Ethiopian Kaizen Institute

Quality Control Circle (QCC)

By: Fekadu Abate

Jan, 2018
 Remember!
-Kaizen is a continuous
improvement of quality &
productivity through workers
participation.
 Outline

Basics of QC Circle activity

QCC introduction process

PDCA cycle

Steps of problem solving (QC story)

Example of QCC activity

 What are QC Circles?

• QC Circles are small groups consisting of front-

line employees who continually and collectively
find a problem and discuss on alternative
remedies to control and improve the quality of
their work, products and services.
 cont….
The members are from the same section
that do the same type of job in order to
have common understanding of problems
and all members participation.
 Basics of QC Circle Activity
• 5-7 (3-10) members
• Has a Leader and Secretary. Leaders
can be from supervisor or leading person
in the workplace.
• Regular meeting at least once every week
for 15 or 30 minutes.
• QCC have to do continuous improvement
activities by tapping members creativity
 Kaizen team members

Mr. Cheru Dubale Mr.Zewudu Abebe

chairman Secretary

Mr. Solomon Mr. Gebeyehu Mr. Shifa Mr. moges

 Cont….
All members participation is required in QCCs.
QCCs solve problems autonomously related to
workplace such as:
• problems of quality, cost,
• problems of morale and safety,
• improvement of service and quality of
work,
• etc.
 Cont….
QCCs use several kaizen tools like QC 7 tools
(Pareto diagram, Fishbone diagram etc), 5S,
Brainstorming, Why-Why Approach, 5W1H etc.

There should be Coordination between QC

circles.
 Types of QCC

 Sub-Circles: if a workplace consists

of more than 7 or 10 employees, it is
better to form more circles (sub
circles), Or if there is shift operation.
sub-circles should have joint meeting
once every 1 or 2 months.
 Cont….
Joint Circles: also called united circles or collaborative
circles. Occurs when..
1)several circles work together to
tackle a single problem
2)When QCC exchange information to tackle
the same problem
3)several QCC work on a significant theme
divided into sub themes.
4) part or all of the members join other QC
circles.
 Cont….
Theme-driven QCC: to solve a problem
effectively, a small group may be formed by the
members from several different sections or
departments or managerial posts.
• The circle is dissolved after the successful
solution of the theme. Its members launch a
different QCC activity under a new theme in
collaboration with other individuals.
 Aims of QCC Activities
To develop members capabilities

To make the workplace more pleasant, vital

and satisfying.

To improve customer satisfaction and

contribute to society.
 Cont…
To create good workers relationship or team
spirit through close discussion.

To develop recognition of importance of

work and raise responsibility.

To establish discipline in workplace and do

proper work by reducing mistakes.
 Activities of QC Circle
Managing the
Learning work Solving
place(workplace problems at
through QC
rules, the work
Circle. standards, places.
5s…)
 Problems not Discussed by QCC
Reward and wages
Personalities
Individual complaints
Staff benefits
Disciplinary policies
Work termination policies
Other matters not connected to work-related
problems
 QC Circle Introduction Process
1. Declaration 2. Establish 3. Organize
of introducing promotion QCCs by
QC Circles and section section
by president committees. committees
of company. .

6. Organize QCC
performance
meeting and 5. Let QCC
presentation, and 4. Train
perform QCC
give recognition activities.
to outstanding leaders.
groups/QCCs.
Promotion System of QC Circle Activities
GM

Core Team
Bureau

Section Section Section

committee committee committee

QCC QCC QCC

Leader Leader Leader

Members Members Members

 Role of Promotion committees/
Kaizen core team
 Set clear policy and goal for QC Circle program
in the company.
 Establish operational guidelines & plans (master
plan, plan on how to monitor, evaluate &
recognize the exemplary performance of QCC
leaders, members…
 Follow the condition of QCC.
 Give guidance, support, and cooperate actively.
 Coordination of QCC activities in the company.
 Formulate a budget for the program and identify
sources of funds.
 Cont ….

 Define qualifications and functions of facilitators

(section committees).
 Evaluate the overall status of the QC Circle
program, including training, rewards and recognition,
promotional activities at least once a year using
criteria and give advise as needed.
Example: sugar corporation
 Formulate corrective and preventive actions based
on findings in the evaluation.
 Role of Section committees
 Provide active support to the QCC &
motivate QCC leaders & members.

 Organizes training courses & programs

for new QCC.

 Organize QCC presentations.

 Coordinate and ensure availability of

facilities to all QCC.
 Cont ….
 Act as a counselor to Promotion committee
and QCC leaders.
 It implements the policies and plans
formulated by the Promotion Committee.
 It handles all paperwork and maintains
records like the QC Circle registry, minutes
of meetings, and QC Circle cases.
 It organizes promotional activities like
competitions and visits to other companies
with QC Circles.
 Section committees/ facilitator
• Each department selects one to three
facilitators, depending on the size of the
company.

• In the beginning, one facilitator is usually

assigned to three QC Circles.

• The QC Circle leaders call on the facilitator

when they need support during meetings.
Section committees/ facilitator cont…
 Role of Leader
 Conducting QC Circle meetings & direct
activities of QC circle.
 Make clear the purpose of the QC circle’s
activities.
 Perform as a member in the QC circle
activities.
 Maintain good atmosphere in which all
members can express their opinions.
 Establish annual activity plan.
 Encouraging members
 Cont….
 Train next leader.
 Participating in industry-wide conventions.
 Studying about QC Circle activities and
disseminating the knowledge.
 Seeking advise and support from the QCC
Office on behalf of its members
 Manage QC circle activities with appropriately
assigning roles to all the members.
  Kaizen team members & their duty
Mr. Alemayhu
chairman and control productivity
& delivery time
Mr.Lema
secretariat and control quality of
product

Ms.Makedasi
control cost and motivation
of workers

Mr.Ashaber Mr. Hailu

controls safety controls 5s layout ,
kaizen board usage
 A Leader

L：listen・・・・Listen carefully to the members.

E：explain ・・・Explain to the members carefully.
A：assist・・・・Assist the members’ activities.
D：discuss ・・・Discuss often with the members.
E：evaluate ・・・Evaluate a result fairly.
R：response ・・・Respond to the result.
 Member's role
Follow the workplace rule and discipline.
Members listen to each other at all times.
Participate and speak actively in QC
Circle meeting.
 cont….
Perform and be responsible to
assigned activity.
Cooperate with other members.
Arrive at meetings on time.
 Conventional Management philosophy
workers or individuals
are treated like robots
 Kaizen Management Philosophy
• All employees are treated as human beings. They
are allowed to use their individual intelligence.

Creativity
Initiative
 PDCA Cycle (Deming cycle)
CORRECT

IF RESULT IS NOT
SATISFACTORY

PLAN DO CHECK

IF RESULT IS
SATISFACTORY
ACTION
(STANDARDISE and
IMPLIMENT)
Example problem= love

ACT PLAN
CHECK DO
PDCA Cycle of Activities

① <P-1> Analyze current situation and identify problems

② <P-2> Examine and analyze causes of high priority problem

③ <P-3> Find countermeasure

④ <D> Implement the measure

⑤ <C> Evaluate results

⑥ <A> Establish new operational standard

 Steps of Problem Solving/QC Story
Step 1 : Identify problems and select
one theme

Step 2 : Study current situation by

Collecting data/facts Technical
Work
standard
standard manual

Step 3 : Set target

Step 4 : Make activity plan

 Steps of Problem Solving/QC Story cont…..
Step 5 : Analysis of causes using Fishbone
diagram.

Step 6 : Discuss on countermeasures and

method of execution.

Step 7 : Implement counter measures.

Step 8 : Confirm effect by comparing with the

set target.

Step 9 : Standardization
 QC circles
QCC solve problems related to QCPDSME:
Quality (Q),
Costs (C),
Productivity (P)
Delivery time (D),
 Safety (S),
 Morale (M),
Environment (E).
No Problem Is A Big Problem!!!!