1.Collect 2 or 3 Persons who are like minded & who can work as a team.
2. One of them who has Good organizing &Communicating ability becomes the Leader.
3. Discuss with any supervisor who is also interested in Quality Circle to, be the Facilitator.
4. Discuss & chose a Name for the Quality Circle.
How To Name Your Quality Circle :
- The name reflects a focus or characteristic
• Eagle- Ability to look very closely & concentrate on it.
• Golden Peacock- Ability to make the product & Surroundings beautiful & others happy.
• White Elephant- Ability to convert a nonperforming Asset to a useful one.
• Woodpecker- To persist with the job till it is completed.
• Blooming Lotus- Converting a good idea into a Happy product.
What is the Role of Facilitator :
• Helps in Communicating with others in the unit.
•Helps communication with outsiders.
•Acts as a Moderator in Quality Circles Discussions
•Educates you in Aspects of Business Which you are not exposed to on a daily basis.
•Arranges required Training
•Helps you develop communication & reporting Skills
What is the role of outside Expert? :
• Is unbiased in his approach
•Brings objectivity to the Discussions
•Trains embers on specialized Tools.
•Acts as a Mentor to the group.
How to Chose a Problem?
•Problem is a Gap between desire or Goal & Actual
•The Goal is,
•A) six sigma Level mistakes - 3 PPM
•B) Productivity improvement cost per unit- Reduce
•C) Eliminate Waste - Better
Resource utilization
•D) Add value to Customer - Eliminate Non value added activity -ON Time Delivery
•E) 5S –Neat, organized, Happy Workplace
•F) Who/GMP- Reliable Product Quality
•We are Knowledgeable about Day to Day Actual.
What is Problem Solving?
• To bridge the gap between Goal & Actual.
•To prevent the Gap From reoccurring.
•To prevent Occurrence of potential Gaps.
What are the steps in Problem Solving?
•Define the Problem
• Collect relevant Data
• Analyze the Data using 7 QC Tools
•Find the root cause
•Plan How to eliminate the root cause
•Implement the Plan
•Monitor performance & check Effectiveness
•Prepare & present a report
•Ensure that the new process ,Method/system is documented & released
•Close the project.
How to Define the Problem
•Define what is working condition or Border condition in which the difficulty is noticed.
•Estimate what is the Benefit if the Difficulty is removed or problem is solved.
• If Possible make this Estimation in financial terms.
•Be as specific as possible in these statements- Avoid Generalities.
How to Collect the Data
•Data is generally available somewhere in the company
•Your facilitator will help in getting the Data
•If data is not available ,then make the plan of How to collect data-use “Check sheet”.-QC Tool
•Decide for how long & how much Data needs to be collected to have a closer idea.
•Plan & collect data
How to analyze the Data?
•A data is only a measure
•A set or trend of Data gives information
of the activity behavior
•Use 7 QC tools to analyze the data
What Do 7 QC tools Do?
•Tools to define a Problem
•Tools to solve a problem
•Tools to report or present a solution to the problem.
What are 7 QC tools ?
•Check sheet- Defining Tools
• Flow chart- Defining Tools
• Pareto analysis- Method to check the right problem to solve
• Fish bone diagram- Method to find root cause
• Design of experiments-Method to find a route cause
• Trend chart/ X-R chart –Method to monitor activity & work out a Potential problem
• Bar chart/pie chart- Method for reporting presentation of solution.
How to Eliminate the Root cause?
• Discuss in detail the source. E.g. Material, specification, vendor, inspection ,Method,
Process, Training etc.
•Discuss what change is required to eliminate the root cause
•Plan how to implement
•Try out if required on a pilot scale
•Make sure that the change plan eliminates the root cause
• Make a Proposal
• Include a preliminary Report to backup the proposal
• Prepare an implementation plan that does not affect the day to day Business.
• Get approval for the plan.
•Monitor the implementation progress.
•Start a controlled change over.
How to Monitor the Effectiveness of the change?
• During the change over collect all relevant data
• Analyze this data .
•Prepare a comparative statement of Pre/post change pattern
• If improvement is not satisfactory –go back to the root cause source stage
How to Prepare & present a Report?
• Define the problem
• Define the Objectives set the project
• Define the team, Facilitator/Expert
• State how the data was collected
• Detail what 7 QC tools were used
• Describe what was the root cause & its source
• Detail the tryout plan
• Describe results of try over
• Detail the change over plan
• Describe the results of Changeover
• Describe how it has been standardized as a change in process, system etc.
• Describe the benefits of project – To team, to company, to customer.
How to Keep track of QC Project?
• Keep a schedule for meeting
• Make sure that the venue & timing is convenient for all team members & facilitator
• Keep the detailed Diary of proceedings
• At the end of each meeting , describe your next step - who,What ,when, & where?
What is the best technique for team discussion?
• Brean storming
• The team leader opens the discussion
• Everyone in team gives their views
• The relevant views even if silly are recoreded
How often to review Progress ?
• Once in 2 month for each qc
• Reviewed by a review manager
• Comments and views are recorded & acted upon
• QCs also express difficulty if any in progressing the project
When to make a presentation ?
• At the end of the project
• Or next previewing day
• The leader starts the presentation & introduces members
• The members in turn make step by step presentation
• The leader concludes the presentation
When to assess QC project ?
• Once in 6 months
• By gm (o) and director level
• An outside expert called in to give independent
assessment
Factors for assessing QC Project:
• Benefits Accrued 7 its financial impact
• Method of project handling
• Collection of Data & analysis & tools used
• Clarity in communication
• Presentation skill exhibited
• Confidence in presentation & conviction about the project
How are QCs Recognized?
• By Awards
• By honoring them in front of friends/ family
• By creating awareness in all on notice boards.
• By nominating for state level QC contests.
• By selecting QC team of the year based on announcement& giving them / family a memorable holiday.
How does QC Benefits YOU ?
• Recognition & pride in your job
•Personality development in terms of communication/ presentation skills
• Knowledge acquisition & Skill updation.
• Better exposure to various aspects of Business.
• Better appreciation of Management.
How does QC Benefit Management?
• Elimination of Waste
• Improved market share/ Growth in Business
• Improved Relation with employees / Family.
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