A Proposal For Another Set Of Quality Tools


Published on

Sometimes the seven basic quality tools don\'t fit. Here\'s an alternative for the contract electronics industry

  • Be the first to comment

  • Be the first to like this

No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide

A Proposal For Another Set Of Quality Tools

  1. 1. A Proposal for Another Set of Quality Tools Brad Myers Quality Manager LaBarge, Inc. Houston, TX Copyright © 2009 Brad L. Myers
  2. 2. Kaoru Ishikawa proposed Seven Basic Quality Tools. These tools are often attributed to W. Edwards Deming who proposed that every employee receive a minimum of 40 hours instruction using these tools. The tools are: Copyright © 2009 Brad L. Myers
  3. 3. <ul><li>Cause & Effect Diagram (Fishbone Chart) </li></ul><ul><li>Check Sheet </li></ul><ul><li>Control Charts </li></ul><ul><li>Histograms </li></ul><ul><li>Pareto Charts </li></ul><ul><li>Scatter Diagram </li></ul><ul><li>Run Chart </li></ul>Copyright © 2009 Brad L. Myers
  4. 4. <ul><li>These seven tools don’t always fit well in the Contract Electronics Manufacturing (CEM) business where it is often difficult to use variable data well. In general, plants that do assemblies tend to have good opportunity to use attribute data, whereas plants that are process based can make good use of variable data. </li></ul>Copyright © 2009 Brad L. Myers
  5. 5. <ul><li>Therefore, histograms, scatter diagrams and some control charts are seldom used in the electronics industry. Also, the prevalent use of computers on the manufacturing floor has made the use of check sheets rare. </li></ul>Copyright © 2009 Brad L. Myers
  6. 6. <ul><li>… so what else should employees know? Ideally, all employees should be able to: </li></ul><ul><li>Participate in improving their processes, especially through Kaizen Events </li></ul><ul><li>Solve problems </li></ul><ul><li>Contribute to leaning their processes </li></ul><ul><li>Keep their areas clean, productive and safe </li></ul><ul><li>Therefore I propose these nine basic quality tools for contract electronics manufacturing: </li></ul>Clearly some things don’t fit… Copyright © 2009 Brad L. Myers
  7. 7. <ul><li>The DMAIC cycle </li></ul><ul><li>Capability as measured in PPM </li></ul><ul><li>Run Chart with Moving Average </li></ul><ul><li>Pareto Chart </li></ul><ul><li>“ 5 Whys” problem solving </li></ul><ul><li>Cause and Effect Diagram </li></ul><ul><li>Value Stream Mapping </li></ul><ul><li>U-Charting </li></ul><ul><li>6S’s </li></ul>Copyright © 2009 Brad L. Myers
  8. 8. These Tools Support DMAIC <ul><li>The last eight tools support the DMAIC cycle (Define, Measure, Analyze, Improve, Control) </li></ul>Copyright © 2009 Brad L. Myers Capability measured in PPM Define, Measure Run Chart with Moving Average Measure, Analyze Pareto Chart Analyze 5 Whys Analyze Cause and Effect Analyze Value Stream Mapping Analyze, Improve U-Charting Control 6S Control
  9. 9. These Tools Can Be Presented in Eight Hours of Instruction <ul><li>The instruction can be delivered in one day , or 7 weekly installments. </li></ul>Copyright © 2009 Brad L. Myers DMAIC and PPM 1 hour Run chart with moving average 1 hour Pareto chart 1 hour 5 Whys, Cause and Effect Diagram 1 Hour Value Stream Mapping 1 Hour U-Charting 2 Hours 6S Orientation 1 Hour Total 8 Hours
  10. 10. This program won’t fix all your quality problems <ul><li>Clearly this is a primary level of instruction, designed to meet Deming’s goal that every employee should have the tools needed to do his job well. </li></ul><ul><li>This is not a substitute for Green Belt and Black Belt levels of instruction. </li></ul>Copyright © 2009 Brad L. Myers
  11. 11. Employees that learn these lessons will be able to: <ul><li>Understand all those charts on the wall </li></ul><ul><li>Fully participate in Kaizen Events </li></ul><ul><li>Solve problems </li></ul><ul><li>Participate in six sigma initiatives </li></ul><ul><li>Contribute to leaning their processes </li></ul><ul><li>Keep their work areas clean, productive and safe </li></ul>Copyright © 2009 Brad L. Myers