【经管类】PDCA--MANUAL-FOR-QUALITY-PROGRESS-TEAMS.ppt
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1、Quality in Action-PDCA Manual-November 00Slide 1PDCAMANUALFORQUALITYPROGRESSTEAMSDISPLAYS&COMPONENTSGlobal Tubes OperationsQuality in Action-PDCA Manual-November 00Slide 2PDCA MANUAL-CONTENTnWhy This Manual?nPDCA Cycle4phasesnPDCA Step By Step7stepswithtoolspresentationnPDCA Project Status SheetnPro
2、ject Board(Visual Management)Quality in Action-PDCA Manual-November 00Slide 3WHY THIS MANUAL?nContinuous improvement is the key to long term successnIt requires involvement of all(from operators to management)nTo secure its future,Global Tube Operations initiate this ambitious programQualityProgress
3、Teams(QPT)usingPDCAmethodologyinallplants6activeteamsineachplantbyDecember2000,muchmorein2001nThis manual aims at supporting Quality Progress Teams in a step by step work approachQuality in Action-PDCA Manual-November 00Slide 4PDCA CYCLEPDCA a method in 4 phasesPLAN:from problem definition to action
4、 planDO:implement action planCHECK:evaluate resultsACT:standardize and extendQuality in Action-PDCA Manual-November 00Slide 5PLANstep 1.Identify problem and set goals1.1Finalizeproblemstatement1.2Collectandorganizedata1.3Setobjectivesandmeasurementsstep 2.Analyze causesSeekpossiblecausesandvalidates
5、tep 3.Generate solution(s)3.1Seekpossiblesolutions3.2Test&selectstep 4.Plan for implementationDevelopactionplan&associatedresourcesQuality in Action-PDCA Manual-November 00Slide 6DOStep 5.Implement action planImplementtheactionsasplanned(coordinateandfollow-up)CollectdataQuality in Action-PDCA Manua
6、l-November 00Slide 7CHECKStep 6.Evaluate results(analyze data)Aretheresultsinlinewithsetobjectives?Whatistheeffectivenessofeachaction?Wheredowehavegaps?Whathavewelearnt?ConfirmactionstostandardizeConfirmnewoperatingstandardsQuality in Action-PDCA Manual-November 00Slide 8ACTStep 7.Standardize and ex
7、tendCreatemeasurestoensurelong-termeffectivenessDocumentthenewrules:setproceduresandindicatorsSharetheprogresstosimilarareasRe-useSolutions(bestpracticesexchange)Quality in Action-PDCA Manual-November 00Slide 9PROJECT SELECTION TEAM ASSIGNMENTManagement responsibility through PDCA steering committee
8、 is to:nSelect new projects focusing on customer requirements and internal prioritiesnSelect associated team leader and sponsornAssist team leader and sponsor at assembling the right team membersImportance for the customer(internal/external).Difficulty for the team9 BOX MATRIXSelecting the right pro
9、blemQuality in Action-PDCA Manual-November 00Slide 10PDCA:STEP BY STEPPLANPLAN1.Identify problem and set goals1.1 Finalize problem statement1.2 Collect and organize data1.3 Set objectives and measurements2.Analyze causes3.Generate solution3.1 Seek possible solutions3.2 Test&select4.Plan for implemen
10、tationDODO5.Implement action planCHECKCHECK6.Evaluate resultsACTACT7.Standardize and extendQuality in Action-PDCA Manual-November 00Slide 11TOOLSProblemstatement5W+1HprocessmappingPLAN-STEP 1.1FINALIZE PROBLEM STATEMENTINPUT:initial problem as formulated and handed-over by the managementTIPSdonotfor
11、mulateproblemasacauseavoidformulationasquestionorsolutiondefineproblemusingavailablefactsisitapriority/realisticproject?OBJECTIVEGiveoperationaldefinitionofproblemPROCESS1.Reviewexistingdatadescribingproblem2.Getteamfeedback-additionalfactualdata3.Goandseetheproblemifpossible4.Completedescription-wh
12、at/where/who/when/howmuch5.IdentifyhowthingswouldbeifproblemwassolvedOUTPUTWhat:problemdescription-whatarethesymptoms?Whereisitdetected?Whoisconcerned?When?Sincewhen?Recurrent?Forever?Whyisitimportant?How much-quantifyintermsof%,n,ppm,time.cleardefinitionofproblem(recordedonprojectsheet)firstdefinit
13、ionofobjectivetobereachedprocessmapQuality in Action-PDCA Manual-November 00Slide 12PLAN:STEP 1.2COLLECT AND ORGANIZE DATAOBJECTIVECollectdatatobetterunderstandtheproblemPROCESS1.Brainstormrequiredadditionaldata2.Mapprocess3.Preparedatacollectionplan(who/what/when/how)4.Executeplan5.Organizedatainme
14、aningfulform(chart,graphs,Pareto)6.AnalyzestructuredinformationOUTPUT(input for step 1.3)allchartsdescribingproblemcompletedescriptionofproblemTIPSunderstandwhyyoumakecharts“Proliferation of charts without purpose is to be avoided”-DemingTOOLSDatacollectionplanChecksheetParetodiagramControlchartHist
15、ogramProcessmappingotherchartsQuality in Action-PDCA Manual-November 00Slide 13Upper control limitAverageLower control limitOut of controlTimeUnitControl ChartTOOLS FOR DATA COLLECTION AND ANALYSISDefectMOTUWETHFRTotalA3B1C5D15E18Total17866542Week/March 2-6Resp.Supervisor:GlenDEFECTS IN FINAL ASSEMB
16、LYCheck sheetRanking of problems(number of events)Frequency(defects/week)Pareto DiagramQuality in Action-PDCA Manual-November 00Slide 14TOOLS FOR DATA COLLECTION AND ANALYSIS-ContdHistogramProcess MappingDEBCGFAOther ChartsQuality in Action-PDCA Manual-November 00Slide 15THE CHECK SHEETGathering and
17、 organizing dataVALUEWhatfactsordatapatternswillhelpustobetterunderstandtheproblemanditscause(s)?Howdowetranslateouropinionsabouttheproblemintofacts?Checksheetsareusedtocapturefactualdatafromthebeginning.Theyarefilledbyoperatorstodescribethesituationfollowingthedatacollectionplan.DefectMOTUWETHFRTot
18、alA3B1C5D15E18Total17866542WEEK/March 2-6Resp.Supervisor:GlenDEFECTS IN FINAL ASSEMBLYQuality in Action-PDCA Manual-November 00Slide 16THE PARETO DIAGRAMShowing the relative importance of problemsRanking of problems(number of events)Frequency(defects/week)DefectRanking of problems(cost)Rework cost/w
19、eek,dollarsDefectVALUEWhatistherelativeimportanceofeachpartoftheproblems?Whatshouldbethestartingpointforproblemsolving?Whereshouldwefocusourattention?Quality in Action-PDCA Manual-November 00Slide 17THE CONTROL CHARTUnderstanding variability in a processVALUEInthevariationweobserveinaproblemcharacte
20、risticorparameter,whatpartisnaturalvariation(withintheprocesscontrollimits)andwhatpartisduetospecificspecialcauses?Howoftendoestheprocessgooutofcontrol?Arethereanydiscernabletrendsthatshouldconcernus?Cananypreventiveactionsbetakenbasedonthesetrends?Upper control limitAverageLower control limitOut of
21、 controlTimeUnitControl chartrandom variation Vs.special eventsQuality in Action-PDCA Manual-November 00Slide 18THE HISTOGRAMShowing the distribution of dataVALUEHowfrequentlydoesacertaineffectoccur?Whatdoesthefrequencydistributionlooklike-anormalcurveorsomeotherstatisticalform?Howfrequentlyisthepro
22、cessoutsideofspecifications?Whatisthenatureofthedeviationoutsideofspecifications,e.g.,syntheticallyornot,.Shaft diameterFrequencyQuality in Action-PDCA Manual-November 00Slide 19CHARTS AND GRAPHSAnalyzing and presenting different types of dataRun chartBar chartABCDEFGPie chartDEBCGFAVALUEWhatarethet
23、rendsorpatternsinthedataovertime?Istheaveragechangingovertime?Dotheresultsvaryovertime?Istherecyclically(e.g.,dayofweekorseason)Doparticulartimes,shifts,oroperatingpracticesshowmoreproblemsthanothers?Radar chartQuality in Action-PDCA Manual-November 00Slide 20PLAN-STEP 1.3SET OBJECTIVES AND MEASUREM
24、ENTSPROCESS1.Fromdataanalysisconfirmproblemstatementandassociatedobjectives(time/cost/quality)andmeasures2.ValidaterestatedobjectiveswithmanagementOBJECTIVEclearlydefineandvalidateobjectivesOUTPUT(=input for step 2)measurableobjectivesagreedbymanagementEXAMPLEWhat:screenscratchesdefectreportedby2cus
25、tomersforA59productsWhere:scratchesaredetectedatcustomerXandYfinalinspectionstationandareexistingatunpacking.NoscratchattubeplantinspectionWho:customerX&Y,warehousing?transport?packing?When:permanentdefectatX,newsinceSeptemberatYhowmuch:defectwas500ppmatX,jumpat3800ppminSeptember,defectwasnotreporte
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