Quality Control for Dummies

ISBN-10: 0470069090
ISBN-13: 9780470069097
Edition: 2007
List price: $22.99 Buy it from $5.50
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Description: So you've been asked to lead a quality control initiative? Or maybe you've been assigned to a quality team. Perhaps you're a CEO whose main concern is to make your company faster, more efficient, and less expensive. Whatever your role is, quality  More...

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Book details

List price: $22.99
Copyright year: 2007
Publisher: John Wiley & Sons, Incorporated
Publication date: 3/27/2012
Binding: Paperback
Pages: 384
Size: 7.25" wide x 9.00" long x 1.00" tall
Weight: 1.496
Language: English

So you've been asked to lead a quality control initiative? Or maybe you've been assigned to a quality team. Perhaps you're a CEO whose main concern is to make your company faster, more efficient, and less expensive. Whatever your role is, quality control is a critical concept in every industry and profession. Quality Control For Dummies is the straightforward, easy guide to improving your company's quality. It covers all of today's available options and provides expert techniques for introducing quality methods to your company, collecting data, designing quality processes, and more. This hands-on guide gives you all the tools you'll ever need to enhance your company's quality, including: Understanding the importance of quality standards Putting fundamental quality control methods to use Listening to your customer about quality issues Whipping quality control into shape with Lean Working with value stream mapping Focusing on the 5S method Supplement a process with Kanban Fixing tough problems with Six Sigma Using QFD to win customers over Improving you company with TOC This invaluable reference is written from an unbiased viewpoint, giving you all the facts about each theory with no fuzzy coverings. It also includes steps for incorporating quality into a new product and Web sites packed with quality control tips and techniques. With Quality Control For Dummies, you'll be able to speed up production, eliminate waste, and save money!

Introduction
About This Book
Conventions Used in This Book
What You're Not to Read
Foolish Assumptions
How This Book Is Organized
Understanding the Basics of Quality Control
Putting Fundamental Quality Control Methods to Use
Whipping Quality Control into Shape with Lean Processes
Surveying Other Quality Control Techniques
The Part of Tens
Icons Used in This Book
Where to Go from Here
Understanding the Basics of Quality Control
Defining and Explaining Quality Control
Looking at Different Definitions of "Quality"
A customer-based definition of quality
The statistical definition of quality
Setting Quality Standards
Preventing Errors with Quality Assurance
Controlling Quality with Inspection
Applying Fundamental Quality Control Concepts
Introducing quality control to your business
Listening to your customers
Measuring your quality
Evaluating your quality
Trimming Down with Lean Processes
Value Stream Mapping
The 5S method
Rapid Improvement Events
Lean Materials and Kanban
Checking Out Additional Quality Control Techniques
Total Quality Management
Six Sigma
Quality Function Deployment
The Theory of Constraints
Understanding the Importance of Ouality Standards
Getting the Quality Just Right
Falling short: The cost of offering too little
Overshooting: Providing too much
Setting Quality Standards as the Rules of the Road
Defining quality standards
Creating quality standards
Surveying quality governing bodies
Recognizing the Roles of Quality Standards in Commerce
Communicating customers' requirements
Cutting costs
Ensuring safety
Securing ISO Certification
Looking at the basics of ISO certification
Checking out ISO standards
Examining the requirements for ISO 9000
Preparing for ISO 9001 certification
Sweating through an ISO audit
Using Quality Assurance for the Best Results
Understanding the Concept of Quality Assurance
Recognizing how quality assurance differs from quality control
Catching errors before they occur
Developing Trusted Suppliers
Verifying quality with a supplier self-survey
Knowing your responsibilities as a buyer
Focusing on the Process with Plan-Do-Check-Act
The major stages of the PDCA Cycle
Tools for working through each PDCA stage
Getting What You Really Need with Product or Service Specifications
Creating clear specifications
Avoiding extras in specifications
The Role of Inspection in Quality Control
Examining the Basics of Inspection
The definition of "defect"
The importance of catching bad products before your customers do
The heart of inspection: Attribute and variable data
Recognizing and Addressing the Challenges of Quality Inspection
Getting a grip on the human aspect of inspection
Totaling the expenses of inspection
Jumping over other inspection hurdles
Choosing the Inspection Approach That Fits Your Company's Needs
Considering different factors as you select an inspection process
Checking out zero and 100% inspection
Surveying lot sampling
Tracking Defects to Improve Your Business
Following trends in your process
Keeping careful records
Calculating the cost of rework
Putting Fundamental Quality Control Methods to Use
Starting Down the Road to Quality
What's New? Introducing Change in Your Company
Having a Sponsor as a Champion of Quality Control
Deciding on the sponsor
Understanding the roles of the sponsor
Talk About It: Quality Communication within an Organization
Listing the types of information to communicate
Determining who communicates different types of information
Creating a stakeholder reporting matrix
Class Is in Session: Training Employees
Ensuring consistency with formal training
Rounding out skills with informal training
Testing the Waters with a Pilot Project
Choosing the right pilot project
Succeeding early with results from the pilot project
Conquering Obstacles as Your Company Implements Change
Staying ahead of potential problems
Getting back on track
Detecting the Voice of the Customer in Quality Issues
Identifying Critical-to-Customer Quality Issues
Product or service performance: I want it perfect!
Delivery: I want it fast!
Cost: I want it cheap!
Gauging Current Customer Desires with the Kano Model
Surveying the Kano Model's categories
Using the Kano Model in a few easy steps
Digging Up Data from (And about) Your Customers
Following some important rules
Putting surveys to work
Using focus groups properly
Tracking with a CRM system
Borrowing from what competitors got right
Examining other ways to seek feedback and information
Preparing to Measure Your Current Quality Process
Mapping Out Metrics and Measuring Processes
Making sense of metrics
Putting measurement processes under the microscope
Equipping Yourself with Tools of the Measurement Trade
Getting a handle on hand tools
Allowing a gauge to do your measuring tricks
Checking out coordinate measuring machines
Collecting Your Quality Data
Planning and Instituting a Data-Collection Process
Knowing exactly what data you're looking for
Working out the data-collection details
Ensuring that everyone measures the same way
Confirming the quality of your data
Absorbing the costs of data collection
Making Sense of Your Data
Coding the data
Using pivot tables
Developing useful data charts
Evaluating Quality with Statistics
By the Numbers: Discovering the Basics of Statistics in Quality
The story that statistics can tell you about quality
The statistics terms that you need to know
Just One of Many: Delving into the Details of Sampling
Understanding why sampling is a smart idea
Examining the factors related to selecting a sample size
Recognizing the importance of random sampling
More Bang for Your Buck: Using Pareto Analysis
Creating a Pareto chart
Interpreting a Pareto chart
The Positive and the Negative: Coming Up with Correlations
What exactly is a correlation?
How do you determine and use a correlation?
Let Me Guess: Predicting Values with Regression Analysis
Getting the gist of regression analysis
Performing a regression analysis
Using the results of a regression analysis
Consistency Counts: Analyzing Variance
Identifying a variance issue
Calculating and using variance
Assessing Quality with Statistical Process Control
Grasping the Basics of Statistical Process Control
The importance of the normal curve
Useful tools for calculating and plotting within SPC
The pros and cons of SPC
Using Control Charts Effectively
Detecting different types of variation
Understanding a control chart's elements
Checking out different kinds of control charts
Building a control chart
Reading a control chart
Responding to different types of variation
Changing your control limits
Calculating Process Capability
Identifying a process's capability
Moving a process closer to customer specifications
Whipping Quality Control into Shape with Lean Processes
Gathering the Nuts and Bolts of Lean Processes
Boning Up on the Lean Basics
Considering Lean cornerstones
Taking important steps for getting Lean and mean
Weighing the pros and cons of Lean
Identifying the Seven Wastes That Can Plague a Process
Waste of overproduction
Waste of waiting
Waste of unnecessary transportation
Waste from unneeded processing steps
Waste of excess inventory
Waste of unnecessary motion
Waste of defective products
Moving to the Beat of Takt Time
Listening to customer demand
Setting the process tempo and considering process design
Balancing for a smooth flow
Getting to the Heart of an Issue with the 5 "Why's"
Digging to find the real problem
Establishing a good environment for asking "why"
Keeping Your Eyes on the Process: Value Stream Mapping
Sketching the Basics of Value Stream Mapping
Breaking down the definition of VSM
Examining important VSM attributes
Walking through the basic steps to create a Value Stream Map
Checking out the advantages of VSM
To the Drawing Board: Creating a Current State Map
Eyeing icons
Mapping the flow of materials and information
Grouping products and services into families to simplify mapping
Do It Over: Building a Future State Map
Evaluating value-added steps and non-value-added steps
Constructing a future state map with your newfound knowledge
Taking action after finishing your future state map
Focusing on the 5S Method
Understanding the Pros and Cons of 5S
The pros
The cons
Rolling Out 5S with Communications Boards
Establishing a facility communications board
Starting a status board for each department
The Sort Phase: Separating the Gravel from the Gems
Preparing to sort
Sorting everything with ease
The Straighten Phase: A Place for Everything and Everything in Its Place
Tidying tools and materials
Putting away personal items
Labeling items
Drawing up "after" floor plans and charts
The Shine Phase: Polishing It All Up!
Gathering the necessary equipment
Recognizing that common areas belong to everyone
Cleaning as you go
Addressing maintenance issues and fixing problems at the source
The Standardize Phase: Using the Best Practices Everywhere
The Sustain Phase: Upholding the Gains
Stressing that 5S is permanent
Keeping up with responsibilities
Doing a daily checkup
Auditing the ongoing results
Empowering Workers to Make Changes with Rapid Improvement
Considering the Pros and Cons of Rapid Improvement Events
The pluses of RIEs
The minuses of RIEs
Seek and Improve: Selecting a Process Victim
Identifying a problematic process
Concentrating on tasks within the process
Finding a Few Good Workers: Staffing an Improvement Team
Workers are the heart of the team
An experienced leader is essential
Managers also have a role to play
Before the Fun Really Starts: Documenting the Current Process
Drawing a map of the process flow
Discovering what the work instructions say
Following a worker through the process
Baselining the process performance
The First Day of the Event: Train the Team
Surveying important presentations
Creating and updating lists and maps
The Second Day: Review the Training and Clean the Work Area
The Third Day: Draft the Improvement Plan
The Fourth Day: Test Changes and Document the Results
Taking the revised process for some test drives
Documenting your tests and research
The Fifth Day: Finalize Changes and Report to Management
One Week Later: Did the RIE Make a Difference?
Looking at Lean Materials and Kanban
Getting the Gist of Lean Materials and Kanban
Contemplating the concept of Lean Materials
Supplementing a process with Kanban
Monitoring a great debate: Push versus Pull
Reviewing the Pros and Cons of Lean Materials
The pros
The cons
Going with the Flow of Lean Materials
Packing materials in the best containers
Setting up "supermarkets"
Arranging for smooth deliveries and working environments
Working with Suppliers to Keep Lean Materials on Track
Encouraging supplier involvement to control costs
Convincing suppliers to ship in smaller lots
Surveying Other Quality Control Techniques
Combining the Best of All Worlds in Total Quality Management
Total Quality Management in a Nutshell
The guiding principles
The major steps
The pros and cons
Shedding Light on TQM Techniques and Tools
Beginning with basic techniques
Emphasizing the deletion of defects
Taking prompt action on data
Surveying the tools of TQM
It Takes a Village: The Main TQM Players
The role of executives
The duties of middle managers
The importance of empowered workers
The value of external customers and suppliers
Perpetual Motion: How to Enjoy Continuous Improvement
Keeping TQM moving forward with the Plan-Do-Check-Act cycle
Watching small improvements add up
Overcoming obstacles
Fixing Tough Problems with Six Sigma
Surveying the Basics of the Six Sigma Way
Injecting statistics into tried-and-true methods: The foundation
Driving for breakthrough results: The goal
Meeting Six Sigma experts: The necessity
Considering the pros and cons of Six Sigma: The dealbreakers
Taking Important Steps to Implement Six Sigma
Project selection: The key to success
Proceed with caution: Doing upfront work before you implement Six Sigma
DMAIC: A five-step program, Six Sigma style
Crunching Some Six Sigma Numbers
Calculating the Rolled Throughput Yield
Understanding the meaning of "Sigma"
Measuring variation with x's and Y's
Putting Everything Together with Process-Review Tools
Painting a complete picture with a SIPOC
Organizing process inputs with Ishikawa's Fishbone
Pinpointing potential process errors with FMEA
Delving into Quality Function Deployment
Organizing the Nuts 'n' Bolts of Quality Function Deployment
The QFD matrix
The pros and cons of QFD
If You Build a House of Quality, Customers Will Come
Identifying customer requirements
Listening to the voice of the marketplace
Converting customer requirements into design specifications
Determining relationships between requirements and specifications
Laying the roof
Digging a basement
Considering the Theory of Constraints
Focusing on the Fundamentals of the Theory of Constraints
Highlighting the principles behind the TOC
Weighing the pros and cons of the TOC
Understanding the Drum-Buffer-Rope System
Marching to the beat of the drum
Managing buffers for maximum results
Feeding a constraint with the rope
Tackling Constraints in Your Process
Identifying a process constraint
Cleaning up the constraint
Subordinating processes to keep materials moving
Elevating the constraint
Improving throughput all over again
The Part of Tens
Ten Steps for Incorporating Quality into a New Product and/or Process
Identify a Problem You Can Solve with a New Product or Service
Define the Critical Characteristics of Each Customer Requirement
Translate Customer Requirements into Measurements
Establish a Capable Prototype Process
Make Your Process Lean
Mistake Proof Your Process
Prepare the Kanban
Test the Process
Incorporate Improvements into the Process Design
Create a Customer-Feedback Mechanism
Ten (Or So) Web Sites with Quality Control Tips and Techniques
International Organization for Standardization
American Society for Quality
Lean Aerospace Initiative
Curious Cat Management Improvement Library
The Northwest Lean Networks
Kaizen Institute
Replenishment Technology Group Inc.
Total Quality Management
i Six Sigma
QFD Institute
AGI
Index

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