Total Quality Management & Basic QC Tools

- a journey of Continuous Improvement

Quality

What is Quality?

Quality defines the standard of goods or services as measured

against others of a similar kind. It is a distinctive attribute or
characteristic possessed by the good or service.

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Look at the products shown below

THUS, GOOD QUALITY IS VERY IMPORTANT

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 Total Quality Management (TQM)

TQM is a set of systematic activities carried out by the

entire organization
to effectively and efficiently achieve
the organization’s objectives
so as to provide products and services
with a level of quality that satisfies customers,
at the appropriate time and price.

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Total Quality Management (1-2)

Total means Involvement and input of everyone

in the company at all levels.

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TQM- A 21st Century Approach

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Managing Quality
Communication & Relationship Building Focus on Customer
focus on suppliers & partners enabling a trust only customers determine the level of quality
based relationship

Continuous Improvement Employee Involvement

right measuring tools, innovative and largely determines the quality of these
creative thinking for higher level of quality products or services

Fact Based Decision Making Process Centric

Not on opinions (emotions / personal fundamental part of TQM, people
interests) and data should support decision support these processes

Strategic & Systematic Approach Integrated Approach

Strategic Plan for quality development integrated organization system

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Benefits of TQM
Collects,
Improves Presents, Reduces
Identifies defects and Continuous
Management
and improves quality
decision
Analyses production improvement
making skills
data

Reduces
Enhances Encourages
Controls cost cycle time
Safety & teamwork
of poor and
Customer and
quality improves
Satisfaction confidence
efficiency

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 PDCA CYCLE
CONTINUAL IMPROVEMENT is an ongoing effort to improve products, services, or processes

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 SDCA CYCLE
SDCA Cycle is a refinement of the PDCA cycle wherein management decides first to establish the standard
before performing the regular PDCA function

The best, safest

Modify the and easiest way, to
standard based on achieve and
the results. maintain a defined
quality level. They
are created with
the employees.

Carrying out
Compare standards which
standards with includes training,
current situation practicing and
to verify intended experience.
use.

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Managing Quality

Daily Work Management

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Managing Quality : Understanding DWM

Work
a Task
mental or physical with
Defined Purpose / Goal
- Assigned Role
and Adds Value
Daily Management
Repeated Regularly Meeting the Objectives of the
activity in accordance to the
Standards
tacking necessary
action to correct any deviation

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Managing Quality : Understanding DWM
Improving
the
Status Quo
Things may not stay there,
they may deteriorate…
maintain the current status

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WHAT IS PROBLEM SOLVING?
The activities to fill the gap
between the current level and the intended target,
maintaining the framework of
the existing system.

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Quality Control Tools

The seven basic Quality Control Tools are:

 Cause and Effect Diagrams (Ishikawa Diagram)

 Flow Charts
 Check Sheets
 Histograms
 Pareto Charts
 Control Charts
 Scatter Diagrams

95% of the problem in a company

can be solved by using 7 QC Tools
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Quality Control Tools – Cause and Effect Diagram (1-7)
Check point : Causal factors which affect the achievement of the
• Cause and Effect managing points
Diagrams (Ishikawa
Diagram), also knows as
Fish Bone Diagram are Man Material
used for understanding
organizational or business P
Q
problem causes.
C
• A brainstorming session is Effect D
required in order to come S
up with an effective cause M
and effect diagram.
Environment Machine Method
• Breaks problems down
into bite-size pieces to
find root cause. CPs MPs

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Quality Control Tools – Flow Charts (2-7)

• One of the basic quality tool that

can be used for analyzing a
sequence of events.
• Identify process improvements.
• Understand the process.
• Shows duplicated effort and other
non-value-added steps.
• Clarify working relationships
between people and
organizations.
• Target specific steps in the
process for improvement.

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Quality Control Tools – Check Sheet (3-7)

• A check sheet is a
structured, prepared
form for collecting and
analyzing data.
• It is a document used to
collect data in real time
at the location where
the data is generated.
• The data it captures can
be quantitative or
qualitative.

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Quality Control Tools – Histograms (4-7)

• To determine the spread or

variation of a set of data
points in a graphical form.
• Allows you to understand at
a glance the variation that
exists in a process.
• The shape of the histogram
will show the process
behavior.
• Used to determine the
capability of a process .
• Starting point for the
improvement process.

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Quality Control Tools – Pareto Charts (5-7)

• Prioritize problems (80:20 Rule)

• Pareto analysis helps graphically
display results so the significant
few problems emerge from the
general background
• It tells you what to work on first
• This helps you to work on the
propriety issues in order to get
the condition under control.

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Quality Control Tools – Control Charts (6-7)

Control Chart – LR – 06.JAN.2018

• The primary purpose of a
600
Control Chart is to predict
500
expected product
400
outcome.
• Predicts process out of 300

MTTR (in min)

control and out of 200

specification limits 100

• Distinguish between 0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85
specific, identifiable -100

causes of variation -200

• Can be used for -300

Events
statistical process control
1σ -1 σ MTTR (in min) Control Line Upper Control Line Lower Control Line

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Quality Control Tools – Scatter Diagram (7-7)
• A scatter plot is a type
of plot or mathematical
diagram using Cartesian
coordinates to display values for
typically two variables for a set of
data.
• The scatter diagram graphs pairs of
numerical data, with one variable
on each axis, to look for a
relationship between them.
• If the variables are correlated, the
points will fall along a line or curve.
The better the correlation, the
tighter the points will hug the line.

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Achieving Quality : Application of Quality Tools
Define / Identify Planning & Evaluation
Analyzing Priortizing
Problem Execution of Result
Check Sheet

Control Chart

Cause and Effect

Scatter Diagram

Histogram

Pareto Chart

Flow Chart

Scatter Diagrams
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Challenging Quality

The way
forward…

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 Thank You!
together as a Team,
on a journey called TQM…

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