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Lean Quality Systems Control, Containment and  Continuous Improvement
Focus on Root Cause of Variability Impact: Cost/ Occurrence  Frequency:  Problems/Opportunities 0 Special Cause  Incidents High Visibility/ Containment Actions Low Occurrence  Variability/Durability Customer Satisfaction Zone Product/Process Robustness Customer Satisfaction Source: J.D. Power & Associates
Quality Systems from Both Ends ,[object Object],[object Object],[object Object]
Quality Loops: Protect the Customer and Feedback for Improvement Quality Loops Zone Workstation Customer Quality Loop 1 Quality Loop 2 Quality Loop 3 Quality Loop 4 Plant / Process
Quality Loop 4 Customer Loop 4 – The Customer Filter Objective  – Feedback from the customer for immediate and effective resolution of real issues, and to align product and process to customer needs and wants.
Quality Loop 4 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Quality Loop 3 Plant / Process Loop 3 – End-of-Process Loop Objective, Ideal  – Act as a rapid representation of customer response. Objective, Pragmatic  – Act as a dynamic filter to protect customer based on Loop 1 and 2 activity.
Quality Loop 3 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Quality Loop 2 Zone Loop 2 – Zone Control  Objective  – To establish a tight filter of quality issues and fast feedback into workstation issues.
Quality Loop 2 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Quality Loop 1  Workstation Loop 1 – Operating / Workstation  Objective  – To prevent defects from reaching the immediate customer, the next step in the process.
Quality Loop 1 ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Key System Wide Issues ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Non-Product / Service Processes ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Quality Filter Product Design Process Running Customer Requirements: Needs, Perceptions & Behaviors Robust and Capable Loop In-Control Loop Building a Robust and Capable Model for Meeting Customer Requirements Quality Response Process Process Design
Contact Me ,[object Object],[object Object],[object Object],[object Object]

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4 loops of quality systems by jamie flinchbaugh

  • 1. Lean Quality Systems Control, Containment and Continuous Improvement
  • 2. Focus on Root Cause of Variability Impact: Cost/ Occurrence Frequency: Problems/Opportunities 0 Special Cause Incidents High Visibility/ Containment Actions Low Occurrence Variability/Durability Customer Satisfaction Zone Product/Process Robustness Customer Satisfaction Source: J.D. Power & Associates
  • 3.
  • 4. Quality Loops: Protect the Customer and Feedback for Improvement Quality Loops Zone Workstation Customer Quality Loop 1 Quality Loop 2 Quality Loop 3 Quality Loop 4 Plant / Process
  • 5. Quality Loop 4 Customer Loop 4 – The Customer Filter Objective – Feedback from the customer for immediate and effective resolution of real issues, and to align product and process to customer needs and wants.
  • 6.
  • 7. Quality Loop 3 Plant / Process Loop 3 – End-of-Process Loop Objective, Ideal – Act as a rapid representation of customer response. Objective, Pragmatic – Act as a dynamic filter to protect customer based on Loop 1 and 2 activity.
  • 8.
  • 9. Quality Loop 2 Zone Loop 2 – Zone Control Objective – To establish a tight filter of quality issues and fast feedback into workstation issues.
  • 10.
  • 11. Quality Loop 1 Workstation Loop 1 – Operating / Workstation Objective – To prevent defects from reaching the immediate customer, the next step in the process.
  • 12.
  • 13.
  • 14.
  • 15. Quality Filter Product Design Process Running Customer Requirements: Needs, Perceptions & Behaviors Robust and Capable Loop In-Control Loop Building a Robust and Capable Model for Meeting Customer Requirements Quality Response Process Process Design
  • 16.

Editor's Notes

  1. Blue – low occurrence variability / durability big issues often based on many confounding issues occurring at the same time Red – 100% occurrence or close to it something gone terribly wrong but low impact; either easy to deal with, fixed or customer accepts Yellow – variation day to day stuff, the stuff our quality systems really exist for; case by case they seem small, but overall impact results in customer satisfaction or dissatisfaction
  2. Objective, Ideal – Loop 2 ‘ should ’ focus on containment and correction. If Loop 2 is the actual quality FILTER, then Loop 3 can focus on being a faster version of Loop 4, meaning a voice of the customer / customer advocate and provides a view into how the customer is receiving the product proactively. Objective, Pragmatic – Often Loop 2 isn ’ t this strong, and Loop 3 must focus more on being reactive rather than proactive. This means trying to catch things in general and dealing with corrective actions from input from Loop 4 and 2. The key here is using the information to develop checks and filters for the right stuff. A filter that tries to catch everything will fail.