Introduction to Statistical Quality Control, 4th Edition Douglas C. Montgomery Arizona State University Introduction to Statistical Quality Control, 4th Edition

Quality Improvement in the Modern Business Environment Chapter 1 Quality Improvement in the Modern Business Environment Introduction to Statistical Quality Control, 4th Edition

1-1. The Meaning of Quality and Quality Improvement 1-1.1 Dimensions of Quality 1-1.2 Quality Engineering Technology Introduction to Statistical Quality Control, 4th Edition

1-1.1 Dimensions of Quality Aesthetics Features Perceived Quality Conformance to standards Performance Reliability Durability Serviceability Introduction to Statistical Quality Control, 4th Edition

1-1.1 Dimensions of Quality Definitions of Quality Quality means fitness for use - quality of design - quality of conformance Quality is inversely proportional to variability. Introduction to Statistical Quality Control, 4th Edition

1-1.1 Dimensions of Quality Quality Improvement Quality improvement is the reduction of variability in processes and products. Alternatively, quality improvement is also seen as “waste reduction”. Introduction to Statistical Quality Control, 4th Edition

1-1.1 Dimensions of Quality – Transmission Example Introduction to Statistical Quality Control, 4th Edition

1-1.2 Quality Engineering Terminology Quality Characteristics Physical - length, weight, voltage, viscosity Sensory - taste, appearance, color Time Orientation - reliability, durability, serviceability Introduction to Statistical Quality Control, 4th Edition

1-1.2 Quality Engineering Terminology Quality engineering is the set of operational, managerial, and engineering activities that a company uses to ensure that the quality characteristics of a product are at the nominal or required levels. Introduction to Statistical Quality Control, 4th Edition

1-1.2 Quality Engineering Terminology Two types of data Attributes Data - discrete data, often in the form of counts. Variables Data - continuous measurements such as length, weight. Introduction to Statistical Quality Control, 4th Edition

1-1.2 Quality Engineering Terminology Specifications Quality characteristics being measured are often compared to standards or specifications. Nominal or target value Upper Specification Limit (USL) Lower Specification Limit (LSL) Introduction to Statistical Quality Control, 4th Edition

1-1.2 Quality Engineering Terminology When a component or product does not meet specifications, they are considered to be nonconforming. A nonconforming product is considered defective if it has one or more defects. Defects are nonconformities that may seriously affect the safe or effective use of the product. Introduction to Statistical Quality Control, 4th Edition

1-1.2 Quality Engineering Terminology Concurrent Engineering Team approach to design. Specialists from manufacturing, quality engineering, management, etc. work together for product or process improvement. Introduction to Statistical Quality Control, 4th Edition

1-2. A Brief History of Quality Control and Improvement (Refer to Table 1-1) Walter Shewhart (1924) introduced statistical control chart concepts. The American Society for Quality Control formed in 1946 (now known as the American Society for Quality (ASQ)). 1950s and 1960s saw an increase in reliability engineering, experimental design, and statistical quality control Introduction to Statistical Quality Control, 4th Edition

1-2. A Brief History of Quality Control and Improvement (Refer to Table 1-1) Competition from foreign industries (Japan) increases during the 1970s and 1980s. Statistical methods for quality improvement use increases in the United States during the 1980s Total Quality Management (TQM) emerges during 1970s and into the 1980s as an important management tool to implement statistical methods. Introduction to Statistical Quality Control, 4th Edition

1-2. A Brief History of Quality Control and Improvement Malcolm Baldridge National Quality Award is established in 1988. ISO 9000 certification activities increase in U.S. industry in the 1990s. Motorola’s Six-Sigma initiative begins in the 1990s. Introduction to Statistical Quality Control, 4th Edition

1-3. Statistical Methods for Quality Control and Improvement Three major areas: Statistical process control (SPC) Design of experiments (DOX) Acceptance sampling Introduction to Statistical Quality Control, 4th Edition

1-3. Statistical Methods for Quality Control and Improvement Statistical Process Control (SPC) Control charts are used for process monitoring and variability reduction. SPC is an on-line quality control tool. Introduction to Statistical Quality Control, 4th Edition

1-3. Statistical Methods for Quality Control and Improvement Design of Experiments Experimental design is an approach to systematically varying the controllable input factors in the process and determine the effect these factors have on the output responses. Experimental designs are off-line quality tools. Crucial for variability reduction. Introduction to Statistical Quality Control, 4th Edition

1-3. Statistical Methods for Quality Control and Improvement Acceptance Sampling Acceptance sampling is the inspection and classification of a sample of the product selected at random from a larger batch or lot and the ultimate decision about disposition of the lot. Two types: 1. Outgoing inspection - follows production 2. Incoming inspection - before use in production Introduction to Statistical Quality Control, 4th Edition

1-4. Other Aspects of Quality Control and Improvement Total Quality Management (TQM) TQM is a managerial framework to accomplish quality improvement. Other names and related approaches: Company-Wide Quality Control (CWQC) Total Quality Assurance (TQA) Six-Sigma Introduction to Statistical Quality Control, 4th Edition

1-4. Other Aspects of Quality Control and Improvement 1-4.1 Quality Philosophy and Management Strategies 1-4.2 The Link Between Quality and Productivity 1-4.3 Quality Costs 1-4.4 Legal Aspects of Quality 1-4.5 Implementing Quality Improvement Introduction to Statistical Quality Control, 4th Edition

1-4.1 Quality Philosophy and Management Strategies Three Important Leaders W. Edwards Deming - Emphasis on statistical methods in quality improvement (see Deming’s 14 points) Joseph Juran - Emphasis on managerial role in quality implementation Armand V. Feigenbaum - Emphasis on organizational structure Introduction to Statistical Quality Control, 4th Edition

1-4.1 Quality Philosophy and Management Strategies Total Quality Management (TQM) Quality Standards and Registration ISO 9000 Six Sigma Just-In-Time, Lean Manufacturing, Poka-Yoke, etc. Introduction to Statistical Quality Control, 4th Edition

1-4.2 The Link Between Quality and Productivity Effective quality improvement can be instrumental in increasing productivity and reducing cost. The cost of achieving quality improvements and increased productivity is often negligible. Introduction to Statistical Quality Control, 4th Edition

Introduction to Statistical Quality Control, 4th Edition 1-4.3 Quality Costs Quality Costs are those categories of costs that are associated with producing, identifying, avoiding, or repairing products that do not meet requirements. These costs are: Prevention Costs Appraisal Costs Internal Failure Costs External Failure Costs Introduction to Statistical Quality Control, 4th Edition

1-4.4 Legal Aspects of Quality The re-emergence of quality assurance as an important business strategy is in part a result of Consumerism Product Liability Introduction to Statistical Quality Control, 4th Edition

1-4.5 Implementing Quality Improvement Strategic Management of Quality Almost all successful efforts have been management-driven. Too much emphasis on registration and certification programs (ISO, QS) Insufficient focus on quality planning and design, quality improvement, overemphasis on quality assurance Poor use of available resources Introduction to Statistical Quality Control, 4th Edition