QC STORY 7
Pocket Book
STEPS
OF QC
STORY
1.0 Problem 4.0 Action
1.1 Importance of the problem 5.0 Action Plan in 3W1H
1.2 Background of the problem 6.0 Budget requirements
1.3 Undesirable results 7.0 Check
1.4 Theme & Target 8.0 Comparison of results
1.5 Team 9.0 Benefits – PQCDM
1.6 schedule for the improvement 10.0 Standardisation
2.0 Observation 10.1 Standardisation in 3W1H
2.1 Features of the problem 10.2 Prepare or Modify the SOP/QCPC
3.0 Analysis 10.3 Communication & training to doers
3.1 Cause & Effect Diagram – Level 1 10.4 Conformance audit method
3.2 Cause & Effect Diagram – Level 2 11.0 Conclusion
3.3 Cause analysis 11.1 The remaining problem is carried
3.4 Cause & Effect Diagram – Level 3 forward
1. PROBLEM
Define the problem clearly:
1.1 Specify the importance of the problem (Linkage of policy) (Check sheet / past data / pareto diagram / Stratification)
1.2 Define the background of the problem (Check sheet / graph & control chart / histogram)
1.3 Write down the undesirable result of the problem / poor performance (Quantify the yearly loss in Rupee value)
(Graph)
1.4 Quantify the target and goal (minimum 50% improvement) (Graph / histogram)
1.5 Introduce the team members during presentation and specify start date, end date meeting day and number of
meetings held. (Guide / leader / members – introduction)
PLAN
1.6 Prepare activity schedule for the improvement. Use week numbers and standard colour codes for action planned
(Blue), achieved (Green) and not achieved (Red) (Gantt chart / arrow diagram)
2. OBSERVATION
Investigation the specific features of the problem from a wide range of different view points
2.1 Discover the features of the problem by investigating time (period) / place (location) / type (specification /class)
/ Symptom (difference in the shape & size) (Data collection / check sheet / stratification)
2.2 Investigate variation in the results (Graph / control chart / histogram / scatter diagram / pareto diagram)
2.3 Collect information from the workplace (GENBA) where the problem exists. (Affinity diagram)
3. ANALYSIS
Find out what the main / root causes are
3.1 Prepare the cause & effect diagram, converting all possible causes identified through braining storming session
DO
(I level)
3.2 Delete irrelevant causes by analysing observation step information and re-draw the CED (II Level)
3.3 Analyse the causes to decide the main causes / root causes. Check in GENBA through data collected already and
through discussions among members and by consulting experts.
(Stratification / histogram / control charts/ scatter diagram)
3.4 Re-draw the CED, Integrating the main causes selected through cause analysis (III Level)
4. ACTION
Take action to eliminate the main causes shown in Level III CED
4.1 Decide the actions for immediate remedy & also for preventing
recurrence (3W 1H format)
4.2 Check budget requirements and arrange for implementing actions (Gantt chart)
3W 1H FORMAT
W – What?
Counter measures to eliminate the causes specified thro’ cause and effect diagram
and confirmed / verified thro’ data available at GENBA.
Do not use vague & ambiguous terms like ‘ensure’
W – When?
The target date / week for completing the action (e.g. Week No. 32/by end of Jan’99 / by 15 Dec’98)
W – Who?
The person in the term who should take responsibility to perform / complete the action
CHECK
H – How?
Clearly specify the methodology to be adopted for carrying out the action points.
5. CHECK
Confirm that the problem is prevented from occurring again
5.1 Compare the result (data) obtained both before and after the action (Pareto diagram / graph & control chart /
histogram)
5.2 Convert the results into monetary terms & compare with target value. (Graph) (if the problem is continuing go
back to step 2 and repeat the process)
6. STANDARDISATION
ACT
Eliminate the cause of the problem permanently and audit for adherence of the improvement
6.1 Standardise the process (5W 1H Format)
6.2 Prepare or modify SOP / QCPC / TSOS / CHECKLISTS
6.3 Arrange for communication and training to the doers (Instructions / demo / OJT)
6.4 Set-up a system for audit of the adherence of improvements and record data
(Check sheet / control chart / trend chart / P-chart / XR chart)
5W 1H FORMAT
W – What?
The remedial action points specified clearly to prevent the problem occur again
(Do not use vague & ambiguous terms like ‘ensure’)
W – Why ?
The reason for the remedial action
W – Where?
Area / GENBA (Work place)
W – When?
The frequency of check or audit to be carried out by various level members during a specific period / occurrence
(eg. Once in 10 components / every one hour / every quarter)
W – Who?
The person/designated to perform the check/audit for the adherence of the improvement point
H – How?
Clearly specified methodology to be adopted to carry out the action point
and details of VCS & Formats to be uses / audits / checks)
7. CONCLUSION
Review the problem solving procedure and plan future actions for continuous improvement.
7.1 Sum up the remaining problems through’ pareto comparison and plan actions to be carried out for solving
other problems (Pareto diagram / QC story steps)
