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Quality History:
Frederick Taylor’s Scientific Mgt. Lean Six Sigma
(Late 1800’s – Early 1900’s)
Work as a system – Work standards Æ Intent drive down labor costs
LOWERED QUALITY BY:
ƒ Component divisions
p
(Division of Labor)
2000-Present
US u
use of Deming & Taguchi
1980
Deming Quality Management
1950
Shewhaart - SPC
Dodg
ge & Romig - AQL
1930
1925
Birtth Of “Taylorism”
1875
Pre-Industriall Revolution
QUALITY TIME LINE
QUALITY FADS
FUTURE
ƒ Work standards (speed over quality, incentive pay) Frederick Taylor
(www.pharmacorner.com)
ƒ Acceptable Quality Levels
Quality History: Dr. Walter Shewhart
Dr. WALTER SHEWHART’S QUALITY
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ (1920’s Bell Labs)
ƒ Invented the control chart
ƒ Invented PDCA Cycle
Dr. Shewhart
(www.pharmacorner.com)
Quality History: WORK STANDARDS (Frank & Lillian Gilbreth)
Process control
Economic, routine operation of the process
Importance of only chance variation (consistency)
Used statistics to identify and remedy root causes of variation
Developed control chart to monitor processes
Reduce process variation Æ Improve the process
Identified:
• Controlled variation (common causes), Predictable
• Uncontrolled variation (special or assignable causes)
Quality History: WORK STANDARDS (Frank & Lillian Gilbreth)
(Early 1900’s) IMPROVED QUALITY BY:
Taylor followers ‐ time studies (e.g. brick laying) Æ
Work Simplification
ƒ Filming Processes (Micro‐motion time studies)
ƒ Human Factors/Safety
LOWERED QUALITY BY:
Frank & Lillian Gilbreth
ƒ Work Standards = cap productivity, stifled CI)
(gilbrethnetwork.tripod.com)
(www.telelavoro.rassegna.it)
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Quality History: H. DODGE & H. ROMIG’S AQL
(1930’s‐1940’s Bell Labs)
ACCEPTANCE SAMPLING
LOWERED QUALITY BY:
ƒ Focused on product = not improvement of process
ƒ Reject parts by AQL ƒ Contained bad parts = not prevention
ƒ Product control
ƒ Keep defective product from customer’s hand
ƒ “Acceptance Sampling” to pass judgement on large quantities
QUALITY HISTORY: Juran’s Quality Mgt.
ƒ (1950’s)
ƒ Dr. Joseph M. Juran – quality is fitness for use
ƒ Wrote the “Quality Control Handbook”
ƒ Founder of ASQC
ƒ Concept of “acceptable level” of defects = Accepted scrap as part of business Æ Encouraged belief in economic trade‐off between continual improvement and the cost to do so Æ (if
uneconomical) Æ doesn’t allow quality and productivity to improve together
Quality History: Dr. Joseph M. Juran
ƒ Quality approach
à Create awareness of need to improve
à Make quality improvement integral part of each job
à Provide training in quality methods
à Establish team problem solving
à Recognize results
ƒ Three Managerial Processes
à Quality Planning
à Quality Control
à Quality improvement
Dr. Juran
(qualitythai.net)
Quality History: FEIGENBAUM’S
FEIGENBAUM’S QUALITY
(1960’s)
Quality History: Dr. Armand Feigenbaum
ƒ Originator of Total Quality
Armand Feigenbaum ‐ A customer Armand Feigenbaum
determination which is based on the customer’s actual experience with the product or service, measured against his or her requirements ‐ stated or unstated, conscious or merely sensed technically conscious or merely sensed, technically operational or entirely subjective ‐ and always representing a moving target in a competitive market
ƒ Quality is a management mindset
ƒ Quality is a fundamental element of a business strategy
ƒ Determining cost of poor quality
ƒ Quality is what the customer says it is
Dr. Feigenbaum
(www.baldrige21.com)
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TQM
ƒ Total Quality Management ‐ places emphasis on continuous process/system improvement as a means of achieving customer satisfaction to ensure long‐term company success ‐ Uses expertise of all employees in conjunction with SPC
Quality History: Crosby’s QUALITY
ƒ (1970’s)
ƒ Philip Crosby –
à Quality is conformance to requirements
à Zero defects. Make it right the first time
à Prevention of defects – find root cause & correct
à Cost of quality – cost to provide customer product or service that meets expectations
à Quality should be led by management
Quality History: GENICHI TAGUCHI
Quality History: Loss Function
ƒ (1980’s)
ƒ Japanese engineer
ƒ Use of designed experiments (DOE)
à Select process/product to be studied
à Identify important variables
à Reduce variability on these variables through redesign, Reduce variability on these variables through redesign process improvement and tolerancing
à Open up tolerances on unimportant variables
Genichi Taguchi ‐ The “loss imparted to society during product use as a result of functional variation and harmful effects” as measured by the customer during field use. Not just a shipping criterion, but a design and manufacturing Criterion
manufacturing Criterion.
ƒ Use inexpensive variables to improve process
Genichi Taguchi
(www.csupomona.edu)
ƒ Loss function concept – costs grow exponentially the farther from the target a process varies
Quality History: GENICHI TAGUCHI
ƒ Intent:
à Improve quality & consistency
à Lower cost
à Identify key product & process factors before production
Taguchi: Signal to Noise Ratio
More Output = More Noise
Output
ƒ Signal to Noise Ratio
ƒ Quality is a design issue, not just production
ƒ Robust parameter design
Value
Value
Waste
Waste
ƒ Design of Experiments (DOE)
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Taguchi: Signal to Noise Ratio
GENICHI TAGUCHI: Design of Experiments
Want More Output Æ Decrease Your Noise Ratio
DOE:
ƒ Select process/product to be studied
ƒ Identify all variables
ƒ Identify significant variables that affect output
ƒ Reduce variability on these variables through redesign, process improvement and tolerancing
ƒ Open up tolerances on unimportant variables
ƒ Use inexpensive variables to improve process
V l
Value
Waste
TAGUCHI’S QUALITY: LOSS FUNCTION
TRADITIONAL VS LOSS FUNCTION
Quality is “loss imparted to society during product use as a result of functional variation and harmful effects.” Harmful effects = unrelated to function
Functional Variation = deviation from intended design
LOSS FUNCTION VS TOLERANCES
TAGUCHI’S LOSS FUNCTION CONCEPT
$$
JAPAN
UPPER
SPEC
LOWER
SPEC
UPPER
SPEC
Co
ost
LOWER
SPEC
US
$
A
B
T
Quality Characteristic
A
B
T
Quality Characteristic
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TAGUCHI’S LOSS FUNCTION
Quality History: Deming
(1950’s –– technically 1930’s
(1950’s technically 1930’s‐‐early 1990’s)
LOWER
SPEC
W. Edwards Deming ‐
Deming ‐ A product or a service possess Quality if it helps someone live better materially and spiritually and enjoys a large and sustainable market. (Balaji
Balaji S. S. Reddie
Reddie, , Founder, The Deming Forum, India)
UPPER
SPEC
Coost
The key to low
cost is to be on
target with the
least variability
$$$
$$
$
T
Quality Characteristic
Quality History: Dr. W. Edwards Deming
ƒ
Turned Japan’s quality around
ƒ
Deadly diseases
ƒ
Obstacles
ƒ
14 points
(www.baldrige21.com)
ƒ
Deming is known to be one of the most
influential persons on Quality as we know it
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