Paul Prunty

The 7 Basic Quality Tools~

The DMAIC Process

Continuous Improvement and …

To a hammer, everything’s a nail … How many tools do you have in your improvement tool kit ?

7 Basic Quality Tools

Paul Prunty

Cause-and-effect diagram also called Ishikawa or fishbone chart

Identifies many possible causes for an effect or problem and sorts ideas into useful categories.

Check sheet

A structured, prepared form for collecting and analyzing data; a generic tool that can be adapted for a wide variety of data

gathering purposes.

7 Basic Quality Tools

Paul Prunty

7 Basic Quality Tools

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Control charts

Graphs used to study how a process changes over time

Flow Chart

Visually shows sequential steps in a process using commonly accepted symbols.

Opportunity is Identified

Leadership

Establish Cross Functional Team

Team

Improvement Actions

Engineering

Measurement System Analysis

(MSA)

Team

Describe / Understand

Process

System OK ? No

Yes

7 Basic Quality Tools

Paul Prunty

7 Basic Quality Tools

Paul Prunty

Histogram

The most commonly used graph for showing frequency distributions, or how often each different value in a set of data

occurs.

7 Basic Quality Tools

Pareto chart

Shows on a bar graph which factors are more significant.

Paul Prunty

Scatter diagram

Graphs pairs of numerical data, one variable on each axis, to look for a relationship.

7 Basic Quality Tools

Paul Prunty

DefineDefine MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl

DMAIC Process Model

Paul Prunty

DMAIC – What is it?

The Quality Council of Indiana, in the QMC/OE Body of knowledge defines DMAIC as a process improvement tool and discusses it under management tools.

GE summarized the DMAIC process steps as:

• Define the customer’s critical-to-quality issues and core business process• Measure the performance of the core business process involved• Analyze the data and determine root causes or improvement opportunities• Improve the target process with creative solutions to fix and prevent problems• Monitor the process to sustain the improvements

DMAIC – What is it?

The Quality Council of Indiana, in the QMC/OE Body of knowledge defines DMAIC as a process improvement tool and discusses it under management tools.

GE summarized the DMAIC process steps as:

• Define the customer’s critical-to-quality issues and core business process• Measure the performance of the core business process involved• Analyze the data and determine root causes or improvement opportunities• Improve the target process with creative solutions to fix and prevent problems• Monitor the process to sustain the improvements

DefineDefine MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl

Define• Select and define project scope

- what needs fixing- what are project goals and objectives

• Define customer critical characteristics / features- who is the customer (internal / external)- what product or service is provided to the customer

• Select team- champion- leader- members

• Develop improvement / implementation plan• Create support infrastructure

Define Phase

Some other skills and toolsBrainstormingTeamingPlanning / Project ManagementAction PlansRun Chart / Trend Chart

Paul Prunty

DefineDefine MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl

Measure• Understand the process

- process map / flow chart- determine current performance- estimate capability of the process

• Identify critical process / product impacts- Key process input variables (KPIV) – the X’s- Key process output variables (KPOV) – the Y’s

• Determine measurement system reliability- conduct measurement system analysis (MSA)

• Determine key metrics• Understand Cause and Effect• Use selective control charting as a diagnostic

MeasurePhase

Opportunity is Identified

Leadership

Establish Cross Functional Team

Team

Improvement Actions

Engineering

Measurement System Analysis

(MSA)

Team

Describe / Understand

Process

System OK ? No

Yes

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Some other skills and toolsProcess Capability Study (Cp, Cpk)MSA Studies (GR & R, Anova)Run Chart / Trend Chart

Paul Prunty

DefineDefine MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl

Analyze• Assess process variation• Determine components of variation (multi-var charts)• Determine the defect cause• Identify critical process / control elements

- products- features- process

• Assess process capability• Determine potential improvement actions

- conduct hypothesis tests- conduct ANOVA

Analyze Phase

Some other skills and toolsBrainstormingProcess Capability Study (Cp, Cpk)Statistical Analysis (e.g. DOE, Anova)5 Why Root Cause Analysis

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Paul Prunty

DefineDefine MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl

Improve• Implement improvement actions• Optimize the process• Implement actions to reduce variability

- target tolerancing- process controls- preventive / corrective actions

• Implement actions to eliminate defects- Special cause variation

Improve Phase

Some other skills and toolsAction Plans

Statistical Analysis (e.g. Cpk)Statistical Analysis (e.g. DOE, Anova)Sample PlansQuality Control Plans

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Paul Prunty

DefineDefine MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl

Control• Monitor and control the process over time

- control plans- control charts

• Mistake proof• Reduce common cause (random) variation• Rule of Thumb: Cp 2 , Cpk 1.5

Control Phase

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Some other skills and toolsPoka-yoke (mistake proof)Statistical Analysis (e.g. Cpk)SPCSample PlansControl PlansPDCA (PDSA) Cycle

Paul Prunty

References:• 7 Basic Tools: Excerpted from Nancy R. Tague’s The Quality Toolbox, Second Edition, ASQ Quality Press, 2004, page 15.• CMQ/OE Primer 2010, Quality Council of Indiana

Learn More:• The Quality Toolbox, Second Edition, Tague, Nancy R.• Implementing Six Sigma: Smarter Solutions Using Statistical Methods, 2nd Edition, Breyfogle, Forrest W

How many tools do you have in your quality tool kit ?

Albert Einstein

Who said:

“The important thing is not to stop questioning.”

“Insanity: doing the same thing over and over again and expecting different results.”  

Paul Prunty

Anything More?