Booklet to start Quality circle in your organisation

1. QUALITY CIRCLE……………SHOP
PROJECT TITLE:……………………………………………………………..
1
Operations U & A
together we can
Quality Circle!

2. INTRODUCTION
TEAM NAME
:
…………………………………………..
LEADER NAME
:…………………………………………..
PROJECT TITLE
:…………………………………………..
AREA
:
…………………………………………..
DATE
:
…………………………………………..
Operations U & A
together we can
2
Quality Circle!

3. TEAM STRUCTURE
HOD/Supervisor
Quality coordinator
Maintenance coordinator
3
Operations U & A
together we can
Quality Circle!

4. Team Attendance
S.
NO
Name
Position in
Team
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
4
Operations U & A
together we can
Quality Circle!

5. GANT CHART
Phase
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
Define
Measure
Analyze
Improve
Control
5
Operations U & A
together we can
Quality Circle!

6. DEFINE PHASE
6
Operations U & A
together we can
Quality Circle!

7. DEFINE PHASE
What is the Problem:
Where is the Problem:
How much is the Problem:
Boundaries of the Problem:
7
Define
Operations U & A
together we can
Quality Circle!

8. SIPOC
• SIPOC(Supplier, Input , Process , Output & Customer)
Specific Process flow chart with SIPOC.
8
Define
Operations U & A
together we can
Quality Circle!

9. DRILL DOWN TREE
……………………
Our Project
……………………
Our target
……………………
What improve
……………………
Company target
9
Define
Operations U & A
together we can
Quality Circle!

10. Review-Define Phase
Phase
Plan/
Actual
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
Plan
Define
Actual
10
Operations U & A
together we can
Quality Circle!

11. MEASURE
PHASE
11
Operations U & A
together we can
Quality Circle!

12. MEASURE PHASE
Line:
Problem:
Where/Area:
Current Level:
12
Measure
Operations U & A
together we can
Quality Circle!

13. Data Collection
Last One year or minimum 6 month data need to
collect.
Data collected for………………Months
Data Type : Continuous / Discrete
Data format……………………
Reference Document…………………
13
Measure
Operations U & A
together we can
Quality Circle!

14. Current Level and Target Level
Current Level Measurement:
Target Level Measurement:
DPMO(Defects per Million Opportunities)
DPMO(Defects per Million Opportunities)
(Total defect/total Production)*1000000:
………………….
(Total defect/total Production)*1000000:
…………………..
Sigma Level:…………………….
Sigma Level:…………………….
Completion time:……………………..
14
Measure
Operations U & A
together we can
Quality Circle!

15. Cause & Effect(Leak reduction)
Man
Material
Method
Machine
15
Measure
Operations U & A
together we can
Quality Circle!

16. KPIV/KPOV
List Down the Cause Variables from C&E diagram
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
16
Measure
Operations U & A
together we can
Quality Circle!

17. FDM(Function Deployment Matrix)
Variables(x’s)
Productivity
Low:3 Mid:5 Max:9
Cost
Low:3 Mid:5 Max:9
Quality
Low:3 Mid:5 Max:9
Total Weightage
17
Measure
Operations U & A
together we can
Quality Circle!

18. SELECTED CAUSE LIST-x’s
List Down the Variables(x) from C&E diagram
x1.
x2.
x3.
x4.
x5.
x6.
x7.
x8.
18
Measure
Operations U & A
together we can
Quality Circle!

19. Review-Measure Phase
Phase
Plan/
Actual
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
Plan
Measure
Actual
19
Measure
Operations U & A
together we can
Quality Circle!

20. ANALYZE
PHASE
20
Analyze
Operations U & A
together we can
Quality Circle!

21. Data collection for small variables(x’s)
S.No
x’s
1
x1
2
x2
3
x3
4
x4
5
x5
6
x6
7
x7
8
Variables
Data type
Remarks
x8
21
Analyze
Operations U & A
together we can
Quality Circle!

22. PARETO CHART –x1
Problem(x1):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
Conclusion:
………………………………………………………………
22
Analyze
Operations U & A
together we can
Quality Circle!

23. PARETO CHART –x2
Problem(x2):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
Conclusion:
………………………………………………………………
23
Analyze
Operations U & A
together we can
Quality Circle!

24. PARETO CHART –x3
Problem(x3):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
Conclusion:
………………………………………………………………
24
Analyze
Operations U & A
together we can
Quality Circle!

25. PARETO CHART –x4
Problem(x4):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
Conclusion:
………………………………………………………………
25
Analyze
Operations U & A
together we can
Quality Circle!

26. PARETO CHART –x5
Problem(x5):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
Conclusion:
………………………………………………………………
26
Analyze
Operations U & A
together we can
Quality Circle!

27. PARETO CHART –x6
Problem(x6):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
Conclusion:
………………………………………………………………
27
Analyze
Operations U & A
together we can
Quality Circle!

28. PARETO CHART –x7
Problem(x7):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
Conclusion:
………………………………………………………………
28
Analyze
Operations U & A
together we can
Quality Circle!

29. PARETO CHART –x8
Problem(x8):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
Conclusion:
………………………………………………………………
29
Analyze
Operations U & A
together we can
Quality Circle!

30. MAJOR CAUSE LIST-Y’s
List the major cause list from pareto chart analysis(80:20 concept)
Need to improve top 20% of cause so as to solve 80% of remaining problem.
Y1.
Y2.
Y3.
Y4.
Y5.
30
Analyze
Operations U & A
together we can
Quality Circle!

31. Review-Analyze Phase
Phase
Plan/
Actual
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
Plan
Analyze
Actual
31
Analyze
Operations U & A
together we can
Quality Circle!

32. IMPROVE
PHASE
32
Improve
Operations U & A
together we can
Quality Circle!

33. Data collection for Main variables(Y’s)
S.No
Y’s
1
Y1
2
Y2
3
Y3
4
Y4
5
Y5
Variables
M
A
S
Improvement
Action
Remarks
E
L
P
33
Control
Operations U & A
together we can
Quality Circle!

34. IMPROVEMENT-Y1
Location:
Before Improvement
After Improvement
Implemented Method:
Effect on implementation:
34
Improve
Operations U & A
together we can
Quality Circle!

35. IMPROVEMENT-Y2
Location:
Before Improvement
After Improvement
Implemented Method:
Effect on implementation:
35
Improve
Operations U & A
together we can
Quality Circle!

36. IMPROVEMENT-Y3
Location:
Before Improvement
After Improvement
Implemented Method:
Effect on implementation:
36
Improve
Operations U & A
together we can
Quality Circle!

37. IMPROVEMENT-Y4
Location:
Before Improvement
After Improvement
Implemented Method:
Effect on implementation:
37
Improve
Operations U & A
together we can
Quality Circle!

38. IMPROVEMENT-Y5
Location:
Before Improvement
After Improvement
Implemented Method:
Effect on implementation:
38
Improve
Operations U & A
together we can
Quality Circle!

39. Review-Improve Phase
Phase
Plan/
Actual
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
Plan
Improve
Actual
39
Improve
Operations U & A
together we can
Quality Circle!

40. CONTROL
PHASE
40
Control
Operations U & A
together we can
Quality Circle!

41. Data collection for Main variables(Y’s)
S.No
Y’s
1
Y1
2
Y2
3
Y3
4
Y4
5
Variables
Data type
Remarks
Y5
41
Control
Operations U & A
together we can
Quality Circle!

42. CONTROL CHART-Y1
• Use Check sheet or other monitoring tool to standardize the
process
42
Control
Operations U & A
together we can
Quality Circle!

43. CONTROL CHART-Y2
• Use Check sheet or other monitoring tool to standardize the
process
43
Control
Operations U & A
together we can
Quality Circle!

44. CONTROL CHART-X3
• Use Check sheet or other monitoring tool to standardize the
process
44
Control
Operations U & A
together we can
Quality Circle!

45. CONTROL CHART-X4
• Use Check sheet or other monitoring tool to standardize the
process
45
Control
Operations U & A
together we can
Quality Circle!

46. CONTROL CHART-X5
• Use Check sheet or other monitoring tool to standardize the
process
46
Control
Operations U & A
together we can
Quality Circle!

47. Current Level and Target Level
Target Level Measurement:
DPMO(Defects per Million Opportunities)
(Total defect/total Production)*1000000:…3/381*1000000=7874
Sigma Level : Calculate from sigma table
Project Achieved Level:
47
Control
Operations U & A
together we can
Quality Circle!

48. Review-Control Phase
Phase
Plan/
Actual
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
WK-
Plan
Control
Actual
48
Control
Operations U & A
together we can
Quality Circle!

49. Summary of the Project
49
Operations U & A
together we can
Quality Circle!