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Continuous Improvements
By Prof. Raghavendran V
By. Prof. Raghavendran V 2
Proactive Improvements
By. Prof. Raghavendran V 3
Proactive Improvements
There are some improvements that they wont use hard data but rely on subjective information. Application of these tools has proven useful in process improvement, cost reduction, policy making & deployment and New-Product Development.
By. Prof. Raghavendran V 4
Proactive Improvements
The tools are very simple, it is effective and it can be key to finding the root cause of a problem in specific terms and then ask why.
You may have to ask why 2 or more times to obtain root cause of the problem.
By. Prof. Raghavendran V 5
Management Tools & Techniques
There are 9 different techniques involved and also called as “Management tools Technique”. There are listed as follows:
1. Forced Field Analysis2. Nominal Group Technique3. Affinity Diagram4. Interrelationship Digraph5. Tree Diagram6. Matrix Diagram7. Prioritization Matrices8. Process Decision Program Chart(PDPC)9. Activity Network Diagram
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Forced Field Technique
This analysis is used to identify the force & factors that may influence the problem or goal.
It helps an organization to better understand promoting & inhibiting forces so that the positives can be reinforced & the negatives can be reduced.
The procedure is define the Objective, determine the criteria for evaluating effectiveness of action
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Forced Field Technique
For Illustration:Objective: Stop Smoking
The Benefit are the determination of the positives and negatives, encouraging people to prioritize the competing forces and identify root causes.
Promoting Forces to stop smoking
Inhibiting forces to cant stop Smoking
Poor Health Habit
Smelly Clothing Addiction
Cost Taste
Impact on others Advertisement
Setting an Example Stress
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Nominal Group Technique
This provides for issue/idea input from everyone on the team and for effective decisions.
For Example: Indian cricket team decides which problem to work on. All players write down on the papers the problems they think is most important.
Ranking is consider to evaluate the problem. The highest number is consider as most important problem.
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Affinity Diagram
This diagram allows the team to creatively generate large number of issues/ideas and logically group them for problem understanding and possible breakthrough solutions.
The procedure is to state the issues in a full sentences, brain storm.
(large group must be divided into small groups with appropriate headings)
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Affinity Diagram
For Illustration for scrambled idea:
What are issues involved in losing the world cup for
England
Not enough experien
ce playersSpin
Tracks
Big Grounds
No form players
No seriousness in playing
Ambience of the crowd
Fear of Terrorism
Fatigue Pitch
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Affinity Diagram
For Illustration for Ordered idea:What are issues involved in
losing the world cup for England
Not enough experience players
Spin Tracks
Big Grounds
No form players
No seriousness in playing
Ambience of the crowd
Fear of Terrorism
Fatigue Pitch
About Technical aspects
About Players
About Public Factors
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Interrelationship Diagraph(ID)
The Interrelationship Diagraph clarifies the inter relationship of many factors of a complex situation. It allows to team to classify the cause & effect relationships among the all the factors.
The procedure is complicated & as follows1. The team should agree on the issue or
problem statement.2. All the ideas or issues must be laid out
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Interrelationship Diagraph(ID)
3. Start with first issue & evaluate with the other issue using cause-effect relationship.
4. The second iteration is to compare second issue with other issue and followed by.
5. The entire diagram should be reviewed where necessary. It is good idea to obtain information from others people Upstream or Downstream.
6. The diagram is completed by tallying the incoming & outgoing arrows and placing this information below the box.
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Interrelationship Diagraph(ID)
Benefits of Interrelationship Diagraph(ID) It allows a team to identify root causes
from subjective data systematically.Cause and effect relationshipsEncourage members to think in
multidirectionalDevelops team harmony and
effectiveness.
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Tree Diagram
This tool is used to reduced any broad objective into increasing levels in detail in order to achieve objective.
Procedure to choose action oriented objective statement.
Secondly, brainstorming, choose the major headings
Thirdly, generate the next level analyzing the major heading.
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Matrix Diagram
Here diagram allows individuals or teams to identify, analyze and rate the relationship among two or more variable.
Data are presented in table form and can be objective or subjective, which can be given symbols with or without numerical values.
There are different formats 2 or variablesL-shaped (2V), T or C or Y-shaped(3V) and X
Shaped (4V).
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For Illustration:
o AlwaysFrequently Occasionally
Tool/ Use Creativity Analysis Consensus
Action
Affinity o o
ID o
Tree Diagram
Prioritization Matrix
o
Matrix Diagram
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Prioritization Matrices
These tools prioritize issues, tasks, characteristics, and based on weighted criteria using combination of tree and matrix diagram techniques.
Prioritization matrices are designed to reduce the teams options rationally before detailed implementation planning occurs.
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Construction of Prioritization Matrices
Construct an L-shaped matrix combing the options
Determine implementation criteria Nominal Group technique.
Prioritize the criteria using NGT, each member weights the criteria so that total weights equal to 1.00
Rank order the options in terms of importance by each criterion
Compute the option importance score
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Process Decision Program Chart
Programs to achieve particular objectives do not always go according to plan, and unexpected developments may have serious consequences. The PDPC avoids surprises and identifies possible countermeasures.
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PDPC
Plan successful conferences
Registration Presentations Facilities
Audio/Visual Fails
Speakers Late Too Long
Have Substitute
Have Backup Use Time
KeeperUse AV Person
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Activity Network Diagram
This tool goes by a number of different names and deviations, such as program evaluation and review technique, Critical Path Method, arrow diagram and activity on node.
It allows team to schedule a project efficiently.
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1) The team brainstorm/document all the tasks to complete project.
2) The first task is always started from extreme left.
3) Any tasks that can be done simultaneously.4) Repeat step 2 & 3 until all tasks are placed5) Number each task & draw connecting
arrows. Determine the completion time and post it in the lower left box. Completion times recorded in hours/days/weeks
6) Determine the critical path by completing the four remaining boxes in each task. These boxes are Earliest start time(ES), Earliest Finish(EF), Latest Start(LS) and latest Finish (LF).
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Reactive Improvements
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Reactive Improvements is also known as Statistical Process Control. This is one of the best technical tools for improving product and service quality. There are seven basic technique and they are:
1. Pareto diagram2. Process flow diagram3. Cause and effect diagram4. Check sheets5. Graphs- Histogram, Line graphs, Pie
charts6. Scatter diagram7. Control Charts
Some what Statistical
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Pareto Diagram
Alfred Pareto conducted extensive studies of the distribution of wealth in Europe.
Pareto diagram is a graph of that ranks data classification in descending order of their numerical value of their frequency of occurrence from left to right in accordance with the variables.
Variables are problems, complaints, causes, type of non conformities.
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Pareto Diagram
Pareto Diagram Concepts:
Category of data0
5
10
15
20
25
30
35
40
45
50
Series 1Series 2Series 3Series 4
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Construction of Pareto diagram
Determine the method of classifying the data (Problem, cause, non conformity and so forth)
Decide if rupees, frequency or both are to be used to rank the characteristics.
Collect data for an appropriate time interval or use historical data.
Summarize the data and rank order categories from largest to smallest.
Construct the diagram and find the vital few.
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Solve the problem: In an recent 1st internal assessment
conducted for 7th mechanical students, the following result declared for 48 students
0-14 marks: 31 Students15-20 marks: 13 Students21-25 marks: 04 Students.Categorize them using Pareto Diagram.
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Pareto Diagram
Students marks0
5
10
15
20
25
30
3531
13
4
0-1415-2021-25
65%
27%08%
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Process Flow Diagram
It shows different activities of a process operation, for a product or services as it moves through the various processing operations.
The diagram makes it easy to visualize the entire system, identify potential trouble spots and locate control activities.
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Process Flow Diagram
For Illustration: let us consider vehicle parking operation in a bus terminus.
Customer gets the tkt for Parking
Customers parks the car
Customers comes back to parking lot to leave
Customers drives the car to exit
Cashier System
Customer Drives the car
Receive tkt from the customer
Stamp the exit time on ticket
Read difference time and collect the time
Put the tkt in Storage Bin
End of the day complete report
Owner of the parking lot gets the accounting report
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Cause and Effect Diagram
A C&E diagram is a picture composed of lines and symbols designed to represent meaningful relationship between effect and causes.
It was developed by Dr. Kaoru Ishikawa 1943 and it is referred as fishbone diagram because of it shape.
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Cause and Effect Diagram
Quality Characteristics
People
Materials Work Methods
Environment Equipment Measurement
Causes
Effect
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Check Sheets
The main purpose of check sheets is to ensure that the data is collected carefully and accurately by operating personnel.
Data should be collected in such a way that it can quickly and easily used and analyzed.
For Illustration: Check sheet for paint nonconformities
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Check Sheets
Check SheetProduct: Bicycle 32 Number inspected:
2222Nonconformity Type Check
Total
Blister 21
Light Spray 38
Drips 22
Overspray 11
Runs 47
Others 5
Total 144
Number
Non Conforming113
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Histogram
Arguably the first ‘Statistical’ technique.It describe the variation in the process.The histogram graphically estimates the
process capability.For any histogram there will graphical and
analytical techniques for summarization.
Graphical technique is a plot or picture of a frequency distribution, which is a summarization of how the data points occur within each subdivision of observed values.
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Histogram
Analytical technique, summarize data by computing measure of the central tendency (Average, Median, Mode)and measure of the dispersion ( Range and standard Deviation).
Illustration for Ungrouped data:Number of daily accounting errors.
0 1 3 0 1 0 1 0
1 5 4 1 2 1 2 0
1 0 2 0 0 2 0 1
2 1 1 1 2 1 1
0 4 1 3 1 1 1
1 3 4 0 0 0 0
1 3 0 1 2 2 3
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Tally of number of daily accounting errors
Number Nonconforming
Tabulation Frequency
0 15
1 20
2 8
3 5
4 3
5 1
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Histogram
Illustration for Grouped data:
Temperature0
5
10
15
20
25
30
35
40
24
34
22Series 1Series 2Series 3
Cell
Interval
Boundary
Mid Point
Frequency
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Histogram
There are 6 different types of histogramAnd they are 1. Symmetrical2. Skewed right3. Skewed left4. Peaked5. Flat6. Bimodal
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Scatter Diagram
This is simplest way to determine, if a C&E relationship exists between two variables.
For Illustrations: in a relationship between automotive speed and mileage.
As speed increases, mileage decreases.Automotive Speed is plotted on the axis and
is the independent variable.Gas mileage is plotted on y axis and this is
dependent variable.
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Scatter Diagram
20 30 40 50 60 70 80 9005
1015202530354045
Y-Values
Y-Values
Speed –Mi/hour
Mileage/ltr
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Scatter Diagram
Other examples for relationship are:Cutting speed and tool lifeTemperature and Lipstick hardnessTraining and errorsBreakdowns and equipment age
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Control Charts
A control chart is a graphical representation of collected information and common tool used in industries in controlling the quality of products or quality characteristics.
It is an aid for analyzing the quality in repetitive process.
It is developed by Dr. W.A Shewhart
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Control Charts
Control charts is classified into types and they are:
1. Variable (Continuous Data)2. Discrete Data (Discontinuous Data)
Variable: Data which can take any value depending on the accuracy of the measuring instrument is called continuous data.
For Ex: Weight of Object can be 1.2 or 1.23 or 1.234 Kg Depends on the accuracy of the instrument.
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Discrete: Data which can take only definite is called discrete data. The values are whole number.
It will be only whole number. For ex: Number of wickets took by bowler.
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Variables
It is common phenomenon, in nature and also in the product produced in industry. There will be lot of variations on so many factors in a twin children.
It is impossible to produce identical parts. Henceforth, tolerance limits came in picture. Variations are due to 2 causes:
1. Variation due to chance causes2. Variation due to assignable causes.
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Variables
1. Variation due to chance causesThe variations due to sheer chance. This is
not permanent factor for variation.For Ex: Voltage Variation, Vibrations on
Machine tool.( It is difficult to avoid the variation)
2. Variation due to assignable causesVariations caused by assigned job. These
are easily traceable.For Ex: Difference among the M/c’s, Men,
materials
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Variable
Based on data, we have:
1. Control Charts for Continuous Data or Variable
2. Control Charts for Discrete Data or Attributes
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Control Charts for Continuous Data or Variable
The data collected for control charts for variable will be measured in two types and they are:
Mean and Range charts also called R Charts
Mean and Standard Deviation also called Charts.
Mean is most common method of measure of central tendency.
R and are most common method to measure of dispersion.
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Mean and Range charts
Procedure for drawing Charts:1. Collect good number of samples of
constant sample size ‘n’ at random at different intervals of time.
2. Measure all the quality characteristics of all which is to be controlled of all the pieces in the sample and of all the samples and record the same in tables.
3. Find the mean of the all the samples.4. Find the mean of the mean .
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Mean and Range charts
5. Find the range of the samples6. Find the mean of the range of all
samples.7. Compute the trial control limits or 3
control limits or control for X and R as follows:
Control limits for X chart:CLX= X± 3 X = X ± 3A2R
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Mean and Range charts
Control for R Chart:UCLR=D4R
LCLR=D3R
Where A2, D3, D4 are factors obtained from Table B, factors for controlling limits.
8. Draw X and R Charts