GROUP C (TOOLS TO MEASURE QUALITY)

Dr.Akbar Hussain Zeeshan khan Sudhir Hareesha Dr. Pavneet Chona Shailja

BASIC TOOLS BY Dr. Akbar and Zeeshan

INTRODUCTION
THE ICEBERG MODEL:
This was given by Barbara Lawton in 1996. The model gives a framework for representing quality improvement tools and methods. This model is divided into three parts: FOUNDATION: This part represents theories ,paradigms, assumptions etc which lie deep under the surface and actually shapes the systems and process we design. MIDDLE PART: This part represents the part under surface which is not seen and is shaped by our theories,eg: six sigma and lean thinking these are the process that provide effective integration of the different tools. TIP: This part represents the tools, methods etc which are like logical results of the process eg:basic tools(check sheet, control chart),management tools(affinity diagram etc),creativity tools(brainstorming,word and picture associations) etc.

The ice berg model: foundation and middle part invisible and tip is visible.

Basic tools
Check sheet: The check sheet is a simple document that is used for collecting data in real-time and at the location where the data is generated. The document is typically a blank form that is designed for the quick, easy, and efficient recording of the desired information, which can be either quantitative or qualitative. When the information is quantitative, the check sheet is sometimes called a tally sheet.
A defining characteristic of a check sheet is that data is recorded by making marks ("checks") on it.

A typical check sheet is divided into regions, and marks made in different regions have different significance. Data is read by observing the location and number of marks on the sheet. 5 Basic types of Check Sheets:

Classification: A trait such as a defect or failure mode must be classified into a category. Location: The physical location of a trait is indicated on a picture of a part or item being evaluated. Frequency: The presence or absence of a trait or combination of traits is indicated. Also number of occurrences of a trait on a part can be indicated. Measurement Scale: A measurement scale is divided into intervals, and measurements are indicated by checking an appropriate interval. Check List: The items to be performed for a task are listed so that, as each is accomplished, it can be indicated as having been completed.

HISTOGRAM

A histogram is a graphical representation, showing a visual impression of the distribution of data. It is an estimate of the probability distribution of a continuous variable and was first introduced by Karl Pearson

SCATTER DIAGRAM
A scatter plot or scattergraph is a type of mathematical diagram using Cartesian coordinates to display values for two variables for a set of data. The data is displayed as a collection of points, each having the value of one variable determining the position on the horizontal axis and the value of the other variable determining the position on the vertical axis. This kind of plot is also called a scatter chart, scatter diagram and scatter graph.

Basic tools
Continued by zeeshan

CAUSE AND EFFECT DIAGRAM:

It was developed by Kaouru Ishikawa in 1943 and is sometimes referred as Ishikawa or Fish-bone diagram. This diagram is composed of lines and symbols designed to represent a meaningful relationship between an effect and its causes. CE diagrams are used to investigate either bad or good effects. It consists of effect on right side which represents quality characteristics that needs to be improved and on left of diagram is its causes which are divided into major and sub-divided into minor. USES: To analyze actual conditions for the purpose of product or service quality improvement and efficient use of resources. Eliminate conditions causing non conformity. Standardize existing operations. Educate and train the personnel to take corrective actions.

PARETO DIAGRAM:
A Pareto chart is a display of frequency of occurrences that help to show VITAL FEW contributors to problem and to take corrective measures to solve them. This chart is named after an Italian economist,Vilfredo Pareto who conducted this study . Later, Dr.Joseph Juran applied this Pareto principle to other applications and found that 80% of variations of any characteristic is due to 20% of possible variations. He coined the phrases VITAL FEW AND USEFUL MANY. This graph ranks the data classification( problems, complaints) in descending order from left to right.
USES: Helps a team to focus on those causes that will have the greatest

impact if solved. Displays the relative importance of problems in a simple, quickly interpreted, visual format. Helps prevent shifting the problem where the solution removes some causes but worsens others

RUN CHART:
It is a line graph of data points plotted in chronological orderthat is, the sequence in which process events occurred and its performance over a specified period . Run Charts are used to assess and achieve process stability by highlighting signals of special causes of variation (trends ,run, cycles). If no trends are seen then the average(median) is calculated= sum of measured values of variable no of data points in chart USES: Using Run Charts can help you determine whether your process is stable (free of special causes), consistent, and predictable. Monitors the performance of one or more processes over time to detect trends, shifts, or cycles. Allows a team to compare a performance measure before and after implementation of a solution to measure its impact.

CONTROL CHART:
This is a run chart which consists of chronological data with upper and lower control limits of common cause variation .It is also called as Shewhart or Process behavior chart. There is a central line which represents the mean value on the chart, diamond shaped points represent data points and limits are chosen so that these points fall within the limits. IN-CONTROL PROCESS :This is the natural or expected situation in which there is stable pattern of random causes which are of less importance and requires management intervention to improve process. Here control limits are at 3sigma distance from median and out of 1000 items 997 lie in limit as in normal distribution curve. OUT-OF CONTROL PROCESS: unnatural situation, assignable causes larger in magnitude, requires correction by people close to the process.

PROCESS MAPPING:
Process mapping is a tool that is used to understand, analyse and document processes and activities in an organisation and assist in identifying opportunities for improvement. It is also called process chart or flow chart. A process map displays the sequential steps involved in converting a specific input into the required output.

Typical reasons for conducting process mapping include: To improve a process, you must understand the process Analytical skills and process mapping skills allow us to understand and communicate processes to management, staff and users.

Shows unexpected complexity, problem areas, redundancy, unnecessary loops, and where simplification and standardization may be possible. Compares and contrasts the actual versus the ideal flow of a process to identify improvement opportunities

Advantages of Process Mapping:

Process mapping can be extremely valuable because it can identify improvements in a number of aspects in the work place, including: Increases understanding of the work process Provides understanding of resource allocation Documents training procedures Tracks workflow Increases staff awareness

Turn TV On

Start/End
Does picture come on? No Is TV plugged in? Yes

Decision
Yes

No

Plug in TV

Activity
Is picture good? Yes Does picture come on? No

Call TV repair man

No Yes

Adjust knobs

Is picture good?

No

Watch program

Yes

MANAGEMENT TOOLS BY Hareesha And Pavneet

 These tools are used to analyze conceptual and qualitatively oriented information that may be prevalent when planning organisational change or project management.

1. Affinity diagrams:
Encourage people to develop creative solutions for problems. List of ideas are created. Individual ideas are written on small note cards. Team members study the cards and group the ideas into common categories. It is a type of brain storming session.

2. Current Reality Tree:

It is the part of the TOC tool kit It employs cause and effect logic Identifies the root causes or the core problems Determines what to change Another purpose of the current reality tree is to create consensus among those involved with a problem.

3. Interrelationship diagraph:
It helps to identify patterns of cause and effect between the ideas Helps the management to recognize the patterns ,symptoms and causes of systems of resistance that can emerge through the development of plans and actions It helps to pinpoint the causes of problems that appear to be connected symptoms.

4.Matrix diagram:
It helps to answer two important questions when sets of data are compared Are the data related? How strong is the relationship is? It lists customers needs on one axis and the in-house standards on the second axis It ensures the completion of the tasks Eg: the quality function deployment house of quality

5. Priorities matrix:
When there are more tasks than the available resources then the management has to prioritize based on the data rather than emotion It prioritize the criteria that have the most influence on the decision Study the possibilities.

6. Tree diagram:
It identifies the tasks and methods needed to solve a problem and reach a goal Creates detailed and orderly view of the complete range of tasks that needed to be accomplished to achieve a goal Tree diagram can be used when once the affinity and interrelationships diagraphs has identified the primary causes and relationships.

Management Tools
Continued by

Pavneet

Process Decision Program Chart Programs to achieve particular objectives do not always go according to plan, and unexpected developments may have serious consequences. the process decision program chart(PDPC) avoids surprises and identifies possible countermeasures.

OBJECTIVE

Plan successful conference

Registration

Presentation

Facilities

WHAT IF

Speakers late

Audio/visual fails

Too long

COUNTER MEASURES

HAVE
SUBSTITUTE

Have backup

Use timekeeper

o
Use AV person

o x

PDCA FOR CONFERENCE PRESENTATION

Arrow Diagram
Purpose: To show the paths to complete a project, find the shortest time possible for the project, and graphically display simultaneous activities.

FAILURE MODE AND EFFECT ANALYSIS(FMEA) Step 1: Severity

Determine all failure modes based on the functional requirements and their effects. Examples of failure modes are: Electrical short-circuiting, corrosion or deformation. Each effect is given a severity number (S) from 1 (no danger) to 10 (critical). These numbers help an engineer to prioritize the failure modes and their effects. Step 2: Occurrence In this step it is necessary to look at the cause of a failure mode and how many times it occurs. A failure mode is given an occurrence ranking (O), again 1 10. Actions need to be determined if the occurrence is high

Step 3: Detection
The proper inspection methods need to be chosen. First, an engineer should look at the current controls of the system, that prevent failure modes from occurring or which detect the failure before it reaches the customer. From these controls an engineer can learn how likely it is for a failure to be identified or detected.

Risk priority numbers

After ranking the severity, occurrence and detectability the RPN can be easily calculated by multiplying these three numbers: RPN = S O D This has to be done for the entire process and/or design. Once this is done it is easy to determine the areas of greatest concern. A few logical but important thoughts come in mind:
Try to eliminate the failure mode (some failures are more preventable

than others)
Minimize the severity of the failure Reduce the occurrence of the failure mode Improve the detection

POKA YOKE
Poka-yoke [poka joke] is a Japanese term that means "fail-safing" or "mistake-proofing". Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur  The concept was formalised, and the term adopted, by Shigeo Shingo as part of the Toyota Production System.

Implementation in manufacturing
Poka-yoke can be implemented at any step of a manufacturing process where something can go wrong or an error can be made. For example, a jig that holds pieces for processing might be modified to only allow pieces to be held in the correct orientation, or a digital counter might track the number of spot welds on each piece to ensure that the worker executes the correct number of welds.

Either the operator is alerted when a mistake is about to be made, or the poka-yoke device actually prevents the mistake from being made. In Shingo's lexicon, the former implementation would be called a warning poka-yoke, while the latter would be referred to as a control poka-yoke.[

Relations Diagram
Relations Diagrams are drawn to show all the different relationships between factors, areas, or processes. Why are they worthwhile? Because they make it easy to pick out the factors in a situation which are the ones which are driving many of the other symptoms or factors. For example, a relations diagram of urban poverty might start out something like this:

Drug use is endemic High unemployment Business leaves the area

There are youth gangs

There is high crime rate

High rate of divorce Property value falls High rate of non marriage Schools gets worse High rate of teen pregnancy People who can afford to leave .leave

ADVANCED TOOLS PRESENTED BY SHAILJA

1.Value stream analysis 2.ANOVA 3.EVOP 4.Hypothesistesting 5.Measurement System Analysis

1.Value stream analysis:

It helps to understand and streamline work processes using tools and techniques of lean manufacturing. The goal of VSM is to identify, demonstrate and decrease the waste in the process. It is also used as strategic planning tool.

2.ANOVA:
ANOVA is used to test whether the means of many samples differ but it does so using variation instead of mean. It compares the amount of variation within the samples to the amount of variation between the means of samples. ANOVA provides an effective technique to separate inherent variance and special cause variance (i.e., group effect variation).

3.EVOP:

Evolutionary operation. EVOP is an ongoing mode of using an operating full-scale process, so that information on how to improve the process is generated from a simple experimental design while production is underway.

4.Hypothesis Testing:
A statistical hypothesis test is a method of making decisions using data, whether from a controlled experiment or an observational study (not controlled). Hypothesis testing is sometimes called confirmatory data analysis. In frequency probability these decisions are almost always made using null hypothesis tests.

5..Measurement System Analysis:

A Measurement system analysis (MSA) is a specially designed experiment that seeks to identify the components of variation in the measurement. MSA analyzes the collection of equipment, operations, procedures, software and personnel that affects the assignment of a number to a measurement characteristic. A Measurement Systems Analysis considers the following: Selecting the correct measurement and approach Assessing the measuring device Assessing procedures & operators Assessing any measurement interactions.

CREATIVITY TOOLS BY SUDHIR

Brainstorming
Prepare the group Define the problem Generate a large number of ideas quickly. No criticism or debate Freewheel Mutate and Combine : modify existing ideas and try to build new ideas from combinations of existing ones. It takes around 30 minutes to an hour. Can be shorter or longer, depending on the difficulty of the problem . Quick
Logical Individual

X
X

Long
Psychological X Group

Knowledge Maps
One objective (quality improvement) Breaking down. Distributing the work or role. We can identify knowledge gaps. what is needed.

Picture Associations
At time of the discharge of the patient is smiling, he/she satisfied. what has improved. If there is no expression, the services are normal. what should we improve. The patient is not in a mud to talk and he/she angry, that means he/she dissatisfied. improve all the services. We are in the starting stage

Word- Associations & Problem reformation

Giving the feedback form to rating our serves: 1. Excellent 2. Good 3. Average 4. Poor

The problem which is identified , how we should do the reformation. Review the possible causes. What is the problem which solutions should be taken. It should be repeated.

Morphological Box
To map out all the combinations of potential solutions that address the essential parts of a problem.
Helps to identify all of the parts of the problem that must be addressed to reach a successful solution. Builds a table that helps to display options for solving each essential part of the problem. Builds a table that helps a team to evaluate several solutions at one time.

TILMAG
It is structured and systematic approach It helps a team to define ideal solutions for the problem. It uses the ideal solution as a starting point. The team identifies the Ideal Solution Elements (ISEs). An ISE is a function or attribute that any potential solution must have.
Create no more than six ISEs that are: - Specific for the given problem - Described in a positive way - Free of jargon - Brief (six words or less), but precise - Tied to customer demands (especially when developing a new product/service

THANKS