1. TQM and Reliability Engineering
New Seven TQM Tools
V. Muralidharan
Dept. of Mechatronics
SRM University
TQM and Reliability Engineering

2. TQM and Reliability Engineering
New Seven Tools
The new seven tools are:
Affinity Diagram
Relationship Diagram
Tree Diagram
Matrix Diagram
Prioritization Matrix (Matrix Data Analysis)
Activity Network Diagram (Arrow Diagram)
Process Decision Program Chart
TQM and Reliability Engineering

3. TQM and Reliability Engineering
1.Affinity Diagram
It helps to identify the various causes for an effect.
The causes are found by constituting small teams in the organization.
The teams can use affinity diagrams to organize their discussion and ideas.
This tool is devised to capture the suggestions of every team member.
TQM and Reliability Engineering

4. Affinity Diagram - Example
Assume an organization is finding 25% defects in materials. A team is constituted to find out different causes of this problem.
Outcome of Meeting
Material Specification
Supplier Commitment
Unsystematic purchase Department
TQM and Reliability Engineering

5. Affinity Diagram - Example
Defective Incoming Materials
Material Specification
Supplier Commitment
Ambiguous
Unskilled employees
Poor quality Mtls
No Contract review
Poor equipment
Unsystematic Purchase Dept.
Unskilled employees
Policy not Clear
Not Systematic
TQM and Reliability Engineering

6. Affinity Diagram Methodology
Define the problem or issue to be explored.
Brainstorm ideas. Write ideas on cards.
Mix the cards and remove the duplicates.
Let the group arrange the notes or cards into related groups.
Now, name the groups. Header cards are placed at the top and should clearly define the common thread that ties all the cards in the group.
TQM and Reliability Engineering

7. 2. Relationship Diagram (RD)
It is generally drawn after the affinity diagram .
Brings out the relation between the identified causes.
It establishes the relationship between the factors identified and grouped.
TQM and Reliability Engineering

8. Relationship Diagram…
RD is used to :
Determine and develop the QA policies
Design steps to improve market share
Improve quality
Vendor development
Improve cycle time
Reduce defects
Reduce quality costs.
TQM and Reliability Engineering

9. TQM and Reliability Engineering
RD – Example
Policy Not Clear
Unskilled employees (1)
No contract review of spec.
Unsystematic purchase Dept. (2)
Defective Material
Ambiguous specification
Poor quality of materials
Lack of supplier commitment
Poor quality of equipment
Unskilled employees of suppliers
TQM and Reliability Engineering

10. TQM and Reliability Engineering
RD - Procedure
The self-adhesive cards prepared for formulating affinity diagram can also be used in RD.
The cards containing causes are placed in White board (1) and (2).
Through brainstorming it is identified that cause 1 is stronger than cause 2 or cause 2 is caused by cause 1.
Now, compare cause 1 with all, if relationship exists draw the relation line from stronger to weaker.
TQM and Reliability Engineering

11. TQM and Reliability Engineering
RD - Procedure
Similarly, cause 2 is compared with all other causes. Since already compared with cause 1 no need again.
Repeat it till all causes have been compared with all others.
TQM and Reliability Engineering

12. TQM and Reliability Engineering
RD - Outcomes
Root cause
A cause which has no incoming arrow is called a root cause.
There are three root causes.
Most important is the one with max. no. of outgoing arrows.
It is otherwise called as Drivers.
Lack of commitment of supplier is a driver.
TQM and Reliability Engineering

13. TQM and Reliability Engineering
RD - Outcomes
Measure of Success
A cause which has a max. number of incoming arrows is called an outcome.
In the example, Defective Material is a outcome.
It is an improvement over an affinity diagram.
It helps in identifying the root causes easily.
TQM and Reliability Engineering

14. 3.Tree Diagram
Tree diagram is used to break down the project into a plant for detailed actions to be carried out.
Tree diagram is a highly effective way of organizing large and complex problems.
Tree diagram is drawn generally after affinity diagram is drawn.

15. TQM and Reliability Engineering
Tree Diagram - Steps
Agree on the objective to be achieved.
Draw an affinity diagram to deduce high-level means of achieving the objectives.
Break down the high level means to sub-means or tasks.
Make sure that the final list of actions consists of everything that is needed to accomplish the objective. It is otherwise called as systematic diagram.
TQM and Reliability Engineering

16. TQM and Reliability Engineering
Tree diagram - steps
The tree diagram searches for the most appropriate and effective paths and tasks to accomplish a specific project.
TQM and Reliability Engineering

17. TQM and Reliability Engineering
Tree Diagram-Example
Contract review of specificaitons
Clear Specifications
Sign off
means
Train Employees
Improved quality
Of Materials
Enhancing commitment of supplier
Train Employees
Tasks
Choose good materials
means
Train Employees
Objective
Enhancing effectiveness of purchase dept.
Train Employees
Formulate policy& Procedure
Tree diagram for Improving Material Quality
TQM and Reliability Engineering

18. Matrix Diagram
Matrix diagram is used in particular for describing the actions required for a process or product improvement.
It is different from the tree diagram.
It is otherwise called as Quality Function Deployment.
Used to arrange large data relating to two or more items and capture the relationship between them.

19. Matrix Diagram - Example
L – Shape
T – Shape
C – Shape
3 dimensional
Inverted Y shape
Most Commonly used
TQM and Reliability Engineering

20. TQM and Reliability Engineering
Matrix diagram - Steps
Select the problem
Form a team with 4 – 5 people
Choose a facilitator for the condition of the team activities.
Determine the product or process variables to be studied.
Decide the matrix type based on task.
Place the information in the matrix.
Determine the symbols to be used to highlight the degree of relationship.
TQM and Reliability Engineering

21. TQM and Reliability Engineering
Matrix Diagram - Steps
Include the legend for the symbol definition.
For eg:
- Always
- Frequently
- Sometimes
Enter symbols into the correct cells
Analyze.
TQM and Reliability Engineering

22. Matrix Diagram - Example
Facilities
5 – Star
3 – Star
Economical
Expensive
Swimming Pool
AC Failure
Restaurant Attached
Clean
Credit Card facility available
Matrix Diagram for Selection of Hotel
TQM and Reliability Engineering

23. Matrix Diagram - Advantages
It helps in presenting complex information in easily understandable form.
It is important to study and understand the relationships for decision making process.
Analysis is quite important for decision making.
If no symbol is marked against a column or a row, then it means that there is no relationship between the two variables.
TQM and Reliability Engineering

24. Process Decision Program Chart
Shortly termed as PDPC.
Useful in executing the tasks without any surprises.
A contingency plan should be identified in order to avoid failure of the process.
Take care of the counter measures.
TQM and Reliability Engineering

25. TQM and Reliability Engineering
PDPC - Example
Draw PDPC for an expert to give a lecture:
Reach the venue in a car
Prepare the presentation in the laptop
Make the presentation using a video projector
TQM and Reliability Engineering

26. TQM and Reliability Engineering
PDPC - Example
Give guest lecture
Car to reach venue
Use laptop
Use video projector
Car Breaks down
video projector fails
File not found
Laptop fails to operate
Hire a car
Use White Board
Take public transport O X
Use overhead Projector X
Use CD
Ask organizer for PC O X O
TQM and Reliability Engineering

27. TQM and Reliability Engineering
PDPC - Steps
Establishing an implementation plan for technology development and product development.
Establishing a policy for forecasting and responding in advance to major events.
Implementing counter measures to minimize nonconformities in the manufacturing process.
Organizing major events such as elections, campaigns., etc.
TQM and Reliability Engineering