Quality Control Circles
My first Productivity newsletter June, 1980 described the importance of Quality Control Circles (QCC). The circle was designed by Kaoru Ishikawa and virtually every Japanese company implemented the process getting all workers into small problem solving teams. Each team normally was a work group with less then 10 people.
Prior to the circles, quality information was in the hands of the quality manager whose job was to maintain quality standards. To obtain high quality products it was necessary to have all workers become self-inspectors of their quality. It was impossible for the quality manager to maintain high standards on their own. But through Ishikawa's instructions the knowledge of the quality manager was taught to all workers. The workers were taught how to use the quality tools:
1. Cause-and-effect diagram (also called Ishikawa or fishbone chart): Used to brainstorm and classify possible causes of problems and their solutions.
2. Check sheet: Used by workers to check off every error or problem found.
3. Control charts: Graphs used to study how a process changes over time.
4. Histogram: A graph to show frequency distributions.
5. Pareto chart: A bar graph to show the most significant problems.
6. Scatter diagram: To look for relationships.
7. Stratification: A technique that separates data gathered from a variety of sources so that patterns can be seen.
All the above were tools originally used by the quality managers.
The work teams would normally address two or three major problems a year and the teams would meet during their breaks, at lunch or before or after work. Periodically, maybe twice a year, the teams would present their results to senior management.
QCC was a wonderful way to show respect to workers and to get them involved in problem solving activities. Through circle activities quality dramatically improved.
I need your help. Still today after more then 40 years since QCC started in Japan, every Japanese company that I visited this past year has circle activities going. Why did the quality movement in America die?
Prior to the circles, quality information was in the hands of the quality manager whose job was to maintain quality standards. To obtain high quality products it was necessary to have all workers become self-inspectors of their quality. It was impossible for the quality manager to maintain high standards on their own. But through Ishikawa's instructions the knowledge of the quality manager was taught to all workers. The workers were taught how to use the quality tools:
1. Cause-and-effect diagram (also called Ishikawa or fishbone chart): Used to brainstorm and classify possible causes of problems and their solutions.
2. Check sheet: Used by workers to check off every error or problem found.
3. Control charts: Graphs used to study how a process changes over time.
4. Histogram: A graph to show frequency distributions.
5. Pareto chart: A bar graph to show the most significant problems.
6. Scatter diagram: To look for relationships.
7. Stratification: A technique that separates data gathered from a variety of sources so that patterns can be seen.
All the above were tools originally used by the quality managers.
The work teams would normally address two or three major problems a year and the teams would meet during their breaks, at lunch or before or after work. Periodically, maybe twice a year, the teams would present their results to senior management.
QCC was a wonderful way to show respect to workers and to get them involved in problem solving activities. Through circle activities quality dramatically improved.
I need your help. Still today after more then 40 years since QCC started in Japan, every Japanese company that I visited this past year has circle activities going. Why did the quality movement in America die?
Labels: defects, Ishikawa, Japan, Lean, QCC, Quality, quality tools
posted by Norman Bodek at
8:06 AM
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