Brief History of Quality: The Good and The Bad€¦ · DARQA Jubilee Conference 2016 Amersfoort, NL May 26 . Bill Bellows, [email protected] Tank Engines ... DARQA Jubilee Conference

Bill Bellows, [email protected]

Brief History of Quality:

The Good and The Bad

Presented by Bill Bellows

President

In2:InThinking Network

Canoga Park, California, USA

Email: [email protected]

DARQA Jubilee Conference 2016

Amersfoort, NL

May 26

mailto:[email protected]


Tank Engines

Rocket Engines


Audiences


The word “quality” has Latin roots, beginning

as “qualitas,” coined by Roman philosopher

and statesman Marcus Tullius Cicero, who

introduced his fellow Romans to the

vocabulary of qualitas, quantitas, humanitas,

and essentia. While Plato invented the phrase

poiotes for use by his peers, Cicero spoke of

qualitas with his peers when focusing on the

property of an object, rather than its quantitas

or quantity.

Abstract


Two-thousand years later, when writing The

New Economics, W. Edwards Deming wrote:

“The basic problem anywhere is quality. What

is quality? A product or a service possesses

quality if it helps somebody and enjoys a good

and sustainable market.”

As with Cicero, Deming saw quality as a

property.

Abstract


Agenda

Preview

Quality and the Greeks

Quality in the Middle Ages

Quality in Industrial Revolution

Quality in the 20th Century


Space Exploration

3 Space

Shuttle Main

Engines


Space Exploration


As Conceived

Replacing the screwdriver

Pilot holes

Hole saw

Drywall installation

Concrete

Product or Service Innovation


As Conceived


Pilot holes

Hole saw


Concrete



As Conceived


Pilot holes

Hole saw


Concrete

The top 5 uses:

1. Replacing the screwdriver

2. Pilot holes

3. Hole saw

4. Drywall installation

5. Concrete



As Managed As Conceived



Interactions - Gaps Actions - Parts

Actions & Interactions


Interactions - Gaps Actions - Parts

Actions & Interactions


Handoff Requirements?

D E F

C

G I H

Task (Action) Flow


What “grade quality” is required for all

purchased parts and services, as well

as tasks completed internally?

Grade Quality


Exam Grade Quality

USA Netherlands UK

A+ 10 A* (first)

A+ 9.5 A* (first)

A+ 9 A* (first)

A+ 8.5 A* (first)

A 8 A (first)

A 7.5 A- (upper 2nd)

B+ 7 B (upper 2nd)

B 6.5 C (lower 2nd)

C 6 D (lower 2nd)

D 5.5 E (third)

F 5 F

F 4 F

F 3 F

F 2 F

F 1 F


Exam Grade Quality

USA Netherlands UK

A+ 10 A* (first)

A+ 9.5 A* (first)

A+ 9 A* (first)

A+ 8.5 A* (first)

A 8 A (first)

A 7.5 A- (upper 2nd)

B+ 7 B (upper 2nd)

B 6.5 C (lower 2nd)

C 6 D (lower 2nd)

D 5.5 E (third)

F 5 F

F 4 F

F 3 F

F 2 F

F 1 F

The Good

The Bad


Grade Quality

The Good The Bad


Strike

Zone

Top of Shoulders

Beneath Kneecap

The Good

On Strike Zones

The Bad


Task Management


Quality Management - 2016


Task (Action) Flow

D E F

C

G I H

P P P

P

P

P P

P

P – The Good


Agenda

Preview





Quality in the 21st Century


Marcus Tullius Cicero, Roman

statesman, lawyer, linguist, politician,

and philosopher

Born 106BC, Died 43BC

Introduced Romans to Greek

philosophy

Executed after power struggle with

Marc Antony



Cicero added words to the Latin,

including

Humanitas, Quantitas, Qualitas

Qualitas – a property of an object,

character, nature

Quantitas – greatness, magnitude, size



Agenda

Preview






Guilds – associations of artisans who

controlled the practice of their craft

Apprentices trained by Master

Craftsman



Guilds included textile workers,

masons, carpenters, money changers,

etc.

Guilds created their own high standards

Declining influence in the 18th and 19th

centuries



Agenda

Preview



Quality in the Industrial Revolution



Guilds perceived by Adam Smith and

Jean-Jacques Rousseau as hindering

market forces over prices, wages, and

profits

Quality in the Industrial

Revolution


Guilds perceived by Karl Marx as

maintaining social classes

Guilds faded in power with the

emergence of the Industrial Revolution


Revolution


In 1776, French General Jean-Baptiste

Vaquette de Gribeauval sponsored

standardized weapons through a royal

order


Revolution


Efforts to execute the royal order of

“Interchangeable Parts” were led by

Honore Blanc

Higher volumes (mass production) and

lower prices of products were attractive


Revolution


Mass production first demonstrated in

1803 at Portsmouth Block Works in

Hampshire, England

By 1808, annual production was

130,000, done with “ten men”, not “one

hundred and ten”


Revolution


Thomas Jefferson learned of Blanc

during his role as US Ambassador to

France, 1785-1789

Blanc declined Jefferson’s offer to

relocate to US

Jefferson shared Blanc’s efforts with

Eli Whitney, leading to first contract with

US Congress for product (rifles) with

interchangeable parts


Revolution


Agenda

Preview






The advancement of machine tools

allowed mass produced parts to be

made to specification limits

The role of examination of parts by a

craftsman was replaced by a quality

inspector

Ransom Olds introduced assembly

lines in 1901 to build the “Curved Dash,”

the first mass produced automobile



Olds Motor Works was sold to GM in

1908

Ford installed the first moving assembly

line in 1913

Model T assembly was divided into 48

steps

Ford hired Frederick Winslow Taylor to

conduct time and motion studies to add

efficiency to these steps



In parallel with Ford hiring Taylor, Bell

Lab’s Walter Shewhart was assigned

the task of developing a method to

manage variation in the production of

telephones

W. Edwards Deming met Shewhart in

1927 and him invited him to lecture on

control charts at the US Department of

Agriculture



During WW2, Deming partnered with

professors to share the theory of control

charts with the US defense industry

Deming was invited to Japan in 1950 to

share Shewhart’s methods for Statistical

Quality Control

During his 1950 visit, Deming also

shared his concept of “Production

Viewed as a System”



In 1982, Larry Sullivan, a senior Ford

manager, travelled to Japan to lead an

internal effort to study automobile

suppliers and the gain explanations for

their “results.” Together, they had captured

nearly 30 percent of the US market share

in automobile sales, beginning with zero in

1950 and growing to 3 percent in 1970.



A summary of his findings were published

in an article for the American Society for

Quality. Excerpts follow:

In March 1982, I was part of a

[management] group [from Ford] that

visited Japan and studied quality systems

at a variety of automotive suppliers.

Source: Variability Reduction: A New Approach to Quality, L. Sullivan, 1983



The most important thing we learned was

that quality in those companies means

something different from what it means in

the U.S. - that it is in fact a totally different

discipline.

Source: Variability Reduction: A New Approach to Quality, L. Sullivan, 1983



One inspiration for challenging the

mental model of “good parts are equally

good” is the 1983 discovery by Ford

Motor Company of a dramatic difference

in warranty claims between automatic

transmissions designed by Ford and

produced in two locations, one in

Batavia, Ohio, the other by Mazda in

Japan.



Much to the surprise of Ford’s corporate

warranty office, the number of

complaints associated with the erratic

shifting of the transmissions produced in

Batavia were a factor of 3 greater than

the complaints against the

transmissions produced by Mazda.





Upon close examination, Ford realized that

their manufacturing focus was on the valve

diameter and the bore diameter, taken

separately

valve diameter

bore diameter



Meanwhile, Ford learned that Mazda’s

manufacturing focus was to actively manage

the gap between the outer diameter of the

valves within the transmission and

the corresponding diameter of the valve

bore.

gap



In doing so, Mazda’s efforts realized the

existence of an ideal gap, resulting from ideal

(“target”) values for both the bore and valve

diameters, with an awareness that variation in

gap size matters.

valve diameter

bore diameter



“A product or a service possesses

quality if it helps somebody and

enjoys a good and sustainable

market.”

W. E. Deming on Quality


“A man’s mind, stretched by a

new idea, can never go back to

its original dimension.”

Oliver Wendell Holmes, Jr.


Brief History of Quality:

The Good and The Bad

Presented by Bill Bellows

President

In2:InThinking Network

Canoga Park, California, USA

Email: [email protected]

DARQA Jubilee Conference 2016

Amersfoort, NL

May 26

mailto:[email protected]

Documents

Brief History of Quality: The Good and The Bad€¦ · DARQA Jubilee Conference 2016 Amersfoort, NL May 26 . Bill Bellows, [email protected] Tank Engines ... DARQA Jubilee Conference