Management and Leadership Flashcards
Who is the father of “scientific manufacturing”, giving “gauging” more legitimacy?
Frederick W. Taylor
When was quality first viewed as a distinct management responsibility and an independent function?
1922, G.S. Radford’s Control of Quality Manufacturing
Which Bell lab employee gave the discipline of quality a scientific footing, with their publication “Economic Control of Quality of Manufactured Product”
W.A. Shewhart
Who first devised a method for addressing the overall level of quality produced by a manufacturing effort, rather than just a specific lot? (Average outgoing quality limit)
Harry Dodge and Harry Romig
Int he 1950s to 60s, quality evolved into a broader discipline. What are the 4 elements that contributed to this growth?
- Quantifying the costs of quality
- Total quality control
- Reliability engineering
- Zero defects
Joseph Juran published the first edition of what book?
Quality Control Handbook
The Department of Defense published a report on reliability engineering which ultimately resulted in which practice?
FMEA
The manufacturing of what led to the implementation of the “zero defects” program?
Pershing missile for the US Army
Quality was redefined in the 60s to 80s with what 4 elements?
- Customers have the final say on how well a product meets their expectations
- Satisfaction is related to competitive offerings
- Satisfaction is former over the product lifetime
- A composite of attributes is needed to provide the most satisfaction
What was the US company that suffered extreme competition from others who produced higher quality products at a lower cost?
Motorola
When did the Quality Control/ Statistical Control Era take place?
1924 to 1950
Who/What are key during the Quality Control/Statistical Control Era?
Shewhart and Bell Labs, WWII demands
When did the Quality Assurance Era take place?
1950 to 1963
Who/What are key during the Quality Assurance Era?
Joseph Juran and Quality Control Handbook, Zero defects, Department of Defense report
When did the Strategic Quality Management Era take place?
1963-1970
When did the Six Sigma Era take place?
1960s to present
What is the first Era identified by David Garvin?
Inspection Era
Who makes up the Pre-Inspection Era?
Craftsmen and guilds
Which country took the lead in applying and being successful at quality control?
Japan
Japanese companies turned to which American quality experts to learn quality concepts?
Deming and Juran
Who are some Japanese quality experts?
Taguchi and Ishikawa
What is a major technique in the Strategic Management Era?
QFD - Quality Function Deployment
What is Quality Function Deployment?
A flexible and comprehensive group decision making technique that result in visible graphs and matrices that can be reused for future product/service deployments.
Who was QFD developed by?
Drs. Akao and Mizuno
What is the Ishikawa diagram also known as?
Fishbone diagram
What is Inspection associated with?
Mistakes and errors detected after production
What is Statistical Control associated with?
Reducing defects by controlling the processes that produced the products
What is Quality Assurance associated with?
Total quality control and top management taking responsibility for quality throughout the organization
What is Strategic Management associated with?
Quality being defined from the customer’s point of view and the organizations strategy being centered on quality
Who is credited with started the modern quality improvement movement?
Deming
What was Deming’s theory?
Management is key - 85% of problems are due to the system, only 15% are due to employees. Deming has famous 14 points for management.
What was one of the first American corporations to seek help from Deming?
Ford Motor Company
What is Six Sigma?
A continuous improvement tool, the best of the best, major components are culture of organization, improvement tools, and support systems for the tools.
What is Lean Thinking?
A continuous improvement tool, focuses on removal of waste in space, storage, inspection, rework, transportation, and work movement
What is 5S?
A continuous improvement tool, work place organization and standardization, Sort, Set in Order, Shine, Standardize, Sustain
What is Kaizen?
Continuous improvement, process-oriented
What is a quality circle?
A volunteer group for making improvements in an area of the company
What is Value Stream Mapping?
A lean thinking tool used to create a material and information flow map of a product of process. Maps the flow of products from raw material through finished product.
What is the Theory of Constraints?
Focuses on system improvement by finding the weakest link of the system (constraint) and correcting it.
What is robustness?
Resistance to the effect of variation by some factor.
What does Taguchi consider to achieve robustness?
- System design
- Parameter design
- Tolerance design
What are the 3 primary factors that control a product process, from Taguchi’s robustness concept?
- Control factors - predictor variable that is controlled
- Signal factors - strongly affect response of process but are controllable and have little effect on variation
- Noise factors - predictor variable that is hard to control or is not desired to be controlled
What is the signal to noise ratio?
Quantifies the effect of variation in controllable factors on the variation in the process output.
What function are S/N ratio calculations derived from?
Quality loss function
What is the quality loss function?
There is an increasing loss (both for producers and society) which is a function of the deviation or variability from the ideal or target value of any parameter.
What is Poka-Yoke?
Japanese term that means “to avoid inadvertent errors”. Error proofing - prevent errors by designing the manufacturing process, tools, etc that an operation cannot be performed incorrectly
What are the 6Ms in a fishbone diagram?
Man, Method, Mother nature, Materials, Measurements, Machines
What ISO standards are the foundation for the Quality Management System?
ISO 9000 standards, 9001, 9004, 19011
What is the first step in strategic planning?
Analysis
What is benchmarking?
The process of identifying best practices in organizations with comparable processes or comparable customer issues for the purpose of determining the current state and a desired future state.
What are the parts of benchmarking, as a process?
- Planning
- Analysis
- Integration
- Action
- Maturity
What are the four benchmarking levels?
- Internal
- Competitive
- Functional
- Generic
What are process performance metrics?
Establish the process’s current situation, compare current status to target
What is Defects per Unit (DPU)?
The measure of capability for discrete data, found by dividing the number of defects by the number of units - a measurement of yield
How can you analyze DPU?
Create Pareto chart or DPU histogram
What is Parts Per Million (PPM)?
A measurement that is expressed by dividing the data set into 1 million equal parts - DPU x 1,000,000
