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Quality Improvement Model

Quality Improvement Model. Define Process. Select Measures. Collect & Interpret Data. Purpose: To provide a sequence of steps to improve any process so that the customers will realize the highest quality and value. Is Process Stable ?. No. Investigate & Fix Special Causes. Yes.

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Quality Improvement Model

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  1. Quality Improvement Model Define Process Select Measures Collect & Interpret Data Purpose: To provide a sequence of steps to improve any process so that the customers will realize the highest quality and value. IsProcessStable? No Investigate & Fix Special Causes Yes IsProcessCapable? No Improve Process Capability Yes Develop Control Plan to Maintain Current Process

  2. Define Process Define Process Select Measures Collect & Interpret Data IsProcessStable? No Investigate & Fix Special Causes 1) Communicate to an individual or a team a clear understanding of the process under study. 2) Establish improved and consistent process operations. 1) Identify and list Suppliers, Inputs, Outputs, and Customers (SIPOC/Big Block) 2) Develop flow chart of process steps (Schematic). 3) Develop process map 3) Assure understanding of related procedures. • Verify practice vs. procedure of S.O.P's 1) Process Map Excel Workbook 2) Flow Charts or Schematic/SIPOC or Big Block/Process Map/Detailed Process Map 3) S.O.P's Yes IsProcessCapable? Improve Process Capability No Yes Develop Control Plan to Maintain Current Process Purposes: Activities: Tools:

  3. Purposes: • 1) Develop understanding of customer needs. • 2) Determine "possible" process response control points. • 1) Review customer needs. • 2) Identify/Develop measures that reflect those needs. • Describe/Review sampling/testing plans and methods. • Process Map Details • Types of Process Control (Monitor, SPC, EPC, SOP) • 1) Customer Input • Sampling and measurement techniques • Process Map Master.XLS Activities: Tools: Select Measures Define Process Select Measures Collect & Interpret Data IsProcessStable? No Investigate & Fix Special Causes Yes IsProcessCapable? Improve Process Capability No Yes Develop Control Plan to Maintain Current Process

  4. Purposes: • 1) Begin collecting and analyzing data from the process. • 1) Analyze existing data from the process. • Determine needs for new data and develop systems for collecting data. • Understand sources of variation in process data • 1) Run Charts • 2) Histograms • 3) Pareto Charts • Cause-Effect Matrix (CandE_Matrix.XLS) • Minitab Software Activities: Tools: Collect & Interpret Data Define Process Select Measures Collect & Interpret Data IsProcessStable? No Investigate & Fix Special Causes Yes IsProcessCapable? Improve Process Capability No Yes Develop Control Plan to Maintain Current Process

  5. Purposes: • Determine stability of key measures of the product. • Understand differences between common and special cause sources of variation. • 3) If not stable, proceed to block on "Investigate and Fix Special Causes". • 4) If stable, proceed to block on "Is Process Capable?" • 1) Collect data from process in time order. • Identify presence of special causes. • Understand how to calculate control limits • Use Minitab to create control charts • Understand differences between Sigma_S and Sigma_C. • Understand differences between control limits and specifications. • Control Charts • Minitab Software Activities: Tools: Is Process Stable? Define Process Select Measures Collect & Interpret Data IsProcessStable? No Investigate & Fix Special Causes Yes IsProcessCapable? Improve Process Capability No Yes Develop Control Plan to Maintain Current Process

  6. Purposes: • 1) Achieve stability of the measures. • 2) Establish permanency of solutions to recurring special causes. • 3) Improve procedures and training. • Daily Operations • 1) Assure consistent operations • Investigate reasons for instabilities • Compensate process when needed • Document root causes of instabilities and compensation effects • Long-Term System Changes • 1) Implement preventive & corrective actions for special causes • 2) Assure stability of raw materials • Analyze data for stability problems, e.g., differences among crews, equipment, etc. (Exploratory Data Analysis • 1) Control Charts • 2) Special Cause Action Plans • 3) SOP's • FMEA • Process Map (Details!), C&E Matrix Activities: Tools: Investigate& Fix Special Causes Define Process Select Measures Collect & Interpret Data IsProcessStable? No Investigate & Fix Special Causes Yes IsProcessCapable? Improve Process Capability No Yes Develop Control Plan to Maintain Current Process

  7. Purposes: • 1) Determine process adequacy. • 2) If not capable, proceed to block on "Improve Process Capability". • If capable, proceed to block on "Develop Control Plan to Maintain Current Process". • Determine test method adequacy. • Compare histogram to customer requirements (specifications). • Calculate C-Family (Cp, Cpk) and P-Family (Pp, Ppk) capability indicies. • Analytical Labs: Calculate percent variation due to the test, percent gauge R&R and P/T Ratio. • 1) Control Charts • Histogram • Minitab Software Activities: Tools: Is Process Capable? Define Process Select Measures Collect & Interpret Data IsProcessStable? No Investigate & Fix Special Causes Yes IsProcessCapable? Improve Process Capability No Yes Develop Control Plan to Maintain Current Process

  8. Purposes: • 1) Determine/Identify fundamental changes to the process to improve capability. • 1) Analyze data statistically (Exploratory Data Analysis - EDA) • 2) Perform trials of possible fundamental changes to the process. • 3) Implement changes (if positive results occur.) • 1) Standardization • 2) Designed experiments (DOE) • 3) Breaking out process steps (Process Map) • 4) Isolating sources of variability (ASM/DOE) • 5) Separating out common causes (stratification. ASM) • Brainstorming • Scatter Plots (C&E / ASM) • Mintab Software Activities: Tools: Improve Process Capability Define Process Select Measures Collect & Interpret Data IsProcessStable? No Investigate & Fix Special Causes Yes IsProcessCapable? Improve Process Capability No Yes Develop Control Plan to Maintain Current Process

  9. Purposes: • 1) To maintain the process improvements that have been made • 2) To continually improve the process. • 1) Implement control charts, strategies for real-time problem solving, SOP and EPC. • Implement systems for summarizing and analyzing data for recurring special causes. • Develop documentation package for process. • Use results from DOE and data analysis to determine critical inputs to control. • 1) Control Charts • 2) Cause-Effect Matrix • 3) Pareto Charts • 4) Brainstorming • 5) FMEA • SCAP • SOP's • Control Plan Summary Sheet.XLS • Process Map Details Activities: Tools: Develop Control Plan to Maintain Current Process Define Process Select Measures Collect & Interpret Data IsProcessStable? No Investigate & Fix Special Causes Yes IsProcessCapable? Improve Process Capability No Yes Develop Control Plan to Maintain Current Process

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