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Booklet to start Quality circle in your organisation
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together we can Quality Circle!Operations U & A
QUALITY CIRCLE-……………SHOP
PROJECT TITLE:……………………………………………………………..
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together we can Quality Circle!Operations U & A
INTRODUCTION
TEAM NAME :…………………………………………..
LEADER NAME :…………………………………………..
PROJECT TITLE :…………………………………………..
AREA :…………………………………………..
DATE :…………………………………………..
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together we can Quality Circle!Operations U & A
TEAM STRUCTURE
HOD/Supervisor
Quality coordinator Maintenance coordinator
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together we can Quality Circle!Operations U & A
Team Attendance
S.NO
Name Position in Team
WK- WK- WK- WK- WK- WK- WK- WK- WK- WK-
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together we can Quality Circle!Operations U & A
GANT CHART
Phase WK- WK- WK- WK- WK- WK- WK- WK- WK- WK-
Define
Measure
Analyze
Improve
Control
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together we can Quality Circle!Operations U & A
DEFINE PHASE
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together we can Quality Circle!Operations U & A
DEFINE PHASE
What is the Problem:
Where is the Problem:
How much is the Problem:
Boundaries of the Problem:
Define7
together we can Quality Circle!Operations U & A
SIPOC
• SIPOC(Supplier, Input , Process , Output & Customer)Specific Process flow chart with SIPOC.
Define8
together we can Quality Circle!Operations U & A
DRILL DOWN TREE
Define
Company target
Our Project
Our target
What improve
……………………
……………………
……………………
……………………
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together we can Quality Circle!Operations U & A
Review-Define Phase
Phase Plan/Actual
WK- WK- WK- WK- WK- WK- WK- WK- WK-
Define
Plan
Actual
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together we can Quality Circle!Operations U & A
MEASURE PHASE
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together we can Quality Circle!Operations U & A
MEASURE PHASE
Line:
Problem:
Where/Area:
Current Level:
Measure12
together we can Quality Circle!Operations U & A
Data Collection
Last One year or minimum 6 month data need to collect.
Data collected for………………MonthsData Type : Continuous / DiscreteData format……………………Reference Document…………………
Measure13
together we can Quality Circle!Operations U & A
Current Level and Target Level
Current Level Measurement:
DPMO(Defects per Million Opportunities)
(Total defect/total Production)*1000000:………………….
Sigma Level:…………………….
Target Level Measurement:
DPMO(Defects per Million Opportunities)
(Total defect/total Production)*1000000:…………………..
Sigma Level:…………………….
Completion time:……………………..
Measure14
together we can Quality Circle!Operations U & A
Cause & Effect(Leak reduction)
Man
MachineMethod
Material
Measure15
together we can Quality Circle!Operations U & A
KPIV/KPOV
List Down the Cause Variables from C&E diagram
1. 9.2. 10.3. 11.4. 12.5. 13.6. 14.7. 15.8. 16.
Measure16
together we can Quality Circle!Operations U & A
FDM(Function Deployment Matrix)
Variables(x’s)Productivity
Low:3 Mid:5 Max:9Cost
Low:3 Mid:5 Max:9Quality
Low:3 Mid:5 Max:9Total Weightage
Measure17
together we can Quality Circle!Operations U & A
SELECTED CAUSE LIST-x’s
List Down the Variables(x) from C&E diagramx1.x2.x3.x4.x5.x6.x7.x8.
Measure18
together we can Quality Circle!Operations U & A
Review-Measure Phase
Phase Plan/Actual
WK- WK- WK- WK- WK- WK- WK- WK- WK-
Measure
Plan
Actual
Measure19
together we can Quality Circle!Operations U & A
ANALYZE PHASE
Analyze20
together we can Quality Circle!Operations U & A
Data collection for small variables(x’s)
S.No x’s Variables Data type
Remarks
1 x1
2 x2
3 x3
4 x4
5 x5
6 x6
7 x7
8 x8
Analyze21
together we can Quality Circle!Operations U & A
PARETO CHART –x1
Problem(x1):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x2
Problem(x2):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x3
Problem(x3):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x4
Problem(x4):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x5
Problem(x5):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x6
Problem(x6):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x7
Problem(x7):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x8
Problem(x8):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
MAJOR CAUSE LIST-Y’s
Analyze
List the major cause list from pareto chart analysis(80:20 concept)Need to improve top 20% of cause so as to solve 80% of remaining problem.
Y1.
Y2.
Y3.
Y4.
Y5.
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together we can Quality Circle!Operations U & A
Review-Analyze Phase
Phase Plan/ Actual
WK- WK- WK- WK- WK- WK- WK- WK- WK-
Analyze
Plan
Actual
Analyze31
together we can Quality Circle!Operations U & AImprove
IMPROVEPHASE
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together we can Quality Circle!Operations U & AControl
S.No Y’s Variables Improvement
Action
Remarks
1 Y1
2 Y2
3 Y3
4 Y4
5 Y5
Data collection for Main variables(Y’s)
SAMPLE
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together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y1
Improve34
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y2
Improve35
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y3
Improve36
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y4
Improve37
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y5
Improve38
together we can Quality Circle!Operations U & A
Review-Improve Phase
Phase Plan/ Actual
WK- WK- WK- WK- WK- WK- WK- WK- WK-
Improve
Plan
Actual
Improve39
together we can Quality Circle!Operations U & AControl
CONTROL PHASE
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together we can Quality Circle!Operations U & AControl
S.No Y’s Variables Data type Remarks
1 Y1
2 Y2
3 Y3
4 Y4
5 Y5
Data collection for Main variables(Y’s)
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together we can Quality Circle!Operations U & A
CONTROL CHART-Y1
Control
• Use Check sheet or other monitoring tool to standardize the process
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together we can Quality Circle!Operations U & A
CONTROL CHART-Y2
Control
• Use Check sheet or other monitoring tool to standardize the process
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together we can Quality Circle!Operations U & A
CONTROL CHART-X3
Control
• Use Check sheet or other monitoring tool to standardize the process
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together we can Quality Circle!Operations U & A
CONTROL CHART-X4
Control
• Use Check sheet or other monitoring tool to standardize the process
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together we can Quality Circle!Operations U & A
CONTROL CHART-X5
Control
• Use Check sheet or other monitoring tool to standardize the process
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together we can Quality Circle!Operations U & A
Current Level and Target Level
Target Level Measurement:
DPMO(Defects per Million Opportunities)
(Total defect/total Production)*1000000:…3/381*1000000=7874
Sigma Level : Calculate from sigma table
Project Achieved Level:
Control47
together we can Quality Circle!Operations U & A
Review-Control Phase
Phase Plan/ Actual
WK- WK- WK- WK- WK- WK- WK- WK- WK-
Control
Plan
Actual
Control48
together we can Quality Circle!Operations U & A
Summary of the Project
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