1) The document provides definitions and explanations of terms related to Quality Control Circles (QCC) such as quality, problem, kaizen, PDCA cycle, and standardization. 2) It describes the 3 basic principles of QCC as rotating the PDCA cycle, judging and acting based on facts and data, and performing standardization. 3) Examples of two quality tools, Pareto diagram and cause-and-effect diagram, are shown to illustrate problems in a press shop and causes of dents on a rear door panel.

1. ( Level –1 )Trainer : Mr. A.S. Rajarajan
Human Resource Division

2. QCC = Quality Control Circle
Purpose of QCC activity :
* To have an enjoyable work place.
What is “ QCC ” ?
* To ensure positive communication
( ie, Superior Me Sub-ordinate )
& thereby build “ Team work “

3. Definitions of frequently used terms :
QC Circle Activity :
* Activity conducted by a group of people in the same workplace.
* Solving of problems by all circle members according to the QC
basic principles & using QC tools
Quality :
* The condition after completion of work.
Problem :
* Gap between the “ Present situation “ and the “ Standard /
Target / Ideal condition “.
Kaizen :
* Changing the present situation to a further better situation.

4. 3 QC Basic Principles
1. Rotate the PDCA CYCLE :
* Appropriate rotation of the PDCA cycle will result in a
good job.
P - Plan D - Do
C -Check A-Action
PDCA cycle Judge and act Standardization
( Note : If 1 rotation of PDCA cycle is not enough, further rotation to be done ).

5. 3 QC Basic Principles ( Contd… ) :
2. JUDGE AND ACT based on the facts and data :
* Check the facts with your 5 senses ( See - Eyes, Feel -
Hands, Hear - Ears, Smell - Nose, Taste - Mouth ) =
Genchi genbutsu .
* Express the fact in words and numerals.
3. Perform STANDARDIZATION and ensure
that everyone keeps up to the standard.
* Standard : Method and rule for simplification, so that
everyone can understands.
* Standardizing action : Setting up and revising standard
operation sheets etc.

6. Problem Solving Procedure Steps of QC circle
Identify the problems.
Grasp the current situation.
Analyze the cause
Carry out the
Countermeasures
Standardize
If ‘OK’
If “ Not OK “
Set the target
( Make an activity plan ).
Check the results.

7. Outline of QC Tools :
Different QC Circle Tools :
* Check sheet.
* Graph.
* Pareto diagram.
* Cause and effect diagram ( Fish bone diagram ).
* Histogram.
* Control chart.
* Scatter diagram.
* Matrix diagram.

8. Problem :
The following table gives us the list of ‘ Quality defects ‘ occurred
in Press shop during Dec’ 03. Sketch a “ Pareto diagram “ for the same.
Press shop : No. of Quality defects :
Part name No. of quality defects
Hood 07
Door 12
Roof 10
Bumper 05
Fender 03
Ex 1. : “ PARETO DIAGRAM “

9. Part name No. of Defect
Door 12
Roof 10
Hood 07
Bumper 05
Fender 03
Ans :
Step - 2 : Cumulative of no. of defect.
Step - 1 : Arrange the list in descending order ( with reference to No. of defects )
Step - 3 : Cumulative in percentage of no. of defect.
No. of Defect
( cumulative )
12
22
29
34
37
Cumulative in %tage
32
59
78
92
100
" PARETO DIAGRAM "
0
2
4
6
8
10
12
14
Door Roof Hood Bumper Fender
No.ofdefects
0
10
20
30
40
50
60
70
80
90
100
%tage
If we eliminate these
3 problems, we can reduce
about 78 % of defects
STEP - 1 STEP - 2 STEP - 3

10. ( Fish bone diagram )
Ex 2. : “ CAUSE AND EFFECT DIAGRAM “
Problem :
Dents occurring on Rr.Door panel. Sketch a “Fish bone diagram “ for the same.
DENT
on Rr. Door
panel
MaterialMan
MethodMachine
Dust on jig surface
Improper use of Hemming gun
TM not following SOP
Fatigue
Not cleaning the jigs
Not following standard methods
Dust on Die surface
Applying more force
while working.
Not related
These are the main
facts to cause this
defects