Six Sigma and Quality Management - Quality and Six Sigma

Six Sigma and Quality Management

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Contents

Articles

Quality Management

1

Quality control

1

Total quality management

3

Quality management system

4

The Roots of Modern Quality Management

8

Walter A. Shewhart

8

W. Edwards Deming

12

Kaoru Ishikawa

25

Joseph M. Juran

28

PDCA

33

Kaizen

35

Just in time (business)

39

ISO 9000

45

Malcolm Baldrige National Quality Award

55

EFQM Excellence Model

61

EFQM Excellence Award

62

SERVQUAL

63

The basics of Six Sigma

65

Six Sigma

65

Seven Basic Tools of Quality

76

Tools

78

Ishikawa diagram

78

Check sheet

82

Histogram

86

Control chart

92

Pareto chart

100

Scatter plot

102

Stratified sampling

104

Flowchart

106

Run chart

111

Statistical process control

113

Systems for Implimentation

117

DMAIC

117

Design for Six Sigma

118

Voice of the customer

121

Poka-yoke

123

Muda (Japanese term)

125

Nemawashi

128

Blue Ocean Strategy

129

TRIZ

135

Lean Six Sigma

140

An Alternative Approach

141

Appreciative inquiry

141

References

Article Sources and Contributors

144

Image Sources, Licenses and Contributors

148

Article Licenses

License

149

1

Quality Management

Quality control

Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects:

1. Elements such as controls, job management, defined and well managed processes,[1][2] performance and integrity criteria, and identification of records

2. Competence, such as knowledge, skills, experience, and qualifications

3. Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit, and quality relationships.

Controls include product inspection, where every product is examined visually, and often using a stereo microscope for fine detail before the product is sold into the external market. Inspectors will be provided with lists and descriptions of unacceptable product defects such as cracks or surface blemishes for example.

The quality of the outputs is at risk if any of these three aspects is deficient in any way.

Quality control emphasizes testing of products to uncover defects and reporting to management who make the decision to allow or deny product release, whereas quality assurance attempts to improve and stabilize production (and associated processes) to avoid, or at least minimize, issues which led to the defect(s) in the first place. For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract.[3]

Maintenance check of electronic equipment on a U.S. Navy aircraft.

X-ray zoom series of a network adapter card.

Total quality control

"Total quality control", also called total quality management, is an approach that extends beyond ordinary statistical quality control techniques and quality improvement methods. It implies a complete overview and re-evaluation of the specification of a product, rather than just considering a more limited set of changeable features within an existing product. If the original specification does not reflect the correct quality requirements, quality cannot be inspected or manufactured into the product. For instance, the design of a pressure vessel should include not only the material and dimensions, but also operating, environmental, safety, reliability and maintainability requirements, and documentation of findings about these requirements.

Quality control

2

Quality control in project management

In project management, quality control requires the project manager and the project team to inspect the accomplished work to ensure its alignment with the project scope.[4] In practice, projects typically have a dedicated quality control team which focuses on this area.

Notes

[1] Adsit, D. (2007) What the call center industry can learn from manufacturing: Part I, In Queue, In_Queue/ vol2no21. html

[2] Adsit, D. (2007) What the call center industry can learn from manufacturing: Part II, In Queue, In_Queue/ vol2no22. html

[3] Position Classification Standard for Quality Assurance Series, GS-1910, [4] Phillips, Joseph (November 2008). "Quality Control in Project Management" (

quality-control-in-project-management). .

References

? This article incorporates public domain material from the General Services Administration document "Federal Standard 1037C" () (in support of MIL-STD-188).

? Godfrey, A. B., Juran's Quality Handbook, 1999. ISBN 007034003. ? Pyzdek, T., Quality Engineering Handbook, 2003. ISBN 0-8247-4614-7.

Further reading

? OSDL Data Base Test Suite Backgrounder (. org/newsroom/press_releases/2003/2003_03_03_beaverton_backgrounder.html), Press releases, Open Source Development Labs, 3 March 2003, archived from the original ( 2003/2003_03_03_beaverton_backgrounder.html) on 5 June 2004, retrieved 29 June 2009

? QACity: Resources for Busy Testers ( front.htm), LogiGear, archived from the original () on 9 October 2004, retrieved 29 June 2009

? Home (. htm), Saksoft, 29 May 2004, archived from the original (. htm) on 10 August 2004, retrieved 29 June 2009

? The Quality Assurance Journal (), 01 April 2010, retrieved 2 May 2010

? Quality Progress Magazine (), 01 April 2010, retrieved 2 May 2010

? Quality Assurance in the View of a Commercial Analytical Laboratory ( q922ehvpaq49pw6q/), 01 April 2010, retrieved 2 May 2010

Total quality management

3

Total quality management

Total quality management or TQM is an integrative philosophy of management for continuously improving the quality of products and processes.[1]

TQM functions on the premise that the quality of products and processes is the responsibility of everyone who is involved with the creation or consumption of the products or services offered by an organization. In other words, TQM capitalizes on the involvement of management, workforce, suppliers, and even customers, in order to meet or exceed customer expectations. Considering the practices of TQM as discussed in six empirical studies, Cua, McKone, and Schroeder (2001) identified the nine common TQM practices as cross-functional product design, process management, supplier quality management, customer involvement, information and feedback, committed leadership, strategic planning, cross-functional training, and employee involvement.[2]

TQM and Six Sigma

The TQM concept was developed by a number of American management consultants, including W. Edwards Deming, Joeseph Juran, and A.V. Feigenbaum.[3] Originally, these consultants won few converts in the United States. However, managers in Japan embraced their ideas enthusiastically and even named their premier annual prize for manufacturing excellence after Deming.

The Six Sigma management strategy originated in 1986 from Motorola's drive towards reducing defects by minimizing variation in processes.[4] The main difference between TQM and Six Sigma (a newer concept) is the approach.[5] At its core, Total Quality Management (TQM) is a management approach to long-term success through customer satisfaction.

In a TQM effort, all members of an organization participate in improving processes, products, services and the culture in which they work.

The methods for implementing this approach come from people such as Philip B. Crosby, W. Edwards Deming, Armand V. Feigenbaum, Kaoru Ishikawa and Joseph M. Juran.

References

[1] Ahire, S. L. 1997. Management Science- Total Quality Management interfaces: An integrative framework. Interfaces 27 (6) 91-105. [2] Cua, K. O., K. E. McKone, and R. G. Schroeder. 2001. Relationships between implementation of TQM, JIT, and TPM and manufacturing

performance. Journal of Operations Management 19 (6) 675-694. [3] 'How to Build Quality,' Economist, September 23, 1989, 91-92.' [4] Anand, G., P. T. Ward, and M. V. Tatikonda. 2010. Role of explicit and tacit knowledge in six sigma projects: An empirical examination of

differential project success. Journal of Operations Management 28 (4) 303-315. [5] "Six Sigma vs. Total Quality Management" (). . Retrieved April 19, 2010.

Further reading

? Deming, W. Edwards. Out of the Crisis (1986) ? Ishikawa, Kaoru. What is Total Quality Control? The Japanese Way (1985) ? Feigenbaum, A.V. Total Quality Control (1991) ? Juran, J.M. Juran on Leadership for Quality: An Executive Handbook (1989) ? Crosby, Philip B. (January 1989). Let's Talk Quality: 96 Questions You Always Wanted to ask Phil Crosby (1st

ed.). McGraw-Hill. p. 208. ISBN 978-0-07-014565-8.

Quality management system

4

Quality management system

A quality management system (QMS) can be expressed as the organizational structure, procedures, processes and resources needed to implement quality management. Early systems emphasized predictable outcomes of an industrial product production line, using simple statistics and random sampling. By the 20th century, labour inputs were typically the most costly inputs in most industrialized societies, so focus shifted to team cooperation and dynamics, especially the early signalling of problems via a continuous improvement cycle. In the 21st century, QMS has tended to converge with sustainability and transparency initiatives, as both investor and customer satisfaction and perceived quality is increasingly tied to these factors. Of all QMS regimes the ISO 9000 and ISO 14000 series are probably the most widely implemented worldwide - the ISO 19011 audit regime applies to both, and deals with quality and sustainability and their integration.

Other QMS, e.g. Natural Step, focus on sustainability issues and assume that other quality problems will be reduced as result of the systematic thinking, transparency, documentation and diagnostic discipline that sustainability focus implies. See sustainability for more on this approach to quality management.

Elements of a Quality Management System

1. Organizational structure 2. Responsibilities 3. Methods 4. Data Management 5. Processes - including purchasing 6. Resources - including natural resources and human capital 7. Customer Satisfaction 8. Continuous Improvement 9. Product Quality 10. Maintenance 11. Sustainability - including efficient resource use and responsible environmental operations 12. Transparency and independent audit

Concept of quality - historical background

The concept of quality as we think of it now first emerged out of the Industrial Revolution. Previously goods had been made from start to finish by the same person or team of people, with handcrafting and tweaking the product to meet 'quality criteria'. Mass production brought huge teams of people together to work on specific stages of production where one person would not necessarily complete a product from start to finish. In the late 19th century pioneers such as Frederick Winslow Taylor and Henry Ford recognized the limitations of the methods being used in mass production at the time and the subsequent varying quality of output. Birland established Quality Departments to oversee the quality of production and rectifying of errors, and Ford emphasized standardization of design and component standards to ensure a standard product was produced. Management of quality was the responsibility of the Quality department and was implemented by Inspection of product output to 'catch' defects.

Application of statistical control came later as a result of World War production methods, and were advanced by the work done of W. Edwards Deming, a statistician, after whom the Deming Prize for quality is named. Joseph M. Juran focused more on managing for quality. The first edition of Juran's Quality Control Handbook was published in 1951. He also developed the "Juran's trilogy," an approach to cross-functional management that is composed of three managerial processes: quality planning, quality control and quality improvement. These functions all play a vital role when evaluating quality.

Quality management system

5

Quality, as a profession and the managerial process associated with the quality function, was introduced during the second-half of the 20th century, and has evolved since then. Over this period, few other disciplines have seen as many changes as the quality profession.

The quality profession grew from simple control, to engineering, to systems engineering. Quality control activities were predominant in the 1940s, 1950s, and 1960s. The 1970s were an era of quality engineering and the 1990s saw quality systems as an emerging field. Like medicine, accounting, and engineering, quality has achieved status as a recognized profession

Quality system for medical devices

Quality System requirements for medical have been internationally recognized as a way to assure product safety and

efficacy and customer satisfaction since at least 1983, and were instituted as requirements in a final rule published on October 7, 1996 [1]. The U.S. Food and Drug Administration (FDA) had documented design defects in medical

devices that contributed to recalls from 1983 to 1989 that would have been prevented if Quality Systems had been in place. The rule is promulgated at 21 CFR 820 [2].

According to current Good Manufacturing Practice (GMP), medical device manufacturers have the responsibility to use good judgment when developing their quality system and apply those sections of the FDA Quality System (QS) Regulation that are applicable to their specific products and operations, in Part 820 [2] of the QS regulation. As with GMP, operating within this flexibility, it is the responsibility of each manufacturer to establish requirements for each type or family of devices that will result in devices that are safe and effective, and to establish methods and procedures to design, produce, and distribute devices that meet the quality system requirements.

The FDA has identified in the QS regulation the essential elements that a quality system shall embody for design, production and distribution, without prescribing specific ways to establish these elements. These elements include:

? personnel training and qualification; ? controlling the product design; ? controlling documentation; ? controlling purchasing; ? product identification and traceability at all stages of production; ? controlling and defining production and process; ? defining and controlling inspection, measuring and test equipment; ? validating processes; ? product acceptance; ? controlling nonconforming product; ? instituting corrective and preventive action when errors occur; ? labeling and packaging controls;

Quality System

? handling, storage, distribution and installation; ? records; ? servicing; ? statistical techniques;

all overseen by Management Responsibility and Quality Audits.

Because the QS regulation covers a broad spectrum of devices and production processes, it allows some leeway in the details of quality system elements. It is left to manufacturers to determine the necessity for, or extent of, some quality elements and to develop and implement procedures tailored to their particular processes and devices. For example, if it is impossible to mix up labels at a manufacturer because there is only one label to each product, then there is no necessity for the manufacturer to comply with all of the GMP requirements under device labeling.

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