Friday, July 29, 2016

New 7 QC Tools; 7 Management and Planning Tools of Quality Control

With advancement in quality management during the past few years qualitative data analysis has become a new challenge along with quantitative data analysis.
The fundamental tools of quality control; Process flow chart, Check sheet, Histogram, Pareto diagram, Cause and effect diagram, Scatter chart, and Control charts, are well enough capable to analyze the quantitative data and to implement statistical process control. But in case of qualitative data analysis the fundamental QC tools are not sufficient to serve the purpose.

With advent of modern quality tools in the field of quality management the problem of qualitative data analysis reached to the solution. These modern quality tools are known as "New 7 Quality Control Tools" 
Basically these tools deal with management and planning of quality control activities like; New product development, Policy deployment, Translating the customer voice into technical requirements, etc. hence these tools are also named as "7 M Tools"

These "New 7 QC Tools" or "7 M Tools" are; 

  1. Affinity Diagram
  2. Interrelationship Digraph
  3. Tree Diagram
  4. Matrix Diagram
  5. Prioritization Matrices
  6. Process Decision and Program Chart
  7. Activity Network Diagram
A brief description of all new 7 tools are given below one by one;

Tool#1: Affinity Diagram

Affinity diagram provides the opportunity of generating a large number of ideas for an issue. Team members brainstorm and collect the ideas as much as possible to solve a problem and paste these ideas on the board to see by all members. Similar type of ideas are then categorized under the same category, and collected in ordered manner for different categories. Similar ideas are under one category.

Tool#2: Interrelationship Digraph

This tool clarifies the interrelationships of many factors of a complex situation. Ideas or issues are placed on paper in circular format. Discuss the issues one by one and find which issue influences others. Draw an arrow between related ideas. An idea from which an arrow coming out is considered as the cause and an idea towards an arrow incoming is considered as the effect. 
Count the number of outgoing and incoming arrows for an issue or idea and write under there. The issue having largest number of outgoing arrows is the 'Driver' and the issue having smallest or no incoming arrow is the 'Key Outcome or Effect'.
The tool serve the purpose of root cause analysis when there are many issues or causes available for a problem.

Tool#3: Tree Diagram

When team wants to screwed an idea into lager details, the tree diagram served the purpose. Tree diagram helps in objective achievement by placing the objective in a seed box on extreme left side on the paper then options and means of objective achievement are brainstormed and place horizontally in three different boxes coming out of the seed box, further at next level each new box broken into three new boxes for further details of objective achievement. 
Tree diagram grows like fusion reaction.

Tool#4: Matrix Diagram

The objective of construction of matrix diagram is to analyze the correlation between two group of ideas. In-fact matrix diagram is the basic technique used in construction of "Quality Function Deployment or House of Quality (QFD/HOQ). A group of ideas are placed in first row of the matrix say "How's" the customer requirement fulfilled? another group say "What's" are the customer requirements? are placed in first column of the matrix.
Each option in first column is compare the relationship with the corresponding options available in first row of the matrix then place a relationship symbol or numeral in the intersection cell of the matrix for the corresponding row and column option. 
Calculate the options importance score and rank accordingly

Tool#5: Prioritization Matrices

This tool prioritize the issues based on weighted criteria using a combination of tree and matrix diagram
First using tree diagram, options of objective achievement are finalized then select the criteria to judge the available options of objective achievement under each criterion.
Prepare a matrix between team members and criteria. Each member then weight the criteria so that all individual criterion weight will equal to 1. Say four team members assign the weights to a criteria as 0.35, 0.15, 0.25, 0.25 then sum of weights is 0.35+0.15+0.25+.025=1.0
Find the sum of each individual  criterion score and then prepare a new matrix in which options came from the tree diagram are ranked under each individual criterion and multiply the criterion score. Sum, all the values under the criteria for each option and judge which option should be implemented first.


Tool#6: Process Decision Program Chart

PDPC is used for forecasting the failures that may happen while delivery of the program, like a conference, project presentation, etc. so that the failure could avoid and some countermeasures prepare accordingly. 
An objective written on the top of a paper or board, say "Successful execution of a conference". In next step write the means of executing the conference, Next write "What if" i.e. possible failure with probability of failure. Further write the countermeasures to tackle the failure. Write 'o' under those options which are accepted and 'x' which are rejected.

Tool#7: Activity Network Diagram

This tool is also know as Program Review and Evaluation Technique (PERT) or Critical Path Method (CPM). It helps to schedule a project efficiently The tool is from project management.
All tasks are writing on board and arranged in a sequence of their implementation one after another. The time of completion of each task is written under each task. Calculate the Earliest Start and Earliest Finish time. Earliest Finish time can be calculated by adding the task time in Earliest Start time. 
Now write the Latest Start and Latest Finish time by moving in reverse direction and find the "Critical Path"
Critical Path is the longest cumulative time of connecting activities when Slack time is zero. Where, 
Slack = Latest Start - Earliest Start

Thursday, May 12, 2016

7 QC Tools and SPC Training; 29 May, 2016 at Bahadurgarh

7 QC Tools and SPC Training Seminar

Date: 29 May, 2016, Time: 9am to 5pm

Place: Omaxe City, Bahadurgarh, Haryana, India

Call to register: 09468267324, or mail at shakehandwithlife@gmail.com

One of the best technical tool for improving product and service quality is statistical process control (SPC). There are seven fundamental tools using which the SPC can be implement at workplace in manufacturing and service industries. The tools not only control the process but also improve the capability of the process. The tools are very high in demand almost every kind of manufacturing and service industry to maintain the quality at par. The application of these tools are realized as reduced cost of poor quality, customer satisfaction, on time service delivery, and higher production efficiency. 

Course highlights

Introduction

  • Mathematical definition and dimensions of quality
  • Understanding SIPOC

7 quality control tools

  1. Process flow chart
  2. Check sheet
  3. Histogram
  4. Pareto Analysis
  5. Fishbone diagram
  6. Scatter chart
  7. Control charts (Mean and Range chart)

Statistical Process Control

  • Causes of variation
  • Investigating an out of control process
  • Basic statistical concepts
  • Process capability analysis Cp and Cpk

Program highlights

  • Highly interactive training from industry expert
  • Course notes handouts with practice data and excel templates
  • Case study
  • Project work
  • Pre and post learning evaluation
  • Networking lunch and tea break
  • Certificate of participation

Participants

  • Junior, Middle and Senior level executives, Team leaders, Process trainers, from quality, production, engineering, maintenance, sales, and accounts dept. from manufacturing and service industry.
  • Academicians, researchers, and students from management and engineering colleges.
  • Students of UG and PG with mathematics and statistics as main subject.

Registration

  • Fees for registration is Rs. 3500/- per participation . Group discount for 3 or more participants is 10%
  • Fees can be paid by cash/cheque/DD/Netbanking
  • Download the nomination form or mail to shakehandwithlife@gmail.com,
  • No. of seats are limited to 15.

Contact for further details

Tuesday, December 22, 2015

7 QC Tools and SPC Training; 18 Dec. 2015 at Bahadurgarh: A Report

7 QC Tools and SPC Training

Dec.18, 2015 at Bahadurgarh

A training on "7 QC Tools and SPC" coursework was held on dated 18/12/2015 in Hotel Royal Choice Bahadurgarh, Haryana, India-124507.
This report includes the details of participating companies, event organization, schedule of the program and the glimpses of the training workshop at different point of time.

Acknowledgement

I sincerely pay my thanks to the participating companies and individuals in this training for learning of continuous process improvement tools
I would like to thanks to Mr. Pramod Deshpande, CEO, Nexgen Fluoropolymers Pvt. Ltd for approval given to the nominees to attend the training, and a sincere thanks to Ms.Tanu Chopra Asst. Manager, HR, for all necessary communication and coordination concern to nominees.

I would like to thanks to Mr. Avadhesh Mishra GM Operations, and Mr. G.S. Prasad Sr. Manager, HR and Admin, Roca Parryware, for approval and necessary communication regarding the nominees to attend the training.

I would like to appreciate Mr. Anil Makkar to nominate himself as individual to participate in this training.

I would like to thanks to all participants;
  • Mr. Naveen Gupta, Director, Nexgen Fluoropolymers
  • Mr. Vinod Jangid, AM R&D, Nexgen Fluoropolymers
  • Mr. Anupam Gogoi, Engineer, Quality, Nexgen Fluoropolymers
  • Mr. Ajay Kumar Jain, Sr. Manager, Production, Roca Parryware
  • Mr. Abhineet Kapoor, Sr. Manager, Quality Assurance, Roca Parryware
  • Mr. Abhimanyu Katoch, Manager, Industrial Engineering, Roca Parryware
  • Mr. Pankaj Pathak, Manager, HR, Roca Parryware
  • Mr. Anil Makkar, Sr. Supervisor, Production, STB Technologies,
 for their sincere behaviour and endeavour to learn during the whole training workshop

At last, I would like to thanks to all Hotel staff for their support and courtesy for creating a conducive learning environment.

Program Schedule

The whole training is divided into two session

Morning Session: 9:00AM to 12:30PM

Theoretical and Mathematical concepts

  • Mathematical definition and dimensions of quality
  • SIPOC
  • All seven tools of quality; Process flow chart, Check sheet, Histogram, Pareto chart, Cause and Effect diagram, Scatter chart, and Control charts with small exercise after every tool
  • Concept of statistical process control
  • Causes of variations
  • Investigating an out of control process
  • Basic concepts of statistics
  • Concept of normal curve
  • Process capability indices (Cp and Cpk)

Evening Session: 1:00PM to 5:00PM

Practical learning and Project work

  • Working with Excel templates for all 7 qc tools and spc
  • Case Study
  • Live project work
  • Learning evaluation quiz
  • Feedback 
  • Awarding participation certificate
A networking lunch and morning and evening tea with snack also given to all participants

Team Ashoka (left) and Team Chankya (Right)

Glimpses of the event

Participants were divided into two teams;
  • Team Ashoka and 
  • Team Chankya







Working on projects

Team Chankya working on their project
















Team Ashoka working on their project


























Mr. Abhimanyu and Mr. Pankaj presenting their team project




Mr. Abhimanyu Katoch and Mr. Pankaj Pathak from team Ashoka presenting their team project on "Overtime Reduction"





Awarding Participation Certificates

To Mr. Naveen Gupta
To Mr. Abhimanyu Katoch

To Mr. Abhineet Kapoor
To Mr. Ajay Kumar Jain

To Mr. Anupam Gogoi
To Mr. Vinod Jangid

To Mr. Pankaj Pathak

To Mr. Anil Makkar




























































































Recommendations and Suggestions

All participants are recommended to identify the problem and start a continuous improvement project at their workplace benefiting to the organization.
Suggested projects are

  • Reducing defects level
  • Increasing productivity
  • Reducing waste
  • Reducing overtime
  • Improving work process
  • Reducing customer complaints
  • Reducing delivery time

Report by

Narender Sharma
Program director and Training facilitator
Call: 9468267324, 8684861131
Websites: www.shakehandwithlife.in, www.shakehandwithlife.puzl.com,

Wednesday, November 25, 2015

7 QC Tools and SPC Training 19-20 Nov.2015 @ Roca, Parryware: A Report

7 QC Tools and SPC Training @ Roca, Parryware 19-11-2015
It was a great experience for me to deliver "7QC Tools & SPC training" at company site RocaParryware, Alwar Rajasthan 

7 QC Tools and SPC Training @ Roca, Parryware 20-11-2015
Roca is a Spanish company and an international brand, manufacturing different kinds of bathroom products across the world.

Parryware, India's leading manufacturer of bathroom products. In 2006 it entered into Roca corporation, Spain and became a Roca group subsidiary in 2008 and turned into wholly subsidiary of Roca group in 2011

Company is deeply concerned about the quality delivered in their product, hence organized the training program for two days  at its manufacturing site Alwar, Rajasthan.
Mr. Narender Sharma with Mr. Avadhesh K Mishra
Mr. Narender Sharma with Mr. Avadhesh K Mishra
Mr.Narender Sharma with Avadhesh K Mishra
Mr. Narender Sharma with Avadhesh K Mishra
The Company intended to aware its staff regarding the 7 quality control tools and SPC, so that they can collect, and analyse the data to make continuous improvement in their respective work process.
The participants were from management, engineering, executive level and almost from every department so that quality can better be spread out in the daily life of the company culture.
The 7 Quality Control tools are highly effective in understanding current process, data collection, data presentation, data analysis, and control the process with use of statistical process control (SPC) technique.
I would like to pay my thanks to Mr.Francesc Recasens Brianso - Manufacturing Manager, and Mr. Ajay Sharma, Sr. Manager training and development, Roca, having chosen me for this opportunity.
I would like to pay my thanks to Mr. Avadhesh K Mishra-General Manager, Operations, Roca, for his gracious presence in the training .
Mr.Narender Sharma with Mr. Narayan Prasad
Mr. Narender Sharma with Mr. Narayan Prasad
I can't move without paying my thanks to Mr. Narayan Prasad, and Mr. Pankaj Pathak for giving unconditional support, necessary arrangements for the training and making all arrangement for my transportation and accommodation which were really be praiseworthy.
Training was organized for two days 19th and 20th Nov. 2015. 
Training started with speech of Mr. Avadhesh Mishra, regarding the importance of 7 QC Tools and SPC to the participants.
Then Mr. Prasad reminded all participants about the quality policy of the company and introduced me to all participants.
After this I had taken the charge to start the training. All participants were grouped into teams and suggested to choose a name for their team. First of all, I had given some questions to all participants for pre-assessment. Then I started with first module of training.
Mr. Narender Sharma while delivering training
Mr. Narender Sharma while delivering training

Module I: 7 QC Tools

  • Mathematical definition of quality. 
  • SIPOC
  • Process flow chart
  • Check sheet
  • Histogram
  • Pareto diagram
  • Cause and effect diagram
  • Scatter chart
  • Control Chart ( Mean chart, Range chart, P-chart, C-chart)
A 5 Min. practice exercise was given to every team after every tool.
Mr. Narender Sharma while delivering training
Mr. Narender Sharma while delivering training
Before starting the 2nd module of training i.e. "statistical process control" A story "Statistics of Love" was shown to all participants to make them comfortable to understand the statistical concepts. 

Module II: Statistical Process Control

  • What are the causes of variations?
  • Basic concepts of SPC
  • Concept of normal curve
  • Process capability analysis Cp and Cpk

Module III: Case Study

After lunch a case study was discussed to better understand the use of 7QC Tools and SPC for analysing and solving the real life problem like;

  • Define the problem
  • Business impact of the problem
  • Data collection and measurement
  • Analysis of data
  • Root cause finding and improvement
  • Control and sustain the improvement

Module IV:

Excel templates were installed to all available laptops, then all participants were trained to use and analysis of templates one by one
Mr. Narender Sharma while delivering training
Mr. Narender Sharma while delivering training
  • Construction and analysis of Process flow chart 
  • Construction and analysis of Check sheet
  • Construction and analysis of Histogram
  • Construction and analysis of Pareto chart
  • Construction and analysis of Cause and effect diagram
  • Construction and analysis of Scatter chart
  • Construction and analysis of Control chart
  • Process capability Cp and Cpk analysis template 

Quiz

At the end of the day a quiz was organized to check the learning evaluation. The quiz was enjoyed by all participants.

Closing Remark

All participants deserve appreciation for their learning attitude and practising the course work responsibly and carefully.

Suggestions and Recommendations

  • Small projects should be started for continuous improvement using 7 QC tools and SPC in every department.
  • Departmental team needs to be created
  • The projects should be selected in concern with department head and considering the improvement opportunity
  • Trainer should be called at regular interval for consulting, data analysis, project report preparation, and motivating the team-mates for goal achievements.
  • Projects should be presented by its team after its successful completion to motivate others
  • Success of the project should be celebrated by the department along with rest of the company.
Report by
Narender Sharma
Training Facilitator
Call: 09468267324, 08684861131

Upcoming open house "7 QC Tools and SPC" training seminar 

Date: 18th Dec. 2015, Place: Bahadurgarh, for registration, training schedule and more details, click here

Friday, October 16, 2015

7 QC Tools and SPC Training December 2015

7 QC Tools and SPC Training December 2015

Place: Bahadurgarh, Haryana, India

The training course aims to skill the managerial and engineering squad and front-line workforce to effective utilization for different tools for root cause finding so that problems could be addressed in right way for quality and productivity improvement.

About 7 QC Tools and SPC


  1. Process flow chart: Finds trouble spots of the process
  2. Check Sheet: Confirms the physical presence of the defects
  3. Histogram: Presents and understand the spread of the data
  4. Pareto Analysis: Identifies vital few instead of trivial many
  5. Fishbone diagram: Finds root cause for an effect
  6. Scatter chart: Confirms the relationship between two variables
  7. Control chart: Remove assignable causes and control the process
  8. SPC and process capability analysis for process improvement

Program Highlights

  • Interactive classroom training with industry expert
  • Networking lunch and tea breaks
  • Working with MS excel
  • Live project and learning evaluation

Course Kit

  • Hard copy of course notes
  • Pen-drive with inbuilt data like; digital copy of course notes, excel templates
  • Handouts

Who should attend this training?

  • Managers at all levels in manufacturing and service industries
  • Individual working professionals
  • Future managers in MBA/BBA/B.E./B.Tech/UG/PG

Nomination/Registration

  • Send nominations before 15 Nov. 2015 and get early bird discount
  • Program date, venue, and last date of registration will be informed to the nominating authority with nominees individually,
  • Training will be organized in Hotel's conference room placed at Bahadurgarh
  • Registration fees is Rs. 3500/ per participant
  • Discount for early bird entries is 10%. Group discount is 15% for 5 or more participant
  • Fees must be deposited before last date of registration by Cash/Cheque/DD/Netbanking

Nomination forms

Please call @ 9468267324, 8684861131, 9315132462

Nomination forms can be download by follow the links