Session 4:
Total Quality
Management
Total Quality Tools and
Statistical Thinking (2)
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Reasons for Using Tools

According to Joseph Juran:

… most people devote too much attention to
control and too little to planning and
improvement …
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Types of Tools

Tools for Quality Planning:
1.
2.
3.

Tools for Continuous Improvement:
1.
2.
3.
4.


Quality Function deployment 
Concurrent Engineering
The New Seven management and Planning Tools
Tools for data Collection and Analysis 
The Deming Cycle
Poka-Yoke (Mistake Proofing)
Benchmarking
Creativity and Innovation
Statistical Thinking
Santiago Ibarreche © 2003
Concurrent Engineering
 Objectives:
1. Distinguishing the character of the product in order to determine
appropriate design, production or operation methods, and
ensuring the rapid repair of products or solution of conflicts
2. Analyzing product and operation functions so all design
decisions can be made with full knowledge of how the item is
supposed to work and so all team members understand it well
enough to contribute.
3. Relating product function to production methods. Computeraided design tools allow a designer to simulate product
performance by varying assumptions within a computer model.
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Objectives: (Cont.)
4.
Performing a design-for-manufacturability study to determine if the
design can be made easier to produce without affecting
performance.
5.
Designing an assembly sequence that integrates quality control
and ensures that each part is designed so that its quality is
compatible with the assembly method.
6.
Designing a factory or operation system that fully involves workers
in the production strategy, operates on minimal inventory, and is
integrated with suppliers' methods and capabilities.
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The Seven New Management and
Planning Tools:
1. Affinity
Diagram / KJ Method
2. Interrelationship Diagraphs
3. Tree Diagrams
4. Matrix Diagrams
5. Matrix data Analysis
6. Process Decision Program Chart
7. Arrow Diagrams
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Affinity Diagram / KJ Method
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Interrelations Diagraphs
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Tree Diagram
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Matrix Diagrams
Example of Quality Function Deployment (House of Quality)
Tech. Req 4
Tech. Req 3
Very Weak relationship(1)
Tech. Req 2
Weak Relationship(3)
Tech. Req 1
Symbols
 Strong Relationship (9)
Tech. Req 1
Tech. Req 2
Tech. Req 3
Tech. Req 4
Vice of Customer
Company A
Company B
Tech. Req 4
Tech. Req 3
¯ Very Weak relationship(1)
Tech. Req 2
° Weak Relationship(3)
Tech. Req 1
Symbols
¿ Strong Relationship (9)
Importance for
Customer
1
2
Customer Requirement 1
Customer Requirement 2
Customer Requirement 3
Customer Requirement 4
Customer Requirement 5
Customer Requirement 6
Customer Requirement 7
Customer Requirement 8
Competitive Evaluation
A
B
Goals
Deployment
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3
4
Evaluation
5
1
2
3
4
5
Matrix Data Analysis
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Process Decision Program Chart (PDPC)
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Example of a CPM Chart
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Types of Tools

Tools for Quality Planning:
1.
2.
3.

Tools for Continuous Improvement:
1.
2.
3.
4.


Quality Function deployment 
Concurrent Engineering 
The New Seven management and Planning Tools 
Tools for data Collection and Analysis 
The Deming Cycle
Poka-Yoke (Mistake Proofing)
Benchmarking
Creativity and Innovation
Statistical Thinking
Santiago Ibarreche © 2003
The Deming Cycle
Plan
Act
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Do
Study
Ishikawa (Fishbone or Cause Effect)
Santiago Ibarreche © 2003