but also quality of all related things such as quality of job and others.
Necessity of Quality First Policy
Because, unlike other problems, a quality problem could be an irrecoverable problem.
Loss due to quality trouble could be enormous since it affects many areas (details on next slide). Also, it is quite difficult to restore the trust once lost. (Cases of * Cadbury's, Colas, recent milk problem & chocolate issue from China, Dairy Industry, auto industry, and tyre industry and so on --). Another example, poor quality of work such as a mistake or a defect in education material not only gives negative effect to the students but also disgraces the department in charge of education material.
Cost Due to Product Quality Troubles
Quality First never permits to neglect cost and delivery, they are as critical as Quality. But they can never allow Quality to be sacrificed.
Is Quality First Policy really necessary! ? Someone said
Quality First Policy concerns only shop floor which manufactures products. It is nothing to do with us because our department doesnt make any products. If a quality problem is dealt with for real, it would cost too much.
It is true that Delivery and Cost are definitely important, but... Quality To plan a product which satisfies of Planning: Customers needs and demands. Quality of Design: Quality of Manufacturing:
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To design a product which is exactly that is planned, has high reliability, and satisfies customers To manufacture a product which is exactly as designed.
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Solving quality problems leads to cost reduction. If a quality problem is solved, various losses decrease, and as a result, the total cost is also reduced in many cases. A car mainly used for shopping does not need a horsepower (quality) like a sports car, but quality attention for this car should be paid on easy handling such as a small radius to turn. As shown in this example, cost reduction could be achieved by selectively solving quality problems.
Summary:
Quality is an important element to influence a customers trust and companys future.

Company must place the first priority on quality. (Supremacy of Quality).
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2.2 Customer-Oriented / Market-in Policy
What is Customer Oriented Policy? It is a way of thinking to figure out customers needs and to provide products or services to meet the needs. We must provide products or services that customers truly need. necessity of customer oriented policy. To make really salable products, it is necessary to pursue customers real demand and to try to reflect the demand to products This is called market-in approach In contrast, a producer-oriented attitude of forcing the producers view to customers is called product-out
<Makers intention and customers reaction>
In the market of small size camera operable with a single touch of button, a company developed and launched the smallest one, which was sold quite well.
After that, they further downsized and brought to the market as a micro camera. However, the micro camera was not sold well because of the operation difficulty and bad design.
Customers never welcome a product which is brought to the market according to companys complacency of the smaller, better to show their the technical ability. And it is important to figure out real demand of customers.
Customer- Oriented Policy is endless!?
Someone said
If all demands of customers are to be satisfied, it will be never done. For example, 100 types of products should be supplied to satisfy 100 customers. Is all we have to do just to satisfy customers?
It is true that satisfying the demand of all customers is difficult, but

Limit the target customers to meet their demands.
Custom-made could be a choice. However, may not find many customers due to some negative factors, such as exceptionally high price or a long delivery time.
Therefore, it is necessary to find out customers demands.

If any trend of demands cannot be figured out, statistic view makes it possible to figure out and to stratify the main demands of customers. As a result, a product thus produced is differentiated from others and has more possibility to have advantages in cost, delivery time and satisfaction than custom-made ones.
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Do not forget corporate responsibility.
For a company, it is necessary to pursue profit.

However, every company has social responsibility and role to contribute to establish a sound society, such as cooperation with the society or responsibility to environment. Therefore, companies should not sell their product against their responsibility and role.
Summary: it is better to think that profit is reward for satisfying customers. Therefore, a product or a service which can be provided only at a price without profit does not fit the customer-oriented policy. It is important to provide a product or a service that can satisfy customers and at the same time make a profit.
2.3 The Next Processes Are Your Customers
to provide a product or a service which satisfies downstream processes

What does Next processes are your customers mean? The next processes mean the processes influenced by the result of your own job. Next processes are your customers teaches you to consider your work to be taken over by the next process with pleasure.
For example, if a problem is found even it does not affect your own process it is important to have an attitude to take measures against it without neglecting it. Following points are important to have such an attitude.
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To communicate well with the earlier process and the next process in order to obtain defect -information and to avoid miscommunication. To establish judgment criteria in order to avoid ambiguity of judgment whether the next processes are affected or not. Necessary points for attitude of next process is to consider from the viewpoint of your downstream processes: To be familiar with the role of the your own process and the following ones.
It is hard enough to do my own work, why do I have to think of the next process! ?
Someone said
-This defective will not be conveyed because it is inspected in the next process. - Considering the next process results no benefit to me but too much job. -It is not my responsibility, since the earlier process is blamed for.
It is true that any detectives should not be
conveyed to the following process, but...

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The reason to pay a great attention to next processes. -To produce only the product the next process
demands.
>Detectives are themselves loss even they are not transferred to the market. Additionally, the more manufacturing proceeds in the next processes, the more loss arises. If loss is taken into account, finding defects by inspection is not enough.
>Building quality into your process will finally help you because you do not have to produce unnecessary products.
Loss of end users credibility is loss of the entire company. --It is sure that the former process is responsible for defectives in the former process. However, if a defective is not found out and an operator neglects the defective in the next process, end users will be in trouble with it. As a result the entire companys credibility will be lost.
> If a defective from the former process is found, do not neglect it nor convey it out to the next Process.
Loss of end users credibility is loss of the entire company. It is sure that the former process is responsible for defectives in the former process. Summary: However, if a defective is are notyour found out and Practicing the next processes customers inan all processes will result in helping you and benefit to operator neglects the defective inbringing the next the company. process, end users will be in trouble with it. As a result the entire companys credibility will be lost. If a defective from the former process is found, do not neglect it nor convey it out to the next Process.
3.1 Priority Principle
What is Priority Principle?
It is an idea to utilize finite resources (manpower, material, money, time and others) and to maximize the effect by mean of selecting critical problems among many problems and work on the critical ones by priority.
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Problems with serious and wide influence. (Importance) Problems expanding influence and scale if left unsolved. (Expanding tendency) Problems causing serious result without immediate measures. (Urgency) and so on 100 96
60 50 40 30 20 10 0 A B C D 48 100 90 80 70 60 50 40 30 20 10 0 84
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3.1 Priority Principle Is Priority Principle obligatory!?
Someone said
There are a lot of important problems, and every problem is important. Despite Priority Principle, I tend to work on immediate problems
The idea of Priority Principle is necessary to enhance quality and benefit.

There is a priority where there are more
than one problems.
1) Even if there are many important problems, an order of priority can be fixed. First, list and organize actual problems, and then, the order of priority is decided taking demand, effect, possibility to realize and others in consideration.
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There is a priority where there are more
than one problems.
2) It is useful to evaluate important problems in
your section objectively comparing with important problems of third parties such as other groups, other sections, other divisions and others. On this occasion, it is important to look over the entirety and to give the highest priority to optimize the whole.
Evaluation index for priority is
important.
In some cases, immediate unimportant problems must be done. Problems with more importance do not necessarily have higher priority. It is necessary to decide the order of priority comprehensively according to the importance, expansion tendency, urgency and others.
Summary To develop quality and benefit and to proceed work efficiently, it is necessary to be conscious of Priority Principle, to clarify the order of priority of problems and challenge, and to utilize the limited resources.
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3.2 Problem Solving Steps
What are Problem Solving Steps?
Job is a series of problem solving. Problem is a gap between expected and actual situation. Solving a problem is to bridge the gap between these situations.
Problem Solving Steps are steps to go through in order to solve problems reasonably, scientifically, efficiently and effectively.
Understanding of problems
Functional Analysis
Understanding the actual situation

Countermeasure planning Evaluation & Confirmation
Goal Setting
Execution of countermeasure
Standardisation & fallow up
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KKD (experience (KEIKEN), intuition (KAN), & guts (DOKYO)) can be use to solve problems!?
Someone said
Problem Solving Steps are time-consuming. It is easier and results are better to solve a problem by KKD. (experience, intuition and gut feeling)
It is often the case that KKD does not contribute to effective problem solving.
Importance of Problem Solving Steps
If you use KKD easily to solve a problem, conversely the problem would become complicated, and thereby you would miss a real cause, take an inconsequent measure or symptomatic treatment.
That is, it takes considerable time. - -
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Importance of Problem Solving Steps If your experience or skill is not enough, the problem cannot be solved well. If your intuition does not hit, it will be impossible to solve the problem in some cases. Sometimes, it is also useful to utilize KKD to proceed the problem solving smoothly. While the basic steps are proceeded, sometime, it is necessary to use knowledge and experience and take guts at execution.
Summary For a reasonable, scientific, efficient and effective problem solving, it is necessary to solve a problem step by step according to Problem Solving Steps, and an unfailing result will follow.
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3.3 Recurrence Prevention
What is Recurrence Prevention?

It is to figure out the primary causes of a problem and to carry out improvement or measure which eliminates the causes in order to prevent the problem from recurring.
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Necessity of Recurrence Prevention
1n this situation, the problem can be recurred. (Ex.) An in-house equipment was broken and production temporarily stopped.
After checking the situation, it was found that the cause is wear of driving part. Therefore, the part was replaced with a new part immediately to resume the normal operation.
(1) Ask repeatedly why did the problem happen? (2) Why was not the problem found in advance?
(1) Why did that problem happen? Designers knowledge about material wear was insufficient. Why was it impossible to detect the problem in advance? There was no quality evaluation system for in-house facility. As just described, it is necessary to step into the heart of a problem such as work practices and job system. The Recurrence Prevention is completed in a real meaning when a measure is taken to eliminate the cause completely. (for example, education of material wear to designers).
Two viewpoints for detecting causes
Even a measure is taken, problems actually occur repeatedly!?
Someone said
Whatever measures are taken, mistakes will happen. So, similar problem could happen again. Even a measure is taken, a different problem could happen next.
Even if Recurrence Prevention is carried out, trouble may not be eliminated.

lt is important to improve continuously.
If causes of problem are grasped superficially, you will have a doubt mentioned above about the recurrence prevention. The idea to continuously improve the base of operation such as work practices and job system underlies for the purpose of recurrence prevention.
In that way, an effect may not appear immediately. However, problems will be certainly decreased by taking such measures continuously.
Major Measures for Recurrence Prevention Documentation and revision of various standards such as operating standards, technical standards and others. Thorough educational training, and review and improvement of education method. Artifice and improvement for materials, equipment, work method and others. Establishment of system where activities mentioned above can be carried out continuously.
Summary
Mistakes are inevitable in jobs. It may be not be exaggeration to say that persons, work sites and companies which do not carry out real recurrence prevention can not be improved forever.
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3.4 Proactive Prevention
What is Proactive prevention

It is an idea not to take a measure after problem is happen, but to predict a problem and to take a measure such as prior elimination of a cause to prevent the problem.
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>It is no wonder for a company to take an action faithfully and quickly for the troubles caused by it. >It is better that a problem does not exist right from the beginning. Because it takes time, energy and manpower. >It causes a company to lose confidence if a problem is treated afterward. >Therefore, it is necessary to make an effort to prevent a problem.
Stage Plan Consideration Possible problems should be figured out at this stage. Control points should be decided at the time of implementing Should be carried out as planned
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Effective methods
Quality deployment, Design review, FMEA, FTA, ---etc;. Quality deployment, process FMEA, QA system chart, QC process chart ---
Do
Check & Act

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Effective feedback for improvement

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Proactive prevention takes too much effort and is less efficient by contrast.
Someone said
Certain degree of trouble cannot be helped.

Recurrence prevention is all we can do
You may have difficulty in material and money
are invested understanding for a potential why manpower, problem, but...

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The reason to focus on elimination of anxious matters The primary reason to lose customers credibility is a trouble. Therefore, anxious matters should be eliminated by all means. Cost aspect Followup measures for defects cause big damage of defect part handling and correction. Additionally, if it results in recall of product from the field, it would cost much more the cost for Prevention in Advance.
Technical aspect A person whose job has problems one after another can not be considered full-fledged, He/she is considered independent when problems are prevented in advance Summary Proactive prevention earns the trust of customers and reduces cost. It also promotes selfdevelopment in ability to consider well and to think ahead.
3.5 Stratification
What is Stratification? It is to focus on similarity and characteristic of data and to classify (make groups) the data thereby so that complicated matters are simplified.
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3.5 Stratification
mm
mm
Painting operation showing the variation in film thickness. The data does not clarify what & where is the problem.
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When we stratify the data wrt man, machine, material, shift/ day, we get clarity. In this case, line B- is showing higher paint thickness.
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3.5 Stratification
Category Examples Individual, age, gender, group, shift, experience,-Type, model., old and new, capability, lines, molds, Manufacturers, lots, components, storage period --Temperature, pressure, speed, procedure -Day, am/pm, day/night, start/finish of operation, season ---measurement equipment, measurement methods, investigation methods --temperature, humidity, weather, with/without vibration and dust,-----by : AVG 93
1
2 3 4 5 6 7
Man / Human
Machine Material Method/ condition Time Measurement/ Investigation Environment
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3.5 Stratification
Clarify feature of data. If feature of data (character or history) is clarified in advance, the data can be stratified by various viewpoints.
Classify data by various viewpoints Dont give up the idea of stratification, even if difference cannot be found when data is stratified from certain viewpoint. The viewpoint of the stratification may not be proper. So it is important to shift your viewpoints to another (apply other view points and methods) and stratify the data again.
3.5 Stratification
Summary The concept of stratification is essential for early detection of problems and exact countermeasure planning. In addition, we have SQC methods to carry out stratification easily and freely.
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4.1 Utilisation of QC Methods
What are QC Methods? QC methods are tools to visualize data and consideration. It is called QC methods because originally they were used in Quality Control (QC). The methods are useful for efficient operations if used in each step of problem solving procedure.
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4.1 Examples of QC Methods
QC seven Tools
Cause & Effect Diagram Pareto Diagram Graphs Check sheets Histogram Scatter diagram Control Chart
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QC seven Tools (New)

Systematic diagram Arrow diagram Matrix diagram Affinity diagram
Association diagram Distribution diagram
Statistical methods
Design of experiments Regression analysis Cluster analysis Factor analysis
Multivariate analysis
Others
Sampling method Reliability engineering FTA FMEA Weibull paper Sampling inspn method
Correlation analysis
PDPC method
by : AVG 97
If QC methods are utilized...
If the data is expressed by words or writing...
It is possible to evaluate data (information) at a glance and to figure out points and problems. Utilizing QC Methods visualizes data and enables to ask other people and intellectuals. Therefore, it eventually a shortcut to solving problems.
How data is conveyed depends on expression ability of senders, and sometime they fail to inform their exact intention. Therefore, too much effort is necessary in communication. It is sometimes difficult to arrange ones thoughts and to make judgments because an enormous amount of data should be organized all by themselves.
by : AVG 98
23 April 2013
Summary By utilizing QC methods, it is easy to carry out Data (information) Stratification, Priority Principle, Dispersion Control. Solution will be figured out effectively and efficiently if QC Methods are utilized with the viewpoints of what you want to get from the existing data. Thereby, it is possible to proceed an operation appropriately and efficiently.
5.1 Respect for People
Human beings have feelings to develop themselves, to delight customers and to contribute to the society. It is necessary to respect these feelings.
23 April 2013
by : AVG
100
X-theory (Negative thinking) A viewpoint of humanity that human beings are basically lazy and they dont work unless they are American scholar Douglas McGregor suggested that participation into decision-making, controlled by carrots and sticks. responsible and challenging work and Y-theory (Positive thinking) good relationship among co-workers A viewpoint of humanity that human beings are maximize motivation to work. basically diligent and they work autonomously without being told if conditions and environments are set up.
23 April 2013 by : AVG 101
Is Humanity Respect necessary!? I wish operators to carry out operations just as instructed without exercising their creativity
No one tries to be proactive in working..
23 April 2013 by : AVG 102
By respecting humanity Operators will perform their work with motivation and efficiency will be improved. Substantial growth will be promoted in work skill problem solving ability. Once the growth is promoted
More advanced problem solving can be challenged. The quality level can be further improved.
23 April 2013 by : AVG 103

Concept of Quality Control

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Concept of Quality Control

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Concept of Quality Control

If PDCA Cycle is proceeded/followed inappropriately, it becomes conventional.

What is the 80% automation rate for?

PDCA must be proceeded to fulfill a purpose.

- to explain using all the possible data on the basis of fact

Nothing indicates the fact better than data.

Therefore, a standardization of 10-second washing can minimize the variance.

Even if an operation is standardized, the standard is not used in fact.

Consider to clarify necessary conditions of standardization

Source Control to control operations not

Necessity of Source Control

Source Control is ldeal !! ?

Source Control is ldeal !! ?

If measures are not taken at the source, it can recur.

Defects in downstream processes affects more significantly.

to try to ensure profit by supremacy in quality .

Quality is an important element to influence a customers trust and companys future.

It is true that satisfying the demand of all customers is difficult, but

Therefore, it is necessary to find out customers demands.

For a company, it is necessary to pursue profit.

to provide a product or a service which satisfies downstream processes

conveyed to the following process, but...

What is Priority Principle?

The idea of Priority Principle is necessary to enhance quality and benefit.

than one problems.

than one problems.

2) It is useful to evaluate important problems in

Understanding the actual situation

Standardisation & fallow up

That is, it takes considerable time. - -

What is Recurrence Prevention?

Two viewpoints for detecting causes

Even if Recurrence Prevention is carried out, trouble may not be eliminated.

What is Proactive prevention

Check & Act

Effective feedback for improvement

Certain degree of trouble cannot be helped.

You may have difficulty in material and money

are invested understanding for a potential why manpower, problem, but...

QC seven Tools (New)

If the data is expressed by words or writing...

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