Tqm

Quality Time Line „ Pre-Industrial

Revolution – Quality controlled by individual craftsmen who were involved in all aspects of product.

„ 1875

– Mass production and the notion of division of labor – F.W. Taylor’s principles of scientific management G. Baker, Department of Statistics University of South Carolina; Slide 1

Quality Time Line „ 1925

– Walter Shewhart of Bell Labs introduces statistical process control „ 1930

– Dodge and Romig of Bell Labs introduce acceptance sampling methods

G. Baker, Department of Statistics University of South Carolina; Slide 2

Quality Time Line „

1945 – American Society for Quality Control

„

1950 – W. Edwards Deming develops a statistically based approach to continuous quality improvement – Deming does not get the attention of US management, but is readily accepted in Japan

„

1951 – Joseph M. Juran publishes his Quality Control Handbook, still in use as a reference many editions later G. Baker, Department of Statistics

University of South Carolina; Slide 3

1

Quality Time Line „ 1980

– US management begins to accept Deming’s approach to continuous improvement – Taguchi’s approach to product design, while initially ignored in Japan, is embraced by Ford Motor Company „ 1990

– TQM – Total Quality Management – QFD – Quality Function Deployment – Six Sigma G. Baker, Department of Statistics University of South Carolina; Slide 4

Quality Management in the US 1930-1970 Product Control is the Approach: ‰ Use of statistical sampling of process output to determine ppm. „ Acceptance sampling Quality Department is the Watchdog „ Separation of Quality and Production Departments Problem solving consists mainly of Firefighting. G. Baker, Department of Statistics University of South Carolina; Slide 5

Quality Management in the US 1980’s „ American

manufacturers strive to regain competitive position.

„ Start

to use statistical process control to understand process variation and reduce it.

„ Importance

of root causes is recognized. G. Baker, Department of Statistics University of South Carolina; Slide 6

2

Quality Management in the US Quality Effort by Activity

Percent Involvement

Japanese Companies Job 1

US Companies

Prod Devel

Design

Manufact

LP Sullivan, “The Seven Stages of CompanyWide Quality Control”, Quality Progress, 5/86

Prob Solve

G. Baker, Department of Statistics University of South Carolina; Slide 7

Quality Management in the US 1990’s „ Quality

is everyone’s responsibility – TQM - Push quality issue upstream to marketing, product design, engineering, production, etc. – Quality Function Deployment – translate needs of customer’s into products – Six Sigma - disciplined, data-driven approach and methodology for eliminating defects in any process. G. Baker, Department of Statistics University of South Carolina; Slide 8

Frederick Winslow Taylor 1884: became an executive at the Midville Steel company 1898: began to work for the Bethlehem Iron Company 1903: devised the concept for the Assembly Line 1856 - 1915

1911: introduced Scientific Management, including time studies, work standards and wage incentives. G. Baker, Department of Statistics

University of South Carolina; Slide 9

3

Walter Shewhart 1925 – started at Bell Labs. 1931 – first addresses the use of control charts as a means of detecting and eliminating sources of variation that are not inherent to the process in

1891 - 1967

Economic Control of Quality of Manufactured Product.

G. Baker, Department of Statistics University of South Carolina; Slide 10

Walter Shewhart „ Shewhart’s

control chart principles

– Process measurements are consistently taken over time – Data plots over time aid in converting numbers into information – Distinction between on-going variations and episodic variations support decisions about correction and improvement of processes G. Baker, Department of Statistics University of South Carolina; Slide 11

H.F. Dodge and H.G. ROMIG

H.G. Romig

H. G.F.Baker, Dodge Department of Statistics

University of South Carolina; Slide 12

4

H.F. Dodge and H.G. ROMIG „ At

Bell Labs same time as Shewhart

„ Acceptance

Sampling

– System of lot by lot inspection of inprocess and finished goods – AQL (acceptable quality level) is a by product ƒ Target level of defective material G. Baker, Department of Statistics University of South Carolina; Slide 13

W. Edwards Deming Out of the Crisis, 1982

The New Economics, 1994

1900 - 1993

G. Baker, Department of Statistics University of South Carolina; Slide 14

W. Edwards Deming „ Eminent

American Statistician in the 1930’s and 1940’s „ Brought statistical thinking and methods to Japan after WWII; to the US in the 1970’s „ How to put quality improvement on an institutional basis rather than a department basis „ Obligations and responsibilities of management spelled out in his “14 Points”. G. Baker, Department of Statistics University of South Carolina; Slide 15

5

W. Edwards Deming – 14 Points (1) (2) (3) (4) (5) (6) (7)

Create constancy of purpose for the improvement of product or service Adopt the new philosophy Cease dependence on mass inspection End the practice of awarding business on the basis of price tag Improve constantly Institute more thorough training Institute leadership G. Baker, Department of Statistics University of South Carolina; Slide 16

W. Edwards Deming – 14 Points (8) Drive out fear (9) Break down barriers between departments (10) Eliminate slogans and targets (11) Eliminate work standards (12)Remove the barriers that rob employees of their right to pride in workmanship (13) Institute programs of education and self-improvement (14) Put everybody to work to accomplish the transformation

G. Baker, Department of Statistics University of South Carolina; Slide 17

Plan-Do-Check-Act Cycle „ Discipline

used in process study Act – implement change if appropriate

Check impacts of proposed change

Plan for a change needed to improve process Do – test change on small scale, collect data G. Baker, Department of Statistics University of South Carolina; Slide 18

6

G. Taguchi Rather than detecting defects, let’s design quality into the product right from the beginning (“an ounce of prevention…”)

1924 -

Design a product/process the performance of which is insensitive to noise G. Baker, Department of Statistics University of South Carolina; Slide 19

Quality Loss

Traditional View of Loss

Quality Characteristic G. Baker, Department of Statistics University of South Carolina; Slide 20

Quality Loss

Taguchi’s Loss Function

Quality Characteristic G. Baker, Department of Statistics University of South Carolina; Slide 21

7

Joseph M. Juran Main contributions in the area of Quality Management. Initially published his Quality Control Handbook in 1951

G. Baker, Department of Statistics University of South Carolina; Slide 22

8