14 WEEKS TOPICS

W1: Quality concept, quality and system connection

W2: Pioneers of Total Quality Management
W3: Quality Costs
W4: Data Analysis
W5: Acceptance Sampling for Non-Measurable Characteristics (Attributes)
W6: Acceptance Sampling for Measurable Characteristics (Variables)
W7: Acceptance Sampling for Measurable Characteristics (Variables)
W8: Midterm Exam
W9: Fundamentals of Process Control Diagrams
W10: Process Control Diagrams for Variables (X-R, X-S, MR-IX)
W11: Process Control Diagrams for Attributes (p, np, c, u)
W12: Process Capability Analysis and Pre-Control
W13: Time Based Process Control Diagrams (EWMA, CUSUM)
W14: Quality standards (ISO 9001, ISO 14001, ISO 22200, ISO 27001, ISO 45001)
RESOURCES TO BE USED
 Alp BARAY, "Üretimde Varyasyon", Çağlayan Kitabevi

 Douglas MONTGOMERY, "Statistical Quality

Control, A Modern Introduction", John Wiley &
Sons, 7th Edition

 Douglas MONTGOMERY, George RUNGER,

"Applied Statistics and Probability for Engineers",
John Wiley & Sons, 5th Edition
 Amitava Mitra, (2016).Fundamentals of Quality
Control and Improvement, John Wiley & Sons,
4nd Edition.

2
QUALITY PIONEERS
 IMPORTANT WARNING

These notes have been prepared by

Dr. Sinem BÜYÜKSAATÇI KİRİŞ and are prohibited to be
printed, reproduced, uploaded to the internet or used in
training seminars by a person or organization without her
consent.
QUALITY PIONEERS: REMINDER

Kaize
QUALITY PIONEERS:
Joseph Juran (1904-2008)

 He worked on quality costs.

 He laid the foundations of Quality Function Deployment (QFD).
 Juran addresses firms' quality-related duties at two levels:
1. The company's duty is to provide fitness for use for its customers.
2. The duty of company departments is to work in accordance with the
standards prepared to ensure suitability for use.
QUALITY PIONEERS:
QUALITY PIONEERS:
Joseph Juran (1904-2008)
QUALITY PIONEERS:
Joseph Juran (1904-2008)

Juran’ın Quality Planning Road Map

1. Identify who the customers are.
2. Determine the needs of those customers.
3. Translate those needs into the
organization's language.
4. Develop a product that can respond to
those needs.
5. Optimize the product features so as to meet
the organization's needs as well as
customer needs.
6. Develop a process which is able to produce
the product.
7. Optimize the process.
8. Prove that the process can produce the
product under operating conditions.
9. Transfer the process to operations.
QUALITY PIONEERS:
Joseph Juran (1904-2008)

Quality Control
This phase includes measuring the quality performance, comparing it with
the standard and working on the differences. The problems in this phase
are problems that appear suddenly and Statistical Process Control should
be used mainly for their solutions.
Quality Improvement
Problems in this stage are chronic (customary, accepted, ongoing)
problems. Chronic problems can only be solved by management. Juran
recommends quality improvement groups to solve these problems. Each
problem should be handled and resolved by a group on a project basis.
Management should also take part in project to support quality
improvement groups and demonstrate their determination.
QUALITY PIONEERS:
Joseph Juran (1904-2008)

Ten Steps to Continuous Quality Improvement

1. Create awareness of the need and opportunity for quality improvement
2. Set goals for continuous improvement.
3. Build an organisation to achieve goals by establishing a quality council,
identifying problems selecting a project appointing teams and choosing
facilitators .
4. Give everyone training .
5. Carry out projects to solve problems.
6. Report progress - enables experience and learning to be shared/sense
of achievement .
7. Show recognition.
8. Communicate results.
9. Keep a record of successes - for reference .
10. Incorporate annual improvements into the company’s regular systems
and processes and thereby maintain momentum.
 QUALITY PIONEERS:
Philip Crosby (1926-2001)

 He argues that profit will increase with quality improvement.

 According to Crosby; Quality costs are not only wasted labor, wasted
equipment time, scrap, rework, and lost sales, but also organizational
costs that are difficult to quantify. Therefore, efforts to improve quality
are better than paying for quality. Thus, costs will be avoided and
“quality will be free”.
 Crosby's approach is "Doing it right the first time "
 He also introduced the concept of "zero defects".
QUALITY PIONEERS:
Philip Crosby (1926-2001)
QUALITY PIONEERS:
Philip Crosby (1926-2001)
 QUALITY PIONEERS:
Armand V. Feigenbaum (1922-2014)
 He is the originator of the Total Quality Control
idea. He defined Total Quality Control as:
‘’Total quality control is an effective system for integrating the quality
development, quality maintenance, and quality improvement efforts of the
various groups in an organization so as to enable production and service at
the most economical levels which allow full customer satisfaction.’’
 Classified costs of quality. The cost of quality isn’t the price of creating a
quality product or service. It’s the cost of NOT creating a quality product
or service..
QUALITY PIONEERS:
Kaoru Ishikawa (1915-1989)
 Leader of the Japanese Quality Movement.
 Ishikawa developed concept of “true” and “substitute” quality
characteristics. Accordingly, true quality characteristics are the
customer's opinion on product performance. Substitute quality
characteristics are the manufacturer's opinion on product performance.
 Advocate the use of the 7 Quality Control tools:
 Cause-effect diagram/fishbone diagram

 Process flow diagram

 Histogram

 Check Sheet

 Scatter diagram

 Pareto graph

 Control charts
QUALITY PIONEERS:
Kaoru Ishikawa (1915-1989)
QUALITY PIONEERS:
Kaoru Ishikawa (1915-1989)

 He was the first to introduce the concept of

quality circles.

Quality circle: It is a group of volunteers, whose

number varies between 5 and 10 people, working
in the same field, doing similar jobs, meeting
regularly, identifying and solving problems related
to their own work.

These quality groups are part of the continuous quality control throughout
the enterprise and develop themselves with the participation of all
members, as well as provide supervision and progress.
QUALITY PIONEERS:
Kaoru Ishikawa (1915-1989)

Objectives of Quality Circles

• Promote job involvement
• Create problem solving capability
• Improve communication
• Promote leadership qualities
• Promote personal development
• Develop a greater awareness for cleanliness
• Develop greater awareness for safety
QUALITY PIONEERS:
Kaoru Ishikawa (1915-1989)

Benefits of Quality Circles

• Self development.
• Promotes leadership qualities among participants.
• Recognition.
• Achievement satisfaction.
• Promotes group/team working.
• Serves as cementing force between
management/non-management groups.
• Promotes continuous improvement in products
and services.
• Brings about a change in environment of more
productivity, better quality, reduced costs,
• Safety and corresponding rewards.
 QUALITY PIONEERS:
Kaoru Ishikawa (1915-1989)
Mr. Ishikawa's philosophy of total quality management can be summarized
by his 11 points:
QUALITY PIONEERS:
Genichi Taguchi (1924-2012)

 Taguchi has considered quality from an engineering point

of view.
 He emphasized the importance of variation for quality.
 Taguchi considers “Design for Quality” at three levels:
 System Design: Functional design on top of existing technology or
architecture
 Parameter Design: Reducing costs and improving performance
without eliminating the causes of variation
 Tolerance Design: reducing variation by controlling causes with a
given cost increase
 He is the founder of Design of Experiment systematic.
QUALITY PIONEERS:
Genichi Taguchi (1924-2012)

When a product moves from its

There is Good or Bad Products
Target will cause the loss even if
only as per Limits
the product lies or not within Limits
QUALITY PIONEERS:
Genichi Taguchi (1924-2012)
QUALITY PIONEERS:
Shigeo Shingo (1909-1990)

 He is the inventor of the Single Minute Exchange of Die

(SMED) and Poka Yoke systems.
 The main purpose of Poke Yoke is to make improvements that will
prevent the mistakes, defects and parts that occur as a result of the
carelessness of the employees.
 Poka Yoke elements include terminator switches, beacons, sensors,
setting pins, counters, etc. Its basic functions are shutdown/stop,
control and warning.
QUALITY PIONEERS:
Shigeo Shingo (1909-1990)
QUALITY PIONEERS:
Shigeo Shingo (1909-1990)
QUALITY PIONEERS:
Taiichi Ohno (1912-1990)

 Creator of the Toyota Production System.

QUALITY PIONEERS:
Masaaki Imai (1930-…)

 Japanese organizational theorist and

management consultant, known for his
work on quality management, specifically
on Kaizen.

Kaizen is a Japanese Word, which

means continuous improvement
or improvement over
improvement. It is process of
continuous improvements in
small increments that make the
process more efficient, effective,
controllable, and adequate
QUALITY PIONEERS:
Masaaki Imai (1930-…)

Kaizen begins with the notion than an organisation can assure its long-
term survival and success only when every member in the operating
system and throughout the firm, actively pursues opportunities to identify
and implement improvements everyday.
Kaizen incremental improvements by understanding the functions of the
current system and its weaknesses or relative inefficiencies. Furthermore,
small improvements gain returns the firm without the need for large,
initial investments to fund major innovations like a new, automated
assembly line.
The quality improvement perspective of kaizen is best described by an old
saying , “Everyday and in every way, we are getting better and better”.