TQM &

QCC / SGAR.Duraisamy M.S, EGMP (IIM-B)

MD- M/s Shrishti Consultants, Chennaird@shrishtibiz.com+91 9445070511

www.shrishtibiz.com

Problems faced by Companies

•LPG (Liberalization, Privatization & Globalization)

•WTO (World of Threats & Opportunities)

•Maintaining quality & supplying ON TIME is not a great thing.

•Resistance to change

•Lack of ownership / responsibility

• Un satisfactory performance on Productivity, Quality, Cost, Delivery, Morale & Safety – (PQCDMS)

External Factors Internal Factors

TQC / TQM is an effort at continuous quality

improvement of all Processes, Products and

Services through TOTAL EMPLOYEE

INVOLVEMENT (TEI) that result in increasing

customer satisfaction, loyalty and improved

business results.

TQC / TQM

Customer

• A CUSTOMER is the most important visitor on our premises.

• He is not dependent on us. We are dependent on him.

• He is not an interruption of our work. He is the purpose of it.

• He is not an outsider on our business. He is a part of it.

• We are not doing him a favour by serving him. He is doing us a favour by giving us an opportunity to do so.

-Mahatma Gandhi

Kaizen Belief… Whatever we do can be continuously

improved- be it our working life or personal life.

What NEXT?

Concept & Implementation ofQCC / SGA

70

20

10

0%

25%

50%

75%

100%

Employees of Orgn

Lower Middle Top

Mission, Strategic planningTask Forces,CFT, SIT, CIP

Suggestion, SGA, QCC

Total Employee Involvement (TEI) Model

1. Self development.2. Mutual development.3. Improvement in Productivity, Quality4. Improvement in communication & Attitude5. Reduction in waste & cost.6. Problem solving opportunities.7. Team building.8. Links all levels of management towards success.9. Get people more involved & Interested in work.10. Improvement in participation.11. Reduces absenteeism & grievances.

What we get from QCC activities

QCC is for

• Self and mutual development of the grass root level employees

• Learning how to be systematic• How to make use of the brain power for the

betterment• Understanding the importance of data• How to collect data, categorize, prioritize• Finding out the inter relationship between data• How to work as a team

We understood that by “BRAIN STORMING” any big Task can be achieved..

Now there is no confusion in my process.

Muda of movement & fatigue is reduced to operator.

I got an opportunity to identify my hidden potentials.

We have understood the strength of PDCA cycle.

TKM

What we got thru SGA / QCC?

Job Satisfaction by Team Work

Computer skills improved

Operator fatigue reduced

House keeping improved

Recognition from co workers

Confidence level improvedWIL-Chennai

What we got thru SGA / QCC?

Acquired problem Acquired problem solving skillssolving skills

Gained knowledge Gained knowledge of Ultra sonic of Ultra sonic welding processwelding process

Gained Self Gained Self confidenceconfidence

Improved Improved Communication skillsCommunication skills

Learned to work in Learned to work in teamteam

Job SatisfactionJob Satisfaction

AIB

What we got thru SGA / QCC?

What we got thru SGA / QCC?• Recognition and self

esteem increased • Individual knowledge

enhanced• Presentation and

communication skill improved

• Approach for problem solving

• Team work and opportunity to expose Hidden skills

Got motivated to do more QCC projects

Mr.Siddaramappa

RADAR GRAPH

012345

Communication

Recognition

Self esteem increased

Presentation Skill

Problem solving

Application of 7QC Tools

To expose Hidden skills

Team work

BEFORE AFTER

…… Together we learn, work and contribute KTTM

What we got thru SGA / QCC?

TKAP

1. Establish a suitable atmosphere.2. Obtain commitment from Top Management3. Select the right people at the right area.4. Select Objectives.5. Expose people to the program.6. Inform and communicate.7. Keep the program voluntary.8. Training is critical.9. Start slowly, Grow slowly.10. Be open and positive.11. Monitor progress and changes

Steps to Start a QCC program

Forming QCC

QCC Structure

People are of different nature

ALIGNMENT THRU QCC / SGA

Training

10 Problem Solving Tools (PST)

1. Flow Diagram2. Brain Storming3. Check sheet4. Stratification5. Pareto Diagram6. Cause & Effect Diagram7. Why-Why Analysis8. Control Chart & Graphs9. Scatter Diagram10.Histogram

Brainstorming is a group participative technique.It unlocks and discloses the untapped creative talentsand resources in people.It is technique for generating the greatest possiblenumber of ideas.

Brainstorming

Check Sheet

• Simple data recording format for collecting data Easily, efficiently and more systematically

Category Jan '15 Feb '15 Mar '15 Total

Rent 7000 7000 7000 21000

Grossories 2000 3000 2500 7500

Entertainment 600 900 1000 2500

Electricity 600 500 400 1500

School fee 700 700 700 2100

Cosmetics 600 900 600 2100

Medical 1000 400 300 1700

Others 3000 2000 2800 7800

Total 15500 15400 15300 46200

Expenditure Detail

• Used to analyse the problem by breaking it apart and examining each piece separately.

•Stratification by itself does not solve problem, but it make it possible to gain insight that will aid in the solution.

Mr AshokDoor No.2 , 32 nd Cross, 9 th Main,4th Block, Jayanagar,Bangalore,Karnataka,India

Level 1 Level II Level III Level IV Level V Level VI Level VII Level VIIITamil Nadu Mysore Shivajinagar 1st Block 1st Main 1st cross Door No.1Karnataka Hassan Jayanagar 2nd Block 2nd Main 2nd cross Door No.2Kerala Dharward Vijayanagar 3rd Block 3rd Main 3rd cross Door No.3Andra Bangalore Indranagar 4th Block 4th Main 32nd cross Door No.4etc. etc. etc. etc. 9th Main 33rd cross Door No.5

etc. etc. etc

India

Stratification

•Combines a column graph and a line graph.•The Pareto analysis helps to identify the VITAL FEW from the TRIVIAL MANY

Vilfredo Pareto, Italian Sociologist-Uneven distribution of wealth.

Pareto of Expenditure

5500

30001400

600 550 425 330

46

7183 88 92 96 98 100

0

3000

6000

9000

12000

Rs

0

25

50

75

100

Cum

%TrivialMany

VitalFew

Pareto Diagram

• Represent the relationship between an effect and its causes.

•It is also called as, “Fishbone diagram” & “Ishikawa Diagram”

Man Machine

Material Method

Cause Effect

Cause & Effect Diagram

Finding Root Cause with 5 Why• 5 Why

– A way of peeling back the problem until the root cause is exposed

– A basic and effective method

– Verifying each answer along the way

5xAsk

“Why!“

4xAsk

“Why!“

3xAsk

“Why!“

2xask

“Why!“Root

Cause1xask

“Why!”

5 Why Example• Problem:

– Spindle not rotating

• Why?– Bearing jammed

• Why?– No lubrication.

• Why?– Lubrication oil tank empty.

• Why?– Operator not filled the oil.

• Why?– Operator could not know the oil level.

• Why?– Oil level indicator not visible.

• Conclusion:– Make oil level indicator visible.

Ask “Why!”

Graph is a pictorial representation of data which is easily understandable at a glance.

020406080

100

Nos

1st Qtr 2ndQtr

3rd Qtr4th Qtr

Production trend

Product x Product Y

Production trend

020406080

100

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

Product x Product Y

Production trend

0

50

1001st Qtr

2nd Qtr

3rd Qtr

4th Qtr

Product x Product Y

Graph

A control chart is a graphical device to aid in process control. It consist of a graph with a central line, “Upper Control Limit” and “Lower Control Limit”.

Quality measured periodically is plotted on the chartand status of control assessed.

Shaft dia (Spec 10 +/- 2mm)

13

10.2109.8

9.5

10.410.5

10

7

9

11

13

1 2 3 4 5 6 7 8

Hour

mm

ActualUSLLSLUCLLCLNominal

Control Charts

•Histogram is a form of column graph which displays the distribution of values obtained whenever numerical data is used.•In a continuous production, it normally takes a bell shape.

Histogram for shaft dia (Spec 10 +1)

0

2

4

6

8

10

12

14

16

18

20

1 2 3 4 5 6 7 8 9 1 0 1 1

DIA

No. o

f pei

cess

1010.5

11

LSL USLNOMINAL

Histogram

A Scatter diagram shows relationship between two variables. (E.g.: Hardness & Wear) Electrode life detail

40

50

60

70

80

64 66 68 70 72 74 76

Hardness in HRB

Scatter Diagram

Example of Q.C.C Case Studies

Reducing Rejections Reducing Cycle Time Reducing Consumables Cost Reducing Energy Cost Improving manufacturing

process Erratic behaviour of machine

Example of Q.C.C Case Studies

Elimination of mosquito menace in the colony

Raising blood donations Reducing accidents Improving security of goods in an

organisation Improving Environment of

Organisation

•Company top rank personnel attending QCC presentations.•Display of team member’s photos and project data on bulletin Boards•Completed projects published in the monthly magazine•Best QCC of the quarter award given in the presence of all employees.•Opportunities for some of the outstanding teams to represent the company in STATE, NATIONAL & INTERNATIONAL level.

Rewards / Recognition

Thank YouR.Duraisamy M.S, EGMP (IIM-B)

MD - M/s Shrishti Consultants, Chennaird@shrishtibiz.com+91 9445070511

www.shrishtibiz.com