Total Quality Management

Unit-III
 Unit-3
• Check list, Flow Chart, Tally charts and
Histograms, Graphs, Pareto Analysis ,Cause
and Effect ,Scatter diagram and regression
analysis.
• Quality Function Deployment-Introduction,
Customer needs, Customer priorities and
competitive comparisons and planned
improvements,
• Design features or requirements
 7 QC tools
• The 7 QC tools are fundamental instruments to
improve the process and product quality.
• They are used to examine the production
process, identify the key issues, control
fluctuations of product quality, and give solutions
to avoid future defects.
• When an organization starts the journey of
quality improvements, the organization normally
has many low hanging fruits; which should be
tackled with these basic 7 QC tools.
 What are the 7 QC Tools?
The 7 QC tools as defined by the American Society
for Quality (ASQ) and accepted throughout the
quality engineering community include:
• Cause-and-Effect Diagrams / Fishbone Diagram
• Pareto charts
• Control Charts
• Scatter diagrams
• Histograms
• Flowcharts
• Checksheet
 Cause-and-effect diagrams
• Fishbone Diagram helps organize ideas and
understand the relationship between
potential causes and an effect or a problem
by formatting, arranging and organizing
potential causes into themes and sub-themes
in preparation for a cause identification
effort.
 Steps for using the tools
• Step 1 - Properly identify the problem in hand
• Step 2 - Add the major factors that contribute
to the problem
• Step 3 - Identify the causes
• Step 4 - Diagram analysis
 Pareto Chart
• A Pareto Chart is a graph that indicates the
frequency of defects, as well as their
cumulative impact. Pareto Charts are useful to
find the defects to prioritize in order to
observe the greatest overall improvement.
• The Pareto Principle states that 80% of the
results are determined by 20% of the causes.
• Therefore, you should try to find the 20% of
defect types that cause 80% of all defects.
 Control Chart
• Control charts are a key part of the management
reporting process that have long been used in
manufacturing, stock trading algorithms, and process
improvement methodologies like Six Sigma and Total
Quality Management (TQM).
• The purpose of a control chart is to set upper and
lower bounds of acceptable performance given normal
variation.
• In other words, they provide a great way to monitor
any sort of process you have in place so you can learn
how to improve your poor performance and continue
with your successes.
 Scatter Diagram
• A scatter plot can suggest various kinds of
correlations between variables
• Correlations may be positive (rising), negative
(falling), or null (uncorrelated).
 Histrogram
• A histogram is an approximate representation
of the distribution of numerical data.
• It was first introduced by Karl Pearson.
• To construct a histogram, the first step is to
"bin" (or "bucket") the range of values—that
is, divide the entire range of values into a
series of intervals—and then count how many
values fall into each interval.
 Flow Chart
• A flowchart is a visual representation of the
sequence of steps and decisions needed to
perform a process.
• Each step in the sequence is noted within a
diagram shape.
• Steps are linked by connecting lines and
directional arrows.
• This allows anyone to view the flowchart and
logically follow the process from beginning to
end.
 Check Sheet
• A check sheet is a structured, prepared form
for collecting and analyzing data. This is a
generic data collection and analysis tool that
can be adapted for a wide variety of purposes
and is considered one of the seven basic
quality tools.
 Quality Function Deployment (QFD)
• QFD is a focused methodology for
carefully listening to the voice of the
customer and then effectively responding
to those needs and expectations.
• Beginning with the initial matrix, commonly
termed the House of Quality, the QFD
methodology focuses on the most
important product or service attributes or
qualities.
House of Quality : Development process for a food processor
Step 1: Capture customer requirements
Step 2: Weigh customer requirements
Step 3: Competitive analysis from the customer’s perspective
Step 4: Define product attributes
 Step 5: Determine direction of improvement
•Up arrow: The attribute has to be increased in order to optimize it
•Down arrow: The attribute has to be decreased in order to optimize it
•Circle: A target value is desired
 Step 6: Determine relationships
•If there’s no connection at all, you specify a value of 0 or leave the field blank.
•A weak relationship is given a score of 1.
•A medium relationship is ranked 5.
•A strong relationship is rated 9.
Step 7: Analyze interrelationships
Step 9: Competitive analysis from the
engineer’s perspective
Step 10: Define target values
 What are the benefits of the house of quality?
• The house of quality offers several advantages.
• The first benefit comes from simply creating the
diagram. Employees from different departments come
together and collaborate on the house of quality.
• This inevitably leads to constructive discussions. The
input from different departments ultimately ensures a
high-quality, long-lasting, and successful product.
• There are also advantages once the house of quality is
fully completed.
• Thanks to visualization, a lot of important information
for planning and development is available at a glance.
• Teams can repeatedly consult the diagram with its
graphs and matrices throughout the product
development.