Concept of Quality Control

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23 April 2013 by : AVG 1

Concept of Quality Control

1.Viewpoints of Control

2. Viewpoints of Assurance

3. Viewpoints of Improvement

4. Statistical Approach

5. Viewpoints of Humanity


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1.Viewpoints of Control1.1 PDCA Cycle

Fig 1.1

Necessity of PDCA:When an operation is carried out, many peoplemay do the operation randomly and think theirjobs are completed when everything is done.The way of job to just Do seems easy, however,it is actually very inefficient.


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Because when an operation is carried out with aninadequate planning, the operation might be carriedout with much time and man-hour increases as aresult. It is important to minimize rework or

duplication of Operations by making a Plan throughthe viewpoints such as Fact Control, Priority Principleand others. (Refer to Fig.1.2)

1.1 PDCA Cycle

Fig 1.2


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1.1 PDCA Cycle


Also, quality of operations is improved by Check

and Action to reflect results of operations. If the

situation changes after a Plan is made, it is

necessary to change implementation (Do) of theoperation.

However, if Check is not carried out, wasteful

implementation continues without being noticed.

For this reason, turning PDCA Cycle is thefundamental of all operations


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There is no sense in turning the PDCA Cycle !?

Someone said: It is just conventional and nonsense.

If PDCA Cycle is proceeded/followedinappropriately, it becomes conventional.

Example of an inappropriate PDCA Cycle.

automation rate of production line is 80% or moreIs it OK because the achievement is 90%


1.1 PDCA Cycle


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What is the 80% automation rate for?

When 80% or more automation rate is decided as

a goal to decrease number of man-hour, even the

goal is accomplished, it makes no sense if the

number of man-hour does not decrease.

PDCA must be proceeded to fulfill a purpose.


1.1 PDCA Cycle


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1.1 PDCA Cycle

Why PDCA is not proceeded appropriately?

The way of operation is incorrect (signal of mistake).

The reason is not pursued thoroughly.

The man-hour for Check and Action is insufficient.What is necessary to proceed PDCA?

A purpose and a goal should be clarified.

Start with an easy PDCA to built confidence.

If PDCA is not proceeded. It cannot be decided whether an operation carried out

at the present is correct or not.


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Summary

Job has a goal of QCDSM (Quality, Cost,

Due date, Safety and Moral). It is importantto proceed P D in accordance with thegoal. And also it is important to proceed CD absolutely to confirm how much the goal

is achieved. It is a fundamental to turnPDCA cycle to achieve a good job.


1.1 PDCA Cycle


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1.2 Fact Control

What is Fact Control?

Fact Control means to carry out jobsusing all the possible fact rather than

experience or intuition. Control byfact means to explain by data and toobjectify subjective judgments.


- to explain using all the possible dataon the basis of fact


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Necessity of Fact ControlRelying on KKD (Kei ken-experience, Kan-Intuition,Dokyo-Guts) can lead to big risks.Following are Examples: based on KKD,

1)material must cause strength deficiency of thispart, but actually

the cause was hardening temperature.

2) We were confident thatexperiences show there is no doubt that next

project will be great success, but actually it wasjust wrong guess.

1.2 Fact Control



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Follow the steps to figure out the fact,[1] Observe actual things at actual places to figure out fact

and phenomenon.[2] Decide which data are collected.

[3] Clarify how to use data.It is incorrect to collect data without a plan.[4] Collect appropriate data

Does sampled data reflect entire picture?Is measuring method appropriate?Is measurement accuracy appropriate?Is measuring instrument reliable?

[5] Analyze data by scientific methods(such as QC method and others).

[6] Consider and collect accurate information.

1.2 Fact Control



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Notes on data collection:

Data collection seems time-consuming However, it saves time for

trial and error by grasping the fact accurately. In addition, when data

is collected, examine the items in advance and avoid collecting

unnecessary data.

KKD is quicker and easier.(KEIKEN =Experience, KAN= Intuition, DOKYO= Gut feeling)Data collection takes time and troublesome.


If only KKD is employed:It is true in some case that KKD is quicker and easier. However, totalman-hour will increase since lack or redo often takes place. Thistendency is especially remarkable for inexperienced persons or evenexperienced persons when they work on new and inexperienced jobs.

1.2 Fact Control

Someone said


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Since experience is definitely important, it is not correct tototally discard KKD. KKD is important at the stage such asextraction of problems, clarification of factors, developingof ideas and others. But, KKD is not so reliable as to solve

all problems by KKD only. KKD is a special method which canbe effected only by considerable experienced persons.


1.2 Fact Control

Summery

Nothing indicates the fact better than data.Appropriate judgment can be made to grasp the

phenomenon by the fact as data. In other words, Fact

Control means to explain by data.


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1.3 Emphasis on Process (Process Control)

Good processes bring Good Results. It is a way ofthinking to controlling and improving an operationmethod to get Good results continuously

Ex-1: Sales division put up an advertisement fora product, and the sales doubled. Going by thesuccess, went for extensive advertisement -met no success.

Process NG, Results GoodConsideration was not given to the content andtarget reader segment.You can not always succeed.


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Ex-2: A screw strength was found not meetingspecification.

After reviewing the Design & Process, it wasdecided to change the material. Strengthimproved but ---Process Good, Results NG

Still this gives an opportunity to investigatefurther, and chances of success next time isgreatly increases.


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Why not control by results!?



Actually, results are important.Operation is not completed without agood result

There is no problem because we have

got a good result so far.

Someone said


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It is true that results are important, but...One need to consider whether these GoodResults can be reproduced.

Even if the results are Bad, can we guaranteethat next time also will be Bad and not Good.?On the other hand, if the process leading to GoodResults and the sequence of operations are

documented -one can always say with confidencenext time same results can be obtained evenwhen the process is carried out by anotherperson.

Why not control by results!?




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When the results are Bad, by recognising where

and went wrong, we can get Good results.

A process connecting an operation method andthe consequence thereby will be a treasure.

The reason why Process Control is important.

Bad effect of Result-oriented approach

In a system to evaluate things depending on theresult, potential things also could be abandoned.

And, it is wasteful.



Problems can be said treasures. It is

important to check not only a result but alsoa process.


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1.4 Standardisation

What is Standardization?

A standard is description which is usedrepeatedly and commonly to instruct how tomake a product or how to proceed an operation.And standardisation is to establish and to utilizethe standard.


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1.4 Standardisation

Example:suppose a process to wash a part for 10seconds,and washing time is different for each operator.If washing the part for more than 10 secondsmakes no difference in the effect, 15-secondwashing is a waste.

On the other hand, washing less than 10secondswould result in a problem of quality.

Therefore, a standardization of10-second washing can minimize the variance.


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Advantages of Standardization

Personal/individual unique techniques can be

accumulated as companys Techniques.

Technical capabilities can be advanced basedon the accumulated techniques.

Cost reduction and convenience can be

advanced by improvement of parts andproducts compatibility and system consistency.


1.4 Standardisation


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Advantages of Standardization

Inter-department cooperation will be improvedto standardize the way to work.

Industrial accidents can be prevented bymaterializing equipment maintenance andaccident prevention.

Company can contribute to consumers andbenefit of society by supplying products whichare full of safety and reliability thanks toproduct specification and others.


1.4 Standardisation


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Standardizationmakes no difference!!?--


Even if an operation is standardized, thestandard is not used in fact.

Standardization makes 100 stupid persons (Itdiscourages individual creativeness)

operations can not standardised becauseoperations are different each time in ourshops

Someone said


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Can we counter these viewpoints?

Consider to clarify necessary conditions of

standardizationIt can be carried out

It is easily to understand

It is easy to followIt will be improved


Standardizationmakes no difference!!?--


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Thought that standardization cannot be used

in fact or cannot be followed may be due to

implementation of standardisation withoutUnderstanding/considering how it can be applied

at the workplace. Operators convenience is not

taken in to account. These types of

standardization are not standardization we are

aiming at.


Standardisation itself is not the Objective or Goal


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Also, standardization itself is not the final

goal, but must be improved continuously.

From another point of view, satndardisationclarifies new problems.

Therefore, standardization is carried out to

develop technical capability and improvement,

and it never results inmaking 100 stupid persons




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Additionally, in the case of different operations

each time we can standardise the thinking

process. Idea can be used in similar processes and

we can get clues to solve the problems.



SummaryDocumentation is not the final step of

standardization. The essentiality ofstandardization is to follow and utilize thestandards, and it is important to improve thestandards continuously.


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1.5 Source Control

What is Source Control?It is often said a bad thing must beeliminated at its source. To provide productsand service which satisfy customers, it is

necessary to go back to upstream processesto find a cause of problem and take measuresto prevent detectives from transferring todownstream processes.

Source Control to control operations notin downstream, but in upstream processes



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Necessity of Source Control

o Prevention is better than Cure is an oldsaying. Similarly, it is necessary to prevent the

mistake at the source is very important ratherthan defect sorting or reworking to salvage.

o A dent or scratch on the car body duringpressing operation can not be corrected

completely in the subsequent process/es likepainting. However well the car was designed,produced and marketed by the sales team cannot find acceptance in the market.

1.5 Source Control



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Necessity of Source Control

If a critical defect is found in a part,

o It may call for total re-call of the productsfrom the field, and result in loss of customer

trust.o Thus, a defect in upstream affects significantly

to the downstream, and the source control isnecessary to avoid waste of manpower or

labour.So, what we should do for the source control?

Key points of the source control are introduced

below.

1.5 Source Control



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Points of Source Control Mechanism and operational flows of developmentand quality assurance are to be systematized.Products are to be planned and designed from the

users point of view.Operation is to be evaluated at each the next step.If the goal is not accomplished, do not proceed tostep of process.Possible troubles are anticipated and to be

prevented.A cause of a trouble is to be traced to upstreamprocesses.

1.5 Source Control



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It is true that immediate response is important,

but----

Source Control is ldeal !! ?


We must take measures for defectivesimmediately. It is not the time for the source

control.Preventing transfer to the following process iseasier.Because it is a problem of source, designing or

planning section should be responsible.

Someone said

f l


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Source Control is ldeal !! ?

If measures are not taken at the source, it canrecur.

Defects in downstream processes affects moresignificantly.

Whole process can be improved when alldepartments participate in the source control.


f C l


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Example:A painting defective was detected in aproduction line. Cause identified as DUST

Handling of the defective product

(outflow prevention)Carry out 4S(cleaning) of the periphery

(Emergency measure)Investigate entry route of dust and takemeasures.

(Source Control)

Without source control, even 4S is carried out,there is a possibility of recurrence.

If measures are not taken at the source, it can recur.


1 Vi i f C l


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Defects in downstream processes Affects moresignificantly. ex: Critical defect is found in a part.

Action after

Problem is noticed

recall all products in market,Indemnity, abasement ofreliance and others(possibility of financial crisis)

Action after shipping recall all products in market

(extensive loss)

Action in factory(response at

manufacturing)

change all products

(considerable loss)

Action in design(response atdesigning)

Modification of drawings.

(Small no. of man hours)


1 Vi i t f C t l


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Whole process can be improved when alldepartments participate in the source control.Problems will decrease if even a downstreamdepartment points it out from the viewpoint of

downstream and consequently, it makes benefitfor the downstream process itself.

Summary

When a problem happens, symptomatic action tendsto be taken. However, it is not a real solution. If thesource control is carried out to solve the sameproblem, you can spend smaller effort in general.


1.5 Source Control

1 Viewpoints of Control


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What is On-site Checking Approach?

It is an attitude to go to the source and toidentify and analyze the facts objectively.


1.6 On-site checking approach

(Genchi Genbutsu)



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Necessity of On-site checking ApproachPDCA Cycle and Fact Control mentioned

before would be useless if these activities are notbased on true facts. For example, if data,measured a measuring equipment withconsiderable margin of error are analyzed with aprejudice that variation of the measured objectsis large, not only correct information cannot beobtained but also time and cost are wasted.





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No good company nor good quality can berealized without washing hands 3 times a day.

Going to the source and observing the facts are

not enough. Diagnosing (watching) using ownhands is necessary for products with Qualitythatcan satisfy customers.

Observing is the first step of On-site CheckingApproach. However, it would be difficult to figureout the true cause by looking vaguely.How and what to observe ???





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Viewpoint for Observation

Compare (line up )actual itemsLook with five senses or even sixth senses

(use of high-speed camera and others)Enlarge the objective

(eyes/ears/nose/skin/feeling and others)See the movement in a slow speed.Disassemble, cut in section or destroy the object or

the product.See the work site when the line is stopped.Carry out the operation by yourself and-----

so on.


1.6 On-site checking approach (Genchi Genbutsu)



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Strict On-site Checking Approachis the fundamental of manufacturing

On-site Checking Approach

Is it really necessary ! ? ,.

Is On-site Checking Approach necessary in thisvirtual era in which remote monitoring andremote operation are in practical use?I have no time to visit the actual place when Imbusy at work.

Someone said





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On-site Checking Approachis necessary, especially in the virtual era.

Machines produce products, but the machines

are made by human.These machines are handled by human beings.Manufacturing is impossible without developingthis human resources. Just considering is notenough, but trying to do by yourself using yourhands and feet is important. Then only the Fivesenses will be developed through frequentrepetition of this action.





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On-site Checking Approachis necessary, especially when you are busy.

It is not by sitting at the table and considering for along time but by touching and confirming actual thingsat the actual place that clarifies problems and helps toproceed with improvement efficiently.

Kiichiro Toyota, the founder of Toyota MotorCorporation, once said Professional technicians and

engineers are developed with increased flair fortechnology and ability to refine technology fostered bygoing to the actual place and confirming actual things.



1 Vi i t f C t l


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SummaryThis is the TOYOTA principle.

This attitude and value concept to give

attention to facts and to objectively observethings as they are

is the biggest stepping stone of Success.

On-site Checking Approach, is being

observed by each of the TOYOTA groupcompanies as a tradition as well as its source

of power.



2 Vi i t f A


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Quality First Policy

to try to ensure profit by supremacy in quality

.

What is Quality First Policy?Quality First Policy is an idea to place top priorityon quality, satisfying requirements of cost and

due date. Here, quality means not only those ofproduct and service, but also quality of all relatedthings such as quality of job and others.

2.Viewpoint of Assurance

2.1 Quality First Policy

2 Vi i t f A


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Necessity of Quality First Policy

Because, unlike other problems, a quality problem couldbe an irrecoverable problem.

Loss due to quality trouble could be enormous since itaffects many areas (details on next slide). Also, it is quitedifficult to restore the trust once lost. (Cases of * Cadbury's,Colas, recent milk problem & chocolate issue from China,Dairy Industry, auto industry, and tyre industry and so on --).

Another example, poor quality of work such as a mistake or adefect in education material not only gives negative effect tothe students but also disgraces the department in charge ofeducation material.



2 Vi i t f A


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Cost Due to Product Quality Troubles

Quality First never permits to neglect cost and delivery,they are as critical as Quality. But they can never allowQuality to be sacrificed.



2 Vi i t f A


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Is Quality First Policyreally necessary! ?

It is true that Delivery and Cost are definitely important, but... Quality

of Planning:

Quality of

Design:

Quality ofManufacturing:

To plan a product which satisfiesCustomers needs and demands.

To design a product which is exactly

that is planned, has high reliability,and satisfies customers

To manufacture a product which isexactly as designed.


Quality First Policy concerns only shop floor which manufacturesproducts. It is nothing to do with us because our department doesntmake any products.

If a quality problem is dealt with for real, it would cost too much.

Someone said

2 Vi i t f A


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Solving quality problems leads to costreduction.If a quality problem is solved, various losses

decrease, and as a result, the total cost is alsoreduced in many cases. A car mainly used forshopping does not need a horsepower (quality)like a sports car, but quality attention for this carshould be paid on easy handling such as a small

radius to turn. As shown in this example, costreduction could be achieved by selectively solvingquality problems.



2 Vi i t f A


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Summary:

Quality is an important element to influence acustomers trust and companys future.

Company must place the first priority on quality.

(Supremacy of Quality).



2 Vi i t f A


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2.2 Customer-Oriented / Market-in Policy

necessity of customer oriented policy.To make really salable products, it is necessary topursue customers real demand and to try to reflect

the demand to products This is called market-inapproach In contrast, a producer-oriented attitude offorcing the producers view to customers is calledproduct-out

What is Customer Oriented Policy?It is a way of thinking to figure out customers needsand to provide products or services to meet the needs.We must provide products or services that customers

truly need.


2 Vie point of Ass ance


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In the market of small size camera operable with a singletouch of button, a company developed and launched thesmallest one, which was sold quite well.

After that, they further downsized and brought to the marketas a micro camera. However, the micro camera was not soldwell because of the operation difficulty and bad design.

Customers never welcome a product which is brought to themarket according to companys complacency of the smaller,better to show their the technical ability. And it is importantto figure out real demand of customers.


2 Viewpoint of Assurance


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Customer- Oriented Policy is endless!?

It is true that satisfying the demand of allcustomers is difficult, but


If all demands of customers are to besatisfied, it will be never done. For example,

100 types of products should be supplied tosatisfy 100 customers.Is all we have to do just to satisfycustomers?

Someone said



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Limit the target customers to meet theirdemands.

Custom-made could be a choice. However, maynot find many customers due to some negativefactors, such as exceptionally high price or along delivery time.

Therefore, it is necessary to find out customersdemands.




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If any trend of demands cannot be figured out,statistic view makes it possible to figure out and

to stratify the main demands of customers.

As a result, a product thus produced isdifferentiated from others and has more possibility

to have advantages in cost, delivery time andsatisfaction than custom-made ones.




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Do not forget corporate responsibility.

For a company, it is necessary to pursue profit.

However, every company has social responsibilityand role to contribute to establish a soundsociety, such as cooperation with the society orresponsibility to environment.

Therefore, companies should not sell their productagainst their responsibility and role.




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Summary:

it is better to think that profit is reward forsatisfying customers. Therefore, a product or aservice which can be provided only at a pricewithout profit does not fit the customer-orientedpolicy. It is important to provide a product or a

service that can satisfy customers and at thesame time make a profit.




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2.3 The Next Processes Are Your Customers

What does Next processes are yourcustomers mean?The next processes mean the processes

influenced by the result of your own job.Next processes are your customers teaches youto consider your work to be taken over by thenext process with pleasure.

to provide a product or a service whichsatisfies downstream processes




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For example,

if a problem is found even it does not affect yourown process it is important to have an attitudeto take measures against it without neglecting it.

Following points are important to have such anattitude.




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To communicate well with the earlierprocess and the next process in order to obtaindefect -information and to avoidmiscommunication.

To establish judgment criteria in order toavoid ambiguity of judgment whether the nextprocesses are affected or not.

Necessary points for attitude of next

process is to consider from the viewpoint of yourdownstream processes:To be familiar with the role of the your own

process and the following ones.




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It is hard enough to do my own work,why do I have to think of the next process! ?

It is true that any detectives should not beconveyed to the following process, but...


-This defective will not be conveyed because

it is inspected in the next process.-Considering the next process results

no benefit to me but too much job.-It is not my responsibility, since the earlier

process is blamed for.

Someone said



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The reason to pay a great attention to nextprocesses.-To produce only the product the next processdemands.

>Detectives are themselves loss even they are nottransferred to the market. Additionally, the moremanufacturing proceeds in the next processes, themore loss arises. If loss is taken into account, findingdefects by inspection is not enough.

>Building quality into your process will finally help youbecause you do not have to produce unnecessaryproducts.





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Loss of end users credibility is loss of the entirecompany.--It is sure that the former process is responsiblefor defectives in the former process.

However, if a defective is not found out and anoperator neglects the defective in the next process,end users will be in trouble with it. As a result theentire companys credibility will be lost.

> If a defective from the former process is found,do not neglect it nor convey it out to the nextProcess.





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Loss of end users credibility is loss of the entirecompany.It is sure that the former process is responsiblefor defectives in the former process.

However, if a defective is not found out and anoperator neglects the defective in the nextprocess, end users will be in trouble with it.As a result the entire companys credibility will be

lost. If a defective from the former process isfound, do not neglect it nor convey it out to thenext Process.

Summary:

Practicing the next processes are your customers in allprocesses will result in helping you and bringing benefit tothe company.



3 Viewpoints of Improvement


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3.1 Priority Principle

What is Priority Principle?

It is an idea to utilize finite resources (manpower,material, money, time and others) and tomaximize the effect by mean of selecting criticalproblems among many problems and work on thecritical ones by priority.




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48

96 100

84

0

10

20

30

40

50

60

A B C D

0

10

20

30

40

50

60

70

80

90

100

Problems with serious and wide influence.(Importance) Problems expanding influence and scale if leftunsolved. (Expanding tendency)

Problems causing serious result without immediatemeasures. (Urgency) and so on




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There are a lot of important problems, and every

problem is important.Despite Priority Principle, I tend to work onimmediate problems

The idea of Priority Principle is necessaryto enhance quality and benefit.



Is Priority Principle obligatory!?

Someone said



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There is a priority where there are morethan one problems.

1) Even if there are many important problems, anorder of priority can be fixed. First, list andorganize actual problems, and then, the order ofpriority is decided taking demand, effect,possibility to realize and others in consideration.





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There is a priority where there are morethan one problems.

2) It is useful to evaluate important problems inyour section objectively comparing withimportant problems of third parties such as othergroups, other sections, other divisions and

others. On this occasion, it is important to lookover the entirety and to give the highest priorityto optimize the whole.





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Evaluation index for priority isimportant.

In some cases, immediate unimportant problemsmust be done. Problems with more importancedo not necessarily have higher priority. It isnecessary to decide the order of prioritycomprehensively according to the importance,expansion tendency, urgency and others.




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Summary

To develop quality and benefit and to proceedwork efficiently, it is necessary to be conscious ofPriority Principle, to clarify the order of priority ofproblems and challenge, and to utilize the limited

resources.




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What are Problem Solving Steps?

Job is a series of problem solving.

Problem is a gap between expected and actualsituation.Solving a problem is to bridge the gap betweenthese situations.

Problem Solving Steps are steps to go through inorder to solve problems reasonably, scientifically,efficiently and effectively.

3.2 Problem Solving Steps




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Understandingof problems

Understanding theactual situation

GoalSetting

FunctionalAnalysis

Countermeasureplanning

Execution ofcountermeasure

Evaluation &Confirmation

Standardisation& fallow up



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KKD (experience (KEIKEN), intuition (KAN), &guts (DOKYO)) can be use to solve problems!?

It is often the case that KKD does notcontribute to effective problem solving.



Problem Solving Steps are time-consuming.It is easier and results are better to solve aproblem by KKD.(experience, intuition and gut feeling)

Someone said



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Importance of Problem Solving Steps

If you use KKD easily to solve a problem,

conversely the problem would becomecomplicated, and thereby you would miss a realcause, take an inconsequent measure orsymptomatic treatment.

That is, it takes considerable time. - -





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Importance of Problem Solving Steps

If your experience or skill is not enough, theproblem cannot be solved well. If your intuition

does not hit, it will be impossible to solve theproblem in some cases.

Sometimes, it is also useful to utilize KKD toproceed the problem solving smoothly. While the

basic steps are proceeded, sometime, it isnecessary to use knowledge and experience andtake guts at execution.





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Summary

For a reasonable, scientific, efficient and effectiveproblem solving, it is necessary to solve a problemstep by step according to Problem Solving Steps,and an unfailing result will follow.





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3.3 Recurrence Prevention

What is Recurrence Prevention?

It is to figure out the primary causes of a problemand to carry out improvement or measure whicheliminates the causes in order to prevent theproblem from recurring.




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Necessity of Recurrence Prevention

1n this situation, the problem can be recurred.(Ex.)An in-house equipment was broken andproduction temporarily stopped.

After checking the situation, it was found that the

cause is wear of driving part. Therefore, the partwas replaced with a new part immediately toresume the normal operation.




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Two viewpoints for detecting causes(1) Ask repeatedly why did the problem happen?(2) Why was not the problem found in advance?

(1) Why did that problem happen?Designers knowledge about material wear was insufficient. Why was it impossible to detect the problem in advance?There was no quality evaluation system for in-house facility.

As just described, it is necessary to step into the heart of a

problem such as work practices and job system. TheRecurrence Prevention is completed in a real meaning when ameasure is taken to eliminate the cause completely.(for example, education of material wear to designers).





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Even if Recurrence Prevention is carried out,trouble may not be eliminated.


3 e po ts o p o e e t

Even a measure is taken, problems actually occurrepeatedly!?

Whatever measures are taken, mistakes will

happen. So, similar problem could happen again.

Even a measure is taken, a different problemcould happen next.

Someone said



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lt is important to improve continuously.

If causes of problem are grasped superficially, youwill have a doubt mentioned above about the

recurrence prevention.The idea to continuously improve the base ofoperation such as work practices and job systemunderlies for the purpose of recurrence prevention.

In that way, an effect may not appearimmediately. However, problems will be certainlydecreased by taking such measures continuously.


p p



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Major Measures for Recurrence Prevention

Documentation and revision of variousstandards such as operating standards, technical

standards and others.Thorough educational training, and review andimprovement of education method. Artifice and improvement for materials,

equipment, work method and others. Establishment of system where activitiesmentioned above can be carried out continuously.


p p



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Summary

Mistakes are inevitable in jobs. It may be not beexaggeration to say that persons, work sites andcompanies which do not carry out real recurrence

prevention can not be improved forever.


p p



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What is Proactive prevention

It is an idea not to take a measure after problemis happen, but to predict a problem and to take ameasure such as prior elimination of a cause to

prevent the problem.

3.4 Proactive Prevention

p p



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p p

>It is no wonder for a company to take an actionfaithfully and quickly for the troubles causedby it.

>It is better that a problem does not exist rightfrom the beginning. Because it takes time, energyand manpower.>It causes a company to lose confidence if a

problem is treated afterward.>Therefore, it is necessary to make an effort toprevent a problem.



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Stage Consideration Effective methods

Plan Possible problemsshould be figured

out at this stage.

Quality deployment,Design review,

FMEA, FTA, ---etc;.Do Control points

should be decidedat the time of

implementing

Quality deployment,process FMEA,QA system chart,QC process chart ---

Check& Act

Should be carriedout as planned

Effective feedbackfor improvement

p p



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You may have difficulty in material and moneyare invested understanding for a potential whymanpower, problem, but...

p p


Proactive prevention takes too much effort and isless efficient by contrast.

Certain degree of trouble cannot be helped.Recurrence prevention is all we can do

Someone said



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p p

The reason to focus on elimination ofanxious mattersThe primary reason to lose customers credibilityis a trouble. Therefore, anxious matters should

be eliminated by all means.

Cost aspect Followup measures for defects cause bigdamage of defect part handling and correction.Additionally, if it results in recall of product fromthe field, it would cost much more the cost forPrevention in Advance.



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Technical aspectA person whose job has problems one afteranother can not be considered full-fledged, He/she

is considered independent when problems areprevented in advance

SummaryProactive prevention earns the trust of customers

and reduces cost. It also promotes self-development in ability to consider well and to thinkahead.


p p



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What is Stratification?

It is to focus on similarity and characteristic ofdata and to classify (make groups) the datathereby so that complicated matters are simplified.

3.5 Stratification

p p



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Painting operationshowing the variationin film thickness. The

data does not clarifywhat & where is theproblem.

3.5 Stratification

mmmm

When we stratify thedata wrt man, machine,material, shift/ day, we

get clarity. In this case,line B- is showing higherpaint thickness.

p p



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Category Examples

1 Man / HumanIndividual, age, gender, group, shift,experience,--

2 Machine Type, model., old and new, capability, lines,molds,

3 Material Manufacturers, lots, components, storageperiod ---

4 Method/ condition Temperature, pressure, speed, procedure --

5 Time Day, am/pm, day/night, start/finish ofoperation, season ----

6 Measurement/Investigation

measurement equipment, measurementmethods, investigation methods ---

7 Environment temperature, humidity, weather, with/withoutvibration and dust,------

3.5 Stratification



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Classify data by various viewpointsDont give up the idea of stratification, even if

difference cannot be found when data is stratifiedfrom certain viewpoint. The viewpoint of the

stratification may not be proper. So it is important toshift your viewpoints to another (apply other viewpoints and methods) and stratify the data again.

Clarify feature of data.If feature of data (character or history) is clarifiedin advance, the data can be stratified by variousviewpoints.

3.5 Stratification



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Summary

The concept of stratification is essential for earlydetection of problems and exact countermeasureplanning. In addition, we have SQC methods to

carry out stratification easily and freely.

3.5 Stratification



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4.1 Utilisation of QC Methods

What are QC Methods?

QC methods are tools to visualize data and

consideration. It is called QC methods because

originally they were used in Quality Control (QC).

The methods are useful for efficient operations ifused in each step of problem solving procedure.



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4.1 Examples of QC Methods

QC seven

Tools

QC seven Tools

(New)

Statisticalmethods

Others

Cause & EffectDiagram

Systematicdiagram

Design ofexperiments

Samplingmethod

ParetoDiagram

Arrow diagram Regressionanalysis

Reliabilityengineering

Graphs Matrix diagram Cluster analysis FTA

Check sheets Affinity diagram Factor analysis FMEA

Histogram Association diagram Multivariate

analysis

Weibull paper

Scatterdiagram

Distribution diagram Correlationanalysis

Samplinginspn method

Control Chart PDPC method



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If QC methods are utilized... It is possible to evaluate data (information) at a

glance and to figure out points and problems. Utilizing QC Methods visualizes data and enables to

ask other people and intellectuals. Therefore, it

eventually a shortcut to solving problems.If the data is expressed by words or writing... How data is conveyed depends on expression ability

of senders, and sometime they fail to inform theirexact intention. Therefore, too much effort isnecessary in communication.

It is sometimes difficult to arrange ones thoughtsand to make judgments because an enormousamount of data should be organized all bythemselves.



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Summary

By utilizing QC methods, it is easy to carry out

Data (information) Stratification, Priority

Principle, Dispersion Control. Solution will befigured out effectively and efficiently if QC

Methods are utilized with the viewpoints of

what you want to get from the existing data.

Thereby, it is possible to proceed an operationappropriately and efficiently.



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23 April 2013 by : AVG 100

5.1 Respect for People

Human beings have feelings to develop

themselves, to delight customers and tocontribute to the society.

It is necessary to respect these feelings.



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23 April 2013 by : AVG 101


X-theory (Negative thinking)

A viewpoint of humanity that human beings are

basically lazy and they dont work unless they are

controlled by carrots and sticks. Y-theory (Positive thinking)

A viewpoint of humanity that human beings are

basically diligent and they work autonomously

without being told if conditions and environmentsare set up.

American scholar Douglas McGregor suggested

that participation into decision-making,responsible and challenging work andgood relationship among co-workers

maximize motivation to work.



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23 April 2013 by : AVG 102


Is Humanity Respect necessary!?

I wish operators to carry out

operations just as instructed without

exercising their creativity

No one tries to be proactive inworking..



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By respecting humanity Operators will perform their work with

motivation and efficiency will be improved.

Substantial growth will be promoted in work skill

problem solving ability.

Once the growth is promoted

More advanced problem solving can be

challenged. The quality level can be further

improved.


Documents

Concept of Quality Control