Continuous Improvement and …
The 7 Basic Quality Tools
~
The DMAIC Process
To a hammer, everything’s a nail …
How many tools do you have in your improvement tool kit ?
7 Basic Quality Tools
Cause-and-effect diagram
also called Ishikawa or fishbone chart
Identifies many possible causes for an effect or problem and
sorts ideas into useful categories.
7 Basic Quality Tools
Check sheet
A structured, prepared form for collecting and analyzing data; a
generic tool that can be adapted for a wide variety of data
gathering purposes.
100
150
200
250
300
350
400
450
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7 Basic Quality Tools
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PVC ppmh
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Control charts
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Graphs used to study how a process changes over time
7 Basic Quality Tools
Flow Chart
Visually shows sequential steps in a process using commonly
accepted symbols.
Opportunity
is Identified
Leadership
Establish Cross
Functional Team
Team
Describe /
Understand
Process
Engineering
Measurement
System Analysis
(MSA)
Team
System OK ? No Improvement
Actions
Yes
7 Basic Quality Tools
Histogram
The most commonly used graph for showing frequency
distributions, or how often each different value in a set of data
occurs.
7 Basic Quality Tools
Pareto chart
Shows on a bar graph which factors are more significant.
7 Basic Quality Tools
Scatter diagram
Graphs pairs of numerical data, one variable on each axis, to
look for a relationship.
30
20
Result
10
0 10 20 30 40 50 60 70 80 90 100
Rx
DMAIC
Define Measure Analyze Improve Control Process
Model
DMAIC – What is it?
The Quality Council of Indiana, in the QMC/OE Body of knowledge defines DMAIC
as a process improvement tool and discusses it under management tools.
GE summarized the DMAIC process steps as:
• Define the customer’s critical-to-quality issues and core business process
• Measure the performance of the core business process involved
• Analyze the data and determine root causes or improvement opportunities
• Improve the target process with creative solutions to fix and prevent problems
• Monitor the process to sustain the improvements
Define Measure Analyze Improve Control
Define
Phase
Define
• Select and define project scope
- what needs fixing
- what are project goals and objectives
• Define customer critical characteristics / features
- who is the customer (internal / external)
- what product or service is provided to the customer
• Select team
- champion
- leader
- members
• Develop improvement / implementation plan
• Create support infrastructure
Some other skills and tools
Brainstorming
Teaming
Planning / Project Management
Action Plans
Run Chart / Trend Chart
Define Measure Analyze Improve Control
Measure
Phase
Opportunity
is Identified
Measure
• Understand the process
Leadership
Establish Cross
Functional Team
- process map / flow chart Team
- determine current performance Describe /
Understand
Process
- estimate capability of the process Engineering
• Identify critical process / product impacts
Measurement
System Analysis
(MSA)
- Key process input variables (KPIV) – the X’s System OK ? No
Team
Improvement
- Key process output variables (KPOV) – the Y’s
Actions
Yes
• Determine measurement system reliability
- conduct measurement system analysis (MSA)
• Determine key metrics
• Understand Cause and Effect
• Use selective control charting as a diagnostic
PVC ppmh
450
400
350
Some other skills and tools 300
Process Capability Study (Cp, Cpk) 250
200
MSA Studies (GR & R, Anova) 150
100
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Run Chart / Trend Chart
Define Measure Analyze Improve Control
Analyze
Phase
PVC ppmh
450
400
Analyze 350
• Assess process variation
300
250
• Determine components of variation (multi-var charts)
200
150
• Determine the defect cause 100
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• Identify critical process / control elements
- products
- features
- process
• Assess process capability
• Determine potential improvement actions
- conduct hypothesis tests
- conduct ANOVA
Some other skills and tools
Brainstorming 30
Process Capability Study (Cp, Cpk)
20
Statistical Analysis (e.g. DOE, Anova)
5 Why Root Cause Analysis Result 10
0 10 20 30 40 50 60 70 80 90 100
Rx
Define Measure Analyze Improve Control
Improve
Phase
PVC ppmh
450
400
Improve 350
• Implement improvement actions
300
250
• Optimize the process
200
150
• Implement actions to reduce variability 100
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- target tolerancing
- process controls
- preventive / corrective actions
• Implement actions to eliminate defects
- Special cause variation
Some other skills and tools
Action Plans
Statistical Analysis (e.g. Cpk)
Statistical Analysis (e.g. DOE, Anova)
Sample Plans
Quality Control Plans
Define Measure Analyze Improve Control
Control
Phase
PVC ppmh
450
Control 400
• Monitor and control the process over time 350
300
- control plans 250
200
- control charts 150
100
• Mistake proof
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• Reduce common cause (random) variation
• Rule of Thumb: Cp 2 , Cpk 1.5
Some other skills and tools
Poka-yoke (mistake proof)
Statistical Analysis (e.g. Cpk)
SPC
Sample Plans
Control Plans
PDCA (PDSA) Cycle
Anything More?
Who said:
“The important thing is not to stop questioning.”
“Insanity: doing the same thing over and over again and
expecting different results.”
Albert Einstein
How many tools do you have in your quality tool kit ?
References:
• 7 Basic Tools: Excerpted from Nancy R. Tague’s The Quality Toolbox, Second Edition, ASQ Quality Press, 2004, page 15.
• CMQ/OE Primer 2010, Quality Council of Indiana
Learn More:
• The Quality Toolbox, Second Edition, Tague, Nancy R.
• Implementing Six Sigma: Smarter Solutions Using Statistical Methods, 2nd Edition, Breyfogle, Forrest W
