The document provides an introduction to the 12 steps of a Quality Circle problem solving process. It begins with problem identification and categorization into A, B, and C problems. Step 2 is problem selection where problems are shortlisted. Step 3 is defining the selected problem using tools like flow diagrams. Step 4 is analyzing the problem through data collection and identifying causes using tools like cause and effect diagrams. Step 5 identifies possible solutions through brainstorming. Step 6 foresees possible resistance to solutions. Step 7 implements solutions on a trial basis. Step 8 involves regular implementation if improvements are seen. Step 9 is follow up and review through control charts. The document outlines techniques used by Quality Circles like brainstorming, data collection, graphs

1. Name – Mayur Patil
Post – Technician Grade 1
Plant – Urea Mechanical
Qualification – Diploma Mechanical Engg
Topic –Introduction of Quality Circle 12 Steps

2. How does a Quality Circle solve a problem
by using A, B, C classification?
Step 1 – Identification of problem

3. They
Generate a list of problems using
‘BRAINSTORMING’

4. ‘A’ Category Problem
Minimum
involvement of other
departments in
solving them.
‘B’ Category Problem
Involvement of other
departments is a
necessity.
‘C’Category Problem
Management sanction
may be needed in
implementing
the solution.

5. Identification of problems
Categorization of problems

6. Job Frequency.
Spares consumption.
Safety.
Environment .
Spillage reduction.
Cost reduction.
High demurrage.
Criteria for short listing of
Problems.
Step 2 –
Selection
of
problem

7. Non availability of temporary electric supply.
High maintenance of clamp assembly.
More time required for material discharge from Hopper.
Failure of clamps due to breaking of arm plate.
Frequent failure of hopper suspension.
Short listed problems

8. 8
Data collection for a problem selection
Jan 13 to Dec 13

9. Use a mile stone chart to plan the time
required for the activities before
starting.

10. MILESTONE CHART
Quality Circle Activity Planning
10. Follow-
up/Review
9. Regular Implementation
8. Trial implementation
and checking
performance
7. Foreseeing possible
resistance
6. Developing solution
5. Data analysis
4. Finding out the root
cause
3. Identifying the causes
2. Analyzing the problem
1. Defining the problem
No. Activity Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Target
Actual
Meeting Day Time No. of projects completed
Project No. Date of beginning Date of completion
Project Reason for selection
Quality Circle Name Department Manager Facilitator Members’ Name
PROJECT STUDY PLANNING IS AN EFFECTIVE METHOD BY WHICH QUALITY CIRCLE MEMBERS ATTAIN THE
SKILL TO PLAN THEIR ACTIVITIES AND EFFECTIVE TIME MANAGMENT

11. Use of flow diagram
helps in having clarity
of the problem by all
members. There may
be some members
who are not aware of
the entire process.
Once the problem is selected Quality Circle is advised to
follow the steps shown here.
DEFINE THE PROBLEM with the help of a flow
diagram.
Step 3 – Define the Problem

12. Analysis is very essential. There may be
certain dimensions of the problem
which are not understood by all. A
discussion will help in pooling up ideas.
ANALYSE THE PROBLEM
METHOD
‘DATA COLLECTION’ on the problem on all
possible aspects.
STEP 4

13. IDENTIFICATION OF CAUSES
METHOD
BRAINSTORMING first and making a CAUSE
and EFFECT DIAGRAM, logically linking the
causes to the main contributory factors.
Identification of causes is not only what we think
as cause for that situation but also all possible
causes. What is expected is a total analysis and
presentation in the form of Cause and Effect
diagram. It needs to be studied and discussed in
detail.
STEP 3

14. FINDING OUT THE ROOT CAUSES and
analysis
METHOD to find out root causes
Identifying the main causes in ‘CAUSE and
EFFECT DIAGRAM’ by ‘DATA
COLLECTION’ and discussion.
Root cause has to be established with the help of data. In
case, for any reason, it is not possible to collect data it
may be established based on experience. But experience
has also to be quantified.
STEP 4

15. METHOD for analysis
Using techniques like LINE
GRAPH, BAR GRAPH, PIE
GRAPH, AREA GRAPH,
HISTOGRAM,
STRATIFICATION, SCATTER
DIAGRAM etc. would help
easy comprehension and
make comparison possible.
FINDING OUT THE ROOT CAUSES and
analysis (contd.)
Step 4

16. GOAL
“No single stationary seal face fail after assembly.”
4
0

17. - Where is problem?
In pump mechanical seal assembly.
3 - ANALYSIS OF PROBLEM (4W - 1H)

18. - What was the loss due to problem?
More time required to complete breakdown of plant pump &
increase the shut down chances.
4W-1H ANALYSIS

19. - When we faced problem?
When spare pump fitting to casing at the place of faulty pump.
4W-1H ANALYSIS

20. - Why problem occurs?
When we dismantle seal assembly stationary seal face found break.
SLEEVE
ROTATING SEAL FACE
COMPRESSION UNIT
FOLLOWER
Stationary seal face found crack

21. SEAL LEAKAGE
HOW PROBLEM COMES?

22. *Extra impact
load
No proper inspection
before assembly
Follower not in equilibrium
during assembly
Minimum clearance between
seal face & follower step
Oval shape of follower
inner diameter
Cross fitting of
stationary seal face
* Uneven
pressure on
seal face
*Improper
method
Stationary faced loosed in
follower
Foreign particle in between
seal faces
Frequently
failure of
pump seal
after assembly.
Locating pin bend
Overload on
seal faces
Over height of
locating pin
Overconfidence
Packing freely fitted in
follower
Over tension on seal faces
Packing not
properly
mounted
Burrs present in
inner side of follower
*Seal packing
ring damage
MACHINE
No proper seal
setting No proper handling
during stuffing box
fitted to bearing
housing
MAN
Retainer unit not working
properly
FISH BONE DIAGRAM
MATERIAL
METHOD

23. WHY WHY ANALYSIS
1) Uneven pressure on seal face during assembly.
Why?
It is fitted in follower by using hand.
Why?
by regular hand fitting practice
Why?
No arrangements to fit stationary seal face in follower.

24. 2) Improper method.
Why?
No Standardization to fit stationary seal face
Why?
By regular hand fitting practice.
Why?
No arrangement to fit seal face in follower
WHY WHY ANALYSIS

25. IDENTIFY SOLUTIONS
METHOD
‘BRAINSTORMING’
Select the appropriate solution
Step 6
STEP 5

26. METHOD
‘BRAINSTORMING’
Identifying the probable
constraints and finding
ways to overcome them.
Step 7
FORESEE the POSSIBLE RESISTENCE for
its implementation.

27. Make a presentation to all involved with the solution i.e.
Dept. Head, Facilitator, other officials, and nonmembers
involved with the implementation. Discuss and evaluate
a system for implementation.
Step 7
FORESEE the POSSIBLE RESISTENCE for
its implementation. (Contd.)

28. Implement the solution on a trial basis and
check performance.
METHOD
Data collection after implementation compared
with the data collected before solving the
problem. Collect fresh data using control chart
and watch process trends. Analyse the result,
discuss and incorporate the changes needed.
Step 8

29. REGULAR IMPLEMENTATION
Once validity is checked and
improvement observed with data, regular
implementation can be effected.
Incorporate the suggestions in the working
system or work instruction sheets (Process
cards.)
Step 9

30. FOLLOW UP / REVIEW
METHOD
Implement evaluation procedure, use
Control Chart, have six monthly
report for evaluation.
Make modifications if necessary.
Step 10

31. What are the techniques used by the
Quality Circle?
Quality Circle uses the following ten
simple problem solving tools.
a. Brainstorming
b. Flow Diagram
c. Data Collection
d. Graphs
e. Pareto Analysis

32. What are the techniques used by the
Quality Circle?
Quality Circle uses the following ten
simple problem solving tools.
f. Cause and Effect Diagram
g. Stratification
h. Scatter Diagram
i. Histogram
j. Control Charts

33. Seven Basic Quality Tools
HISTOGRAM
PARETO
CHART
CAUSE &
EFFECT
FLOWCHART
CHECK
SHEET
CONTROL
CHART
SCATTER
DIAGRAM

38. What is Brainstorming?
Brainstorming is a group
technique for generating
new and useful ideas.
It uses a few simple rules
for discussion on a
subject matter that
contributes to originality
and innovation.

39. Shop floor workers

40. What is Data collection?
Data collection is nothing but the
collection of the required
‘information’ in figures for the
statistical analysis of a problem.
This provides a sound basis for
decision making and corrective
action.

41. These numbers are called data. They are
expression of facts of any activity or feature in
numerical terms.
TYPE NUMBER CUM % OF CUM
OF OF TOTAL %
DEFECT FANS
F. Regulator 40 40 27% 27%
G. Bend in Screws 25 65 17% 44%
A. Motor winding 20 85 13% 57%
B. Bend in wings 15 100 10% 67%
C. Cracks in Central rod 14 114 9% 76%
E. Scratches 12 126 8% 84%
D. Capacitor 10 136 7% 91%
H. Others 14 150 9% 100%
Total 150 100%

42. What is Graph?
Graph is a pictorial
representation of data which,
when presented, is easily
understandable. It helps to
represent large amount of
information comprehensively but
in a compact manner.

43. As Graphs are pictorial
representation of data,
they make it easy for
anybody to understand the
information.
i.e. from top management
to grass root level
employees.

44. in shop floor
0
5
10
15
20
25 Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Months
Foundry
Rejections
(%)

45. In offices
Sales Up

46. What is
Stratification?
Stratification is the
process of separation
of data into categories.

47. Stratification is the process to classify
large amount of data to find out whether
we can get indication of problem point.
It is too
complicated !!
Then
Stratify it!!
Mumbai, we have
a problem !!
What is it ?

48. In a manufacturing organisation
absenteeism was very high.

49. They had 60% of the employees staying
in the colony and balance in the city
which was 20 Kilometres away.
Staff
Quaters
Septa Inds. Ltd.

50. Absenteeism
was first
segregated
month wise.

51. It revealed that it was more in
January, May, June and December.
0
10
20
30
40
50
60
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Number
of
Absentees

52. It was further
stratified shift
wise.

53. It was found that in December and
January it was more in early morning
shift starting at 6 AM and in night shift
starting at 10 PM
0
5
10
15
20
25
30
Morning Shift
Afternoon Shift
Night Shift
Number
of
Absentees
JANUARY
0
5
10
15
20
25
30
35
Morning
Shift
Afternoon
Shift
Night Shift
Number
of
Absentees
DECEMBER

54. In May and June it was during
shift starting at 2 PM.
0
5
10
15
20
25
30
35
40
45
Morning
Shift
Afternoon
Shift
Night Shift
Number
of
Absentees
MAY
0
5
10
15
20
25
30
35
40
Morning
Shift
Afternoon
Shift
Night Shift
Number
of
Absentees
JUNE

55. Then it was checked as to
how many of the colony people were
absent and how many from the city.

56. Further Stratification revealed that
people residing in the city were
absent in most of the cases.
0
10
20
30
40
50
60
70
80
90
100
Colony
residents
City residents
In the months of December &
January
Number
of
Absentees
0
10
20
30
40
50
60
70
80
90
100
Colony
residents
City residents
In the months of May & June
Number
of
Absentees

57. This helped to workout an
action plan.
I think we should
put more of colony
people in the
problem shifts.

58. 0
100
200
300
400
500
600
700
800
100
80
60
40
20
0
%
No
of
complaints
Types of defects
What is a Pareto
diagram?
Pareto diagram is a
technique of arranging
data according to
priority or importance
and using into a
problem solving
framework.
This helps to find out
the ‘VITAL FEW’ from
the ‘USEFUL MANY’ for
problem selection.

59. What is a cause and effect
diagram?
Any defect in a component, a
product or service could be
due to one or more causes. To
find out the relationship
between the causes and
effect, a diagram is drawn
systematically by mapping out
all the probable causes
influencing the effect. This is
called a cause and effect
diagram.

60. ANGLE BEFORE LAPPING
ANGLE
AFTER
LAPPING
10 20 30 40 50 60 70 80 90
10
20
30
40
50
60
70
80
90
What is Scatter
Diagram?
Scatter Diagram is a
graphical representation of
relationship between two
variables. It can be between
a Cause and Effect and
between two causes.
It also reveals the nature of
relationship between two
variables and their
approximate strength.

61. As said a Scatter
diagram
is a graphical
representation
of relationship
between two variables

62. It can be a Cause and
Effect relationship
OBESE
Overeating
CAUSE EFFECT
Lack of exercise

63. What is Histogram?
Histogram is a
graphical
representation of a
frequency
distribution which
is a summary
variation in a
product or process.
30
0
5
10
15
20
25
WEIGHT (gms)
FREQUENCY

64. Control Charts
Control charts present the results of a process over time.
They are used to determine if the process is under control.
They are used to monitor any type of variable output.
Can be used to monitor
• Cost and schedule variances;
• Volume and frequency of changes;
• Errors in the project documentation

65. Checklist
It is a list with
previously defined
options that are used
as a guide to control
risks.
It allows a thorough
evaluation in a short
period of time.

66. What are the overall benefits a
member gets?

67. Members get many benefits. They
improve their knowledge. They learn to
work together. They learn to interact
better.

68. They learn to present before the
management their case study, which
helps to boost their morale and
confidence. They learn to work
systematically.

69. They learn to plan their activities. Above all they
learn simple techniques which help in solving their
problems effectively and ultimately helps in
problem prevention in their work area.

70. What is a Management Presentation?
A management presentation is where the leader and
members describe to their management what project
they have been working on and what recommendations
they wish to make concerning it. Participants use charts
which are prepared by them. This event represents a
most exciting form of participation, communication and
recognition for all.

72. ii. Organising Drama Skits on Quality
Circle themes and awarding trophies for
the best ones.

73. iv. Honouring best QCs on Republic Day would be
a good way of recognising them. On such
occasions, family members, friends and general
public will come to know of their good work. This
will give them immense pride in their
achievements.

74. vi. Declaring best Circle of the year, half year, for the
quarter and so on and putting up photo of the
group at vantage points - Reception Hall, Canteen
etc. This will go a long way in boosting the self-
esteem needs of people.

75. viii. Conducting regular Quiz Programmes on QC for
Quality Circle teams coming from different
divisions and awarding token gifts for winners. The
enthusiasm generated in such programmes should
be seen to know the impact of these on the
motivation of QCs.

76. What is being done in India
by QCFI?

77. Quality Circle Forum of India was
established as a non-profit body in the
year 1982 with Hyderabad as its
Headquarters.
QCFI has
* Patron Members
* Institutional Members
* Quality Circle Members
* Individual Members

78. North East West South
Delhi Calcutta Mumbai Chennai
Kanpur Guwahati Pune Madurai
Chandigarh Durgapur Vadodara Neyveli
Jhalawar Rourkela Nagpur Coimbatore
Faridabad Bhilai Jabalpur Cochin
Gwalior Bokaro Bangalore
Koraput Hyderabad
QCFI has 25 Chapters all over India.