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Integrated Quality Model

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George Ungurean

on 7 December 2016

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Transcript of Integrated Quality Model

PDCA
Deming Cycle
is an iterative four-step management method used in business for the control and continuous improvement of processes and products. In Six Sigma programs, the PDCA cycle is called "define, measure, analyze, improve, control" (DMAIC).
VOC
PROCESS MAP
Process maps are used to develop a better understanding of a process, to generate ideas for process improvement or stimulate discussion, build stronger communication, and improve quality.
Manufacturing process
uses many outstanding quality and improvement tools, techniques, methods and standards that guide organization to a high level of institutionalized quality culture.
Integrated Quality Model
The organization shall:
a) determine the processes needed for the quality management system and their application throughout the organization,
b) determine the sequence and interaction of these processes
FMEA
MSA
refers to a data-driven improvement cycle used for improving, optimizing and stabilizing business processes and designs.

The DMAIC improvement cycle is the core tool used to drive Six Sigma projects. However, DMAIC is not exclusive to Six Sigma and can be used as the framework for other improvement applications.
Quality Planning
Quality Control
Quality Assurance
Quality Prevention
TQM
5 Levels of Quality Management
Quality Team
Entire Organization
5 Levels of Quality Management
DMAIC
SPC
Statistical process control is a method of quality control which uses statistical methods. SPC is applied in order to monitor and control a process. Monitoring and controlling the process ensures that it operates at its full potential. At its full potential, the process can make as much conforming product as possible with a minimum (if not an elimination) of waste (rework or Scrap).
8D -Eight Disciplines
Problem Solving
Six Sigma
Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes. It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization who are experts in these methods.
Lean Six Sigma
Quality Audits
How all of these tie together ?
D0: Plan
D1: Use a Team
D2: Define and describe the Problem:
D3: Develop Interim Containment Plan;
D4: Determine, Identify, and Verify Root Causes and Escape Points
D5: Choose and Verify Permanent Corrections (PCs) for Problem/Non Conformity
D6: Implement and Validate Corrective Actions
D7: Take Preventive Measures
D8: Congratulate Your Team
Lean Six Sigma is a managerial concept combining lean manufacturing and Six Sigma that results in the elimination of the eight kinds of waste
(muda):

defects, overproduction, waiting, non-utilized talent, transportation, inventory, motion, extra-processing
.
Provide
CHECK SHEETS
according to control plan
CONGRATULATIONS

THANK YOU
george.iulian.ungurean@gmail.com
Machine Method Man Power
Material Measurement Mother Nature
PROBLEM
Failure mode and effects analysis is a proactive tool, technique and quality method that enables the identification and prevention of process or product errors before they occur.
SEVERITY x OCCURRENCE x DETECTION =
R
ISK
P
RIORITY
N
UMBER
D
efine
M
easure
A
nalyze
I
mprove
C
ontrol
Clause 4.1, “General requirements of the ISO 9001 Standard” states that:
sources & resources
en.wikipedia.org
isixsigma.com
quality-one.com
prezi.com
plan–do–check–act
The Pareto principle (also known as the
80–20
rule) states that, for many events, roughly 80% of the effects come from 20% of the causes. A Pareto chart, is a type of chart that contains both bars and a line graph, where individual values are represented in descending order by bars, and the cumulative total is represented by the line.
Pareto Chart
The 5 Whys is an iterative question-asking technique used to explore the cause-and-effect relationships underlying a particular problem. The primary goal of the technique is to determine
the root cause
of a defect or problem.
5 Whys
A histogram is a bar graph of raw data that creates a picture of the data distribution. The bars represent the frequency of occurrence by classes of data.
A histogram shows basic information about the data set, such as central location , width of spread , and shape. Use histograms to assess the system’s current situation and to study results of improvement actions.
HISTOGRAM
CAPA
Corrective action and preventive action ( also called corrective action/preventive action) are improvements to an organization's processes taken to eliminate causes of non-conformists or other undesirable situations. CAPA is a concept within good manufacturing practice (GMP), and numerous ISO business standards. It focuses on the systematic investigation of the root causes of identified problems or identified risks in an attempt to prevent their recurrence (for corrective action) or to prevent occurrence (for preventive action).
Six Sigma is a set of techniques and tools for process improvement.
LEAN SIX SIGMA ORGANIZATION STRUCTURE
MBB
- Black Belt trained with at least two years experience. Teaches Lean Six Sigma
Yellow Belt
- Lean Six Sigma awareness
Green Belt
- Focus on tools usage, DMAIC and Lean principles application
Black Belt
- Full time project leader
The check sheet is a form (document) used to collect data in real time at the location where the data is generated. When a process has been identified as a candidate for improvement, it's important to know what types of defects occur in its outputs and their relative frequencies. This information serves as a guide for investigating and removing the sources of defects, starting with the most frequently occurring.
Check Sheet
Control chart
Scatter plot
A scatter plot, scatterplot, or scattergraph is a type of mathematical diagram using Cartesian coordinates to display values for two variables for a set of data. The data is displayed as a collection of points, each having the value of one variable determining the position on the horizontal axis and the value of the other variable determining the position on the vertical axis.
Control charts, also known as Shewhart charts or process-behavior charts, in statistical process control are tools used to determine if a manufacturing or business process is in a state of statistical control. The purpose of control charts is to allow simple detection of events that are indicative of actual process change.
In this quality model the tools, techniques, methods and standards are grouped into five levels, logically arranged, as to show how the process enhaces,from the lowest level to the most complex one. In order to acquaint Total Quality Management in Your Organization you got to explore each of these 5 levels. This is a step by step model that guides your organization to a high level of institutionalized quality culture.
george.iulian.ungurean
Identify processes and draw a
PROCESS MAP
Determine where, with whom, where and what you want to measure/verify
CONTROL PLAN
Work with
PROFESSIONAL PEOPLE
Use only
CERTIFIED MEASURING TOOLS
Know the specifications limits of processes from
ACCURATE DOCUMENTATION
tools / techniques / methods / standards
actions
Transform data into
STATISTICS
Transform statistics into
CHARTS
Know and prioritize your biggest problems
(PARETO)
Present them to the team in daily, weekly and monthly
QUALITY MEETINGS
tools / techniques / methods / standards
actions
Implicate operators in the quality process providing
SELF CONTROL CARTS
Do
INTERNAL TRAININGS
for operators to extend awareness of quality
Discuss with operators about encountered problems during
QUALITY AUDITS
For small problems provide
OPEN ISSUE LIST
naming tasks, people and time limits
Determine the root cause of problems
(5 WHYS, FISHBONE DIAGRAMS)
For bigger problems provide team based projects in order to eliminate the root cause generating them
(8D, PDCA, DMAIC, ERROR DIAGNOSTICS AND REPRODUCTION)
tools / techniques / methods / standards
actions
actions
tools / techniques / methods / standards
Provide a client oriented system -
CUSTOMER CLAIM MANAGEMENT
With R&D support, analyze client requirements and upgrade, improve, redesign
FMEA
Define stability of your processes
SPC
Implicate managers in quality process providing
LAYERED PROCESS AUDITS (LPA)
Provide
SUPPLIER SUPPORT & AUDIT
Establish
CORRECTIVE AND PREVENTIVE ACTIONS (CAPA)
Improve performance of your team with
EXTERNAL TRAININGS (LEAN, MSA, TQM, SIX SIGMA)
Your organization is now aware of what a quality culture system is about
BUT DON`T STOP
Total Quality Management
means
continuous improvement
now be
LEAN
and go
SIX SIGMA
by George Ungurean

Ishikawa diagram
Measurement systems analysis evaluates the test method, measuring instruments, and the entire process of obtaining measurements to ensure the integrity of data used for analysis (usually quality analysis) and to understand the implications of measurement error for decisions made about a product or process. MSA is an important element of Six Sigma methodology and of other quality management systems.
Ishikawa diagrams
(also called fishbone diagrams, herringbone diagrams, cause-and-effect diagrams, or Fishikawa)
are causal diagrams that show the causes of a specific event. Common uses of the Ishikawa diagram are product design and quality defect prevention, to identify potential factors causing an overall effect. Each cause or reason for imperfection is a source of variation. Causes are usually grouped into major categories to identify these sources of variation.
SIPOC
Let`s randomly name some of them
In process improvement, SIPOC is a tool that summarizes the inputs and outputs of one or more processes in table form.
s
uppliers
i
nputs
p
rocess
o
utputs
c
ustomers
V
oice
o
f the
c
ustomer is a term used in business to describe the in-depth process of capturing a customer's expectations, preferences and aversions. Voice of the Customer studies typically consist of both qualitative and quantitative research steps.
Quality audit is the process of systematic examination of a quality system carried out by an internal or external quality auditor or an audit team. It is an important part of organization's quality management system and is a key element in the ISO quality system standard, ISO 9001.
ISO 9001:2015
Keep a
LESSON LEARNED
database with solutions for problems successfully eliminated
Keep a
BEST PRACTICE
database for successfully provided improvement projects
www.barlinek.com.pl
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