QUALITY TOOLS

QUALITY TOOLS

1. POKA-YOKE

   • Creator
     • SHIGEO SHINGO. Japanese industrial engineer and develped and spread the method, related to the Toyota production system and lean manufacturing
   • What is it?
     • A techinque used to prevent human error during a process. It means "mistake- proofing" or "error prevention
   • What was it created?
     • Because relying only on workers being careful wasn´t enough. Errors can happen due to distractions, fatigue, confusion, or lack of information.
   • Objetives
     • Provement human error, detect errors early, reduce rework and waste, reduce cost, facilitate operatins
   • Development
     • The concept comes from the Toyota production system ( japan, 20th century)
       • Originally called "Baka-Yoke"(foolproof), later changed to "Poka - Yoke".

2. HISTOGRAM

   • What is it for?
     • Visualizes how data is grouped, summarizes a lot of information in a simple way, helps find varitions and problems.
   • Importance in quality
     • It is one of the basic quality tools. It helps to compare result, detect problem and propose improvements.
   • Uses
     • Quality: variation and tolerances, statistics: analysis of variables, mateorology: temperature, rain and wind.
   • What is it?
     • It is a bar graph with adjacent barts that represent quantitative data. Whit equal intervals, the height of each bar represents the frequency.

3. QUALITY CIRCLES

   • What are quality circles?
     • They are small groups. Workers from the some or a related area participe. They are analyzing the causes. They propose improvement.
   • Who created quality circles?
     • Japanese chemical engineer and quality management specialist. He championed quality circles in japan during the 1960s. He promoved worker participation in problemsolving.
   • How does aquality circle work?
     • Detect a problem, analyze its cause propose solutions, select the best solution implement it, evaluate results, continuously improve
   • Benefits of quality circles
     • For workers
       • Greaterparticipation, skill development, better communication, increased motivation and team work
       • For the company
         • Fewer errors, lower cost, higher productivity, better quality, continuous and improvement.
   • Importance in the automotive industry
     • The automotive industry requires: QUALITY, SAFETY, PRODUCTIVITY, CONTINUOUD IMPROVEMENT.

4. DEMING CIRCLE

   • What is the deming circle?
     • The demin circle is a continuous improvement method developed based on the ideas of William Edwards Deming
   • What is it for?
     • Improve processes, detect and resolve problems, reduce errors and waste, improve quality, increase efficiency, prevent the recurrence of problems, pursue continuous improvement.
   • Stages of the deming cycle
     • Plan: the problem is identified and what needs improvement is analyzed, objetives are estabilished and a solution is propose
       • DO: this is the stage where the plan is put into practice
         • Check: here the results obtained are reviewed and compare with the established objetives and it is determined whether the solution worked or if problem still exis
           • ACT: in this strange, decision are made based on the results, if the solution worked, it´s established as a new way of working, if it didn´t work,changes are made, and the circle begins again

5. PARETO GRAPH

   • What is it?
     • Analytical tool that combines a bar chart and a cumulative percentage line to identify the few causes that generate the majority of the problems.
   • Fundament
     • It is based on the pareto principle, which states that 80% of effects or problems stem from 20% of the causes. This is know as separating the "vital few" from the "trivial many".
   • Graph components
     • X-axls( horizontal): Shows the categories of causes or defects. Left Y- axls (vertical): Shows the frequency or cost of each category. Right Y- axls(vertical): shows the cumulative percentage(from 0% to 100%).
   • What is ti?
     • The pareto chart is a quality tool that enables the identification and priorization of the most significant problems whithin any campany.