New 7 QC tools - math.mun.cavariyath/New7QCTools.pdf · New vs. Old • Old 7 QC tools • 1. Check...

New7QCtools�

ByShuaiZhangKunWang�

Newvs.Old�

•  Old7QCtools•  1.Checklist•  2.Fishbonediagram•  3.Controlchart•  4.Histogram•  5.Paretochart•  6.Sca>erdiagram

•  7.Stra@fica@on�

Feature:

Dataorienta@on:Focusonnumericaldatameasureandcalcula@on.

Newvs.Old�

•  However,manycustomerrequirementscannotalwaysbeadequatelyexpressedbynumericaldataalone. �

Newvs.Old�

•  Nevertheless,evenverbalstatementscanbeexpressionsoffacts,becauseitrepresentsfacts,weoughttouseverbaldataaswellasnumericaldatainmanagingquality.�

Newvs.Old�

•  1.Rela@onsdiagram

•  2.Treediagram•  3.Arrowdiagram•  4.Affinitydiagram

•  5.Matrixdiagram•  6.Matrixdataanalysisdiagram

•  7.Processdecisionprogramchart.(PDPC)�

Features

•  Combineverbalwithnumerical

•  Lookingforrootcause•  Clarify,priori@zegoalsandschedule

•  Involveeveryoneintofullcoopera@on

•  Generateideas

Newvs.Old�

•  New7QCtoolsarecompa@blewithOld7QCtools,andcomplementthem.�

Strategic,orienta@ons�

Tac@cal,measures�

New7�

Old7 �

1.RelaConShipDiagram�

•  DecideEFFECTS•  DecideIMMEDIATECAUSES•  ConnectIMMEDIATECAUSEStoEffects•  TakingImmediateCausesaseffecttofindCAUSESforthem

•  ExploreRELATIONSHIPofCausesandConnectthem•  Findingmoreimportantcausesandprominentlinks•  MakethelinkSHORT,makethediagramCOMPACT•  Titleit

1.Rela@onShipDiagram �

1.Rela@onShipDiagram �

ApplicaCons•  Explorecauseandeffectrela@onships•  Especiallyforcomplexsitua@onswherethecausesarelikelytobeMUTUALLYRELATED�

2.AffinityDiagram�

•  Organizelargenumberofideasintoalogicalway,makethemintoasystema@cordertohelpyouplanac@ons �

2.AffinityDiagram�

•  1.SUBJECTTOPICS•  2.GenerateaLargeNumberofIDEAS

•  3.Decide#andTitle,createaCARD•  4.Distributealltheideasamongthecards

•  5.Arrangethecardsaccordingtotherela@onshipsbetweenthegroups

•  6.Titleit

2.AffinityDiagram�

ApplicaCons•  Breakupanycomplexproblemortaskintosmallermoreeasilymanageablebits

2.AffinityDiagram�

•  Example:

YoucanorganizethecustomercomplainsandrequirementsinanAffinityDiagram�

2.AffinityDiagram�

2.AffinityDiagram�

2.AffinityDiagram�

3.TreeDiagram�

•  Iden@fyahighPRIORITYPROBLEMthatneedtobesolvedearliest.

•  ChooseFORM:TreeorCascade?•  Iden@fyPRIMARYMEANS•  Iden@fySECENDARYMEANSforprimarymeans•  TERTIARYMEANS•  Con@nuetheprocess@llthegroupfeelsthattheENDofthelinehasbeenreached

•  UseofPOST‐ITPAD•  ConsensusofMEANS•  Titleit �

3.TreeDiagram�

Cascade�

3.TreeDiagram�

TreeForm�

3.TreeDiagram�

ApplicaCons•  Developasystema@cstepbystepstrategytoachieveanobjec@ve.

•  Devisesolu@onforproblems�

Reference�

•  Applica@onofSevenNewQCTools�ByMuhammadAmjadManager,

QualityAssuranceNewageCables(Pvt)Limited,Lahore–Pakistan�•  7ADVANCEDQCTOOLS,CompiledfromDLShahTrustpublica@onByB.Girish,Dy.DirectorNa@onalProduc@vityCouncil,Chennai �

4.MatrixDiagram�

•  Purpose:Exploretheexistenceandtheextentofrela@ons between individual items in 2 sets offactors or features and characteris@cs andexpress them in a symbolic form that is easy tounderstand.

•  Mostlyusedtounderstandtherela@onsbetweenthe customer expecta@ons as expressed by thecustomers and product characteris@cs asdesigned, manufactured and tested by themanufacturer.�

Procedures�

1.  Determine2setsoffactorsforwhichtherela@onsareneededtobeestablished.

2.  Dividethefeaturesandcharacteris@csintoprimary,secondaryandter@arycharacteris@cs.

3.  Placethefeaturesver@callyonthelegsideofthematrixandcharacteris@cshorizontallyontopofthematrix.

4.  Entertheimportanceofthefeaturesonthecolumnagerthatfortheter@aryfeatures.�

Procedures(Con@nue)�

5.  Inthemainbodyofthematrix,usethesymbolstorepresentthedegreeofconnec@onsbetweenthefeaturesandthecharacteris@cs.

Applica@on �

•  Matrixdiagramcanbeusedtosolveproblemsbyarrangingdatainsuchawaythattherela@onsbetweenrelevantfactorsarebroughtintosharpfocus.

•  Thereisnolimittotheuseofthetool.•  Themostimportantapplica@onofmatrixdiagramisinclarifyingrela@onsbetweenindividualfeaturesofcustomerrequirementsandindividualproductcharacteris@cs. �

ExampleofMatrixDiagram�

5.MatrixDataAnalysisDiagram�

•  Purpose:Topresentnumericaldataabouttwosetsoffactorsinamatrixformandanalyzeittogetnumericaloutput.

•  Canbeappliedinunderstandingtheproductsandproductscharacteris@cs.

Procedure�

1.  Decidethetwofactorswhoserela@onsaretobeanalyzed.

2.  Checkthenumberofindividualitemsinthetwofactors.

3.  Prepareamatrixtoaccommodatealltheitemsofthetwofactors.

4.  Enternumericaldatainthematrix.5.  Givethediagramasuitable@tle.

Example�

6.ProcessDecisionProgramChart�

Purpose：Toprepareforabnormaloccurrenceswithlowprobabilitywhichmayotherwisebeoverlookedandtopresenttheoccurrencesaswellasthenecessarycountermeasurestoguardagainstsuchoccurrencesintheformofavisualchart. �

Procedure�

1.  Prepareanormalflowchartwithallexpectedeventsinthechart.

2.  Considerthepossibleoccurrencesthatwillaffecttheprocessanddemonstratethroughbranchingatappropriateloca@ons.

3.  Considerhowtheabnormaloccurrenceswillinfluencetheprocessandfindwaystocounterthem.

4.  Showthecountermeasuresconnec@ngtotheabnormaloccurrencesononesideandtheprocessofthegoalontheother.

Applica@ons �

•  Thistoolhasthewidestrangeofapplica@onsfromthesimplesttothemostcomplex.

•  Thetoolcanbeusedtopreventproblemsbyiden@fyingopportuni@esforerroranddevisingmeasurestoavoidfailure.

•  Itcanbeusedduringtheimplementa@onofsolu@onsforpredic@ngresistanceandforplanningmeasurestoovercometheresistance

Examples�

7.ArrowDiagram�

Purpose:Tocreateavisualpresenta@onofthestepsofaprocessortasksnecessarytocompleteaprojectwithspecialemphasisonthe@metakenfortheseac@vi@es.�

Procedure�

1.  Listallthetasksorac@vi@esneededtobeaccomplishedbeforetheprocessoftheproject.

2.  Decidewhichstepsareundertakeninseriesandwhichstepscanberuninparallel.Arrangetheac@vi@esinapropersequence.

3.  Prepare‘EventNodes’atthecomple@onofstepsandnumberthem.

4.  Writethedescrip@onofthestepanddecidethe@merequiredforcomple@ngeachstep.

Procedure(Con@mue) �

5.  Calculatetheearliest@metoreachaneventnodeforthestartoftheprocess.

7.  Agerthe@meforalleventnodesincludingthecomple@onoftheprocessortheprojectisavailable,onecalculatesthelatest@mebywhichaneventnodemustbereached.

Applica@on �

•  Thediagramisalsousefulinplanningandschedulingstepsincomplicatedprocesses,especiallyinplanningandschedulingprojectswhichinvolvealargenumberofac@vi@es.

Example�

1.  Iden@fythetasks.E.g:1,2,3,…,15.2.  Knowthe@meeachtaskneeds.3.  Determinewhichtaskscanberuninparallelandin

normalsequences.4.  Drawthesequencediagramandfindthecri@calpath.5.  Calculatetheprojectdura@on.6.  Calculatetheearlieststar@ng@me(ortheearliest

finishing@meoflasttask)andthelatestfinishing@meofeachtask(thelateststar@ng@meforthefollow@ngtask).

7.  Markthe@meindica@on. �

Example. �

Example. �

Example�