Lecture 1B

History of quality control

INDE 430: Statistical Quality Control

Dr. Nadine Moacdieh
Fall 2016

Adapted from Montgomery (2009)

Chapter 1

Date: August 31, 2016

 Course topics

Acceptance
sampling
Process
capability
Statistical analysis
process
Inferences control
about process
Engineering quality
statistics
Introduction fundamentals
to quality
 Important definitions
Cost of quality (COQ): any cost that would not
have been expended if quality were perfect

e.g., product Prevention costs: Appraisal costs: e.g., inspection and

design, process associated with efforts associated with test of incoming
design, training towards ensuring high measuring or evaluating material, product
inspection and test
quality materials/components

COQ

Internal failure costs: External failure costs: e.g., returned

e.g., downtime, associated with product product failures after it is products, warranty
scrap, rework, failures prior to delivery supplied to customer charges, liability
failure analysis costs
 Important definitions
Need to find minimum COQ
 Important definitions
Quality engineering: set of operational,
managerial, and engineering activities that a
company uses to ensure that the quality
characteristics of a product are at the required level
 Important definitions
Critical-to-quality characteristics or quality
characteristics: characteristics of a product or
service that the consumer thinks of as quality
Physical: length, weight, viscosity
Sensory: taste, appearance, color
Time orientation: reliability, durability, serviceability
Important definitions

Quality characteristics

Variables data: quality Attributes: quality

characteristics that are characteristics that are
continuous (e.g., discrete (e.g., manual
weight) or automatic)
 Important definitions
Specifications: desired measurements of quality
characteristics
Actual diameter of a part
Amount of time to process an order
Number of loan applications that must be processed
 Important definitions
Nonconformity: failure to meet one or more
specifications
Defect: nonconformity that is serious enough to
significantly alter the safety or effective use of the
product
 History of quality control
Frederick Taylor
Focus was more on
productivity and
standardization
Not so much emphasis on
quality

1910s 1920s 1930s 1940s 1950s

Frank and Lilian Gilbreth

 History of quality control
Walter A. Shewhart
Worked at Bell Labs
Developed the first control
chart around 1924

1910s 1920s 1930s 1940s 1950s

Shewhart cycle
 History of quality control

W. Edwards
Deming

1910s 1920s 1930s 1940s 1950s

Met Shewhart at Western

Electric
Worked with US defense in
WWII
Sent to Japan after WWII
Japan adopted many
aspects of his philosophy
 Demings 14 points
Deming emphasized continuous improvement and
summarized his theory in 14 points
1. Create a constancy of purpose focused on the improvement of products
and services
2. Adopt a new philosophy that recognizes we are in a different age
3. Do not rely on mass inspection to control quality
4. Do not award business to suppliers on the basis of price alone, but also
consider quality
5. Focus on continuous improvement
6. Practice modern training methods and invest in on-the-job training
7. Improve leadership and supervision methods
8. Drive out fear
9. Break down barriers between functional areas of the business
10. Eliminate targets, slogans, and numerical goals for the workforce
11. Eliminate numerical quotas and standards
12. Remove the barriers that discourage employees from doing their jobs
13. Institute an ongoing program of education for all employees
14. Create a structure in top management that will vigorously advocate the
first 13 points
 History of quality control
Worked at Western Electric
and influenced by
Shewhart
Known for Juran Trilogy for Joseph Juran
quality improvement

1910s 1920s 1930s 1940s 1950s

Planning

Improvement Control
 History of quality control
Other quality gurus:
Kaoru Ishikawa (1915-1989): promoted widespread use of
cause and effect diagrams
Armand Fiegenbaum (1922-2014)
Author of Total Quality Control, promoted overall organizational
involvement in quality
Three-step approach emphasized quality leadership, quality
technology, and organizational commitment
 Quality management strategies
Total Quality Management
ISO 9001
Six-Sigma
 Total quality management (TQM)
Began in 1980s based on philosophies of Deming,
Juran, and Fiegenbaum
Use quality councils and high-level teams to deal
with strategic quality initiatives
Emphasis on training but not so much on statistical
tools
TQM had only modest success
 Quality management strategies
Total Quality Management
ISO 9001
Six-Sigma
 ISO 9001
ISO has developed a series of standards for quality
systems
ISO 9001 is applicable to any type of system
 ISO 9001
ISO 9001 certification
Certification occurs in many phases
More than one million organizations are ISO 9001
certified
ISO itself does not carry out the certification; this is done
by certified bodies
Only lasts for three years
 ISO 9001

http://www.iqs.ltd/i/index.php
 ISO 9001
Some of the requirements for ISO 9001
Quality Management System
Ex: Establish a quality management program
Management Responsibility
Ex: Customer requirements are determined and met
Product Realization
Ex: Ensure that purchased material meets specifications
Measurement, analysis, and improvement
Ex: Monitor information relating to customer perception
ISO 9001
ISO 9001
 ISO 9001
Advantages of ISO 9001 certification
Improves quality and financial performance
Gives confidence to purchasers
Disadvantages of ISO 9001 certification
Expensive
Time-consuming
Does not necessarily guarantee quality
 Quality management strategies
Total Quality Management
ISO 9001
Six-Sigma
 Six Sigma

Developed by Motorola in the late 1980s to reduce

variability in key product quality characteristics
A disciplined and analytical approach to process
and product improvement
Specialized roles for people: Champions, Master
Black belts, Black Belts, Green Belts
 Six Sigma

6 sigma:
probability of
3 sigma: preparing a
probability of product within
preparing a the specifications
product within is 0.9999998
the specifications => 0.2 defective
is 0.9973 parts per million
=> 2700 (ppm)
defective parts
per million (ppm)
 Six Sigma
Companies that have used six sigma

Reduced defects
by approximately Saved millions of
1300% Extended the dollars and
deployment of six reduced the
sigma to more than number of
500 suppliers processing errors
 Six Sigma
Many generations of six sigma:
Generation I: focused on defect elimination and basic
variability reduction
Generation II: tied the efforts to projects and activities
that improved business performance through cost
reduction
Generation III: creating value throughout the
organization and for the stakeholders