2. Quality Circle is a small group doing similar work who
voluntarily meet together on a regular basis to identify
improvements in their respective work areas.
It is "a way of capturing the creative and innovative
power that lies within the work force“
It helps to identify, analyze and solve work-related
problems and meet at intervals to discuss problems of
quality and to devise solutions for improvements
It consists of minimum three and maximum twelve
members in number.
INTRODUCTION
3. HISTORY
After the Second World War Japanese economy was in the doldrums. Seeing
this disastrous effect of war, Americans decided to help Japan in improving
the quality standards of their products.
General Douglas Mac Arthur who, at that time, was the commander of the
occupational forces in Japan took up the task of imparting quality awareness
among Japanese to help them improve their products and the reliability of
manufacturing systems
Thus, by 1975, they were topping the world in quality and productivity.
The answer to this was painstaking and persevering efforts of the Japanese
leaders and workers and the development and growth of the philosophy of
small working groups.
Dr. Kaoru Ishikawa (1915-89) known as “Father of Quality Circle” for his
role in starting Quality Control Circles(QCC) in Japan in the 1960s to
improve Quality, Productivity, and the work environment.
4. 5CHARACTERISTICS
Quality circle are small primary groups of employee whose lower limit is three and upper
limit twelve.
The membership of quality circle is most voluntary.
Each circle is lead by area supervisor .
The member meet regularly every week or according to an agreed schedule.
The circle members are specially trained in techniques of analysis and problem solving.
The basic role of circles to identify and solve work related problems for improving quality
and productivity.
Quality circle enable their member to exercise their hidden talents for tackling challenging
tasks.
5. MULTIFACED OBJECTIVES
Improved
Organizational
Culture
Positive working environment.
Higher motivational level.
Development of Team
Spirit
Eliminate inter departmental conflicts.
Self Development
Bring out ‘Hidden Potential’ of people
People get to learn additional skills.
Change in Attitude.
From "I don’t care" to "I do care“
Continuous improvement in quality of work life through
humanization of work.
6. HOW DO QUALITY CIRCLES WORK?
Training on problem-solving tools and techniques like 7 QC tools, 8D, 5 Whys,
and Poka-Yoke, etc. must be given to the workforce for effective implementation of
QC Circles projects in an organization. The quality circle steps include:
•Step 1: Training on 7 QC tools and Poka-Yoke
•Step 2: Forming and naming quality circles-
• QC circles are formed with 4 to 6 members.
• One member acts as a leader by rotation.
• One supervisor acts as a facilitator.
•Step 3: Identify Quality Circle themes
•Step 4: Select a project based on priority.
•Step 5: Find the best solution using standardized methodology.
8. STEPS IN QUALITY
CONTROL
1.Defining
the
Problem
1.Analyzing
the Problem
1.Identifyi
ng the
Cause
1.Finding
out the
Root Cause
1.Data
Analysis on
Root Cause
1.Developi
ng Solution
1.Foreseein
g Possible
Resistance
1.Trail,
Implement
and
Checking
Performance
1.Regular
Implement
ation
1.Follow –
up / Review
9. TOOLS FOR QUALITY CIRCLES
The most common QC tools and techniques used in QC Circle projects to analyze the
problem, discover the root causes and helps to implement the effective
countermeasures are:
7 QC Tools
•Check sheet
•Fishbone diagram or Cause and effect diagram
•Pareto chart
•Control Chart
•Histogram or Frequency distribution chart
•Stratification of data
•Scatter diagram
10. CHECK
SHEET
Check Sheet is the simplest quality tool. Basically it aims to standardize
and organize the collection of data. This collection may be through
tables, worksheets or tables.
Uses: To distinguish between fact & opinion.
To collect data about the type of problem/defects/rejection or non-
conformance.
Benefits: Helps to detect how often a problem occurs.
It facilitates systematic record keeping or data collection
Check Sheet is also called
as Tally Sheet and is used for
collecting and analyzing data.
Data collection is an important
activity in the problem solving
process as it provides a basic for
further action.
11. The brainstorming technique is used here for potential cause
identification.
Uses: Helps to determine the Root Cause of a Problem.
To identify the Key Inputs variables – Primary, Secondary
and Tertiary causes.
FISHBONE
DIAGRAMS
“Fishbone Diagram” also
known as “Ishikawa
diagram” and “Cause and
Effect diagram.
It helps to Identify all
potential or probable causes
and select the best cause
which contributes to the
problem/effect.
12. “Pareto Chart” also called as “Pareto Diagram“.
Named after Italian Economist Wilfredo Pareto.
Uses --Grasp the problem.
-Narrow problem area and prioritize high impact issues
-Break big problems into smaller problems.
-Systematic analysis of causes based on magnitude.
-To confirm the improvement results.
PARETO
CHART
A Pareto chart is a bar graph.
The lengths of the bars represent
frequency or cost (time or
money), and are arranged with
longest bars on the left and the
shortest to the right. In this way
the chart visually depicts which
situations are more significant.
13. Control charts, also known as Shewhart charts or process-
behavior charts, are a statistical process control tool used to
determine if a manufacturing or business process is in a state of
control.
Benefits of Control charts
• To predict process visually.
• Helps to identify Common and Special cause of variations.
• Provides indication for taking action.
CONTROL
CHART
The control chart is a graph
used to study how a
process changes over
time.
Data are plotted in time
order. A control chart always
has a central line for the
average, an upper line for
the upper control limit, and
a lower line for the lower
control limit.
Control charts for attribute
data are used singly.
14. A Histogram is a pictorial representation of a set
of data, and the most commonly used bar graph
for showing frequency distributions of
data/values.
PURPOSE OR BENEFITS OF HISTOGRAM
A bar graph that shows the frequency distribution
of values/data.
Useful to understand the spread or variations,
location, and shape of the data.
To know whether a process is stable and
predictable.
To know whether the process produces within
specification.
HISTO-
GRAM
15. Stratification is a technique or method that can be
defined in many ways:
It involves observing data, splitting them into distinct
classes or categories to see a different process for better
analysis.
Data recording/observation carried out from multiple
sources like shifts, machines, days, people, etc.
Benefits of Stratification
• Overall improve in product and process quality.
• Unknown strands of data can be identified.
• Systematic reduction of Process Variation-common
cause of variation.
Stratification of data
16. It is a visual & statistical testing quality tool that is used to find
out the relationships between two variables.
USE: Used in problem-solving to establish a root cause.
• Examine root cause theories in Cause & Effect.
PURPOSE/BENEFITS
• To analyzes strength & find out the relationship between two
variables.
• Provides the data to confirm a hypothesis that two variables are
related
• For Better process management in the variable analysis.
• Establish a relationship between two sets of numerical data.
• To track trends & patterns of different measures.
SCATTER
DIAGRAM
17. To develop, enhance and utilise human resources effectively;
To improve quality of products/services, productivity and
reduce cost of production per unit of output;
To satisfy the workers’ psychological needs for self-urge,
participation, recognition etc., with a view to motivating them.
To improve various supervisory skills like leadership, problem
solving, inter-personal and conflict resolution; and
To utilise individual imaginative, creative and innovative
skills through participation, creating and developing work
interest, including problem solving techniques etc.
To make use of the knowledge and skills of the workers.
To develop good relations between workers and managers
and create cordial industrial relations.
OBJECTIVES
18. BENEFITS
Benefits to the Organization:
Improvement in the job performance of
members
Development of solutions to the identified
areas.
Improvement in two-way communication
among members and members and
management.
Promotion of participative management
culture and team work
Generation of pride among members in doing
a meaningful job
Benefits for the Members:
Satisfaction and self-esteem and
esteem from others.
Improved job satisfaction.
Self-development in terms of skills,
knowledge, sensitivity skills etc.
Satisfaction of social and
psychological needs.
19. IMPLEMENTING QUALITY CIRCLES
When implementing quality circles, it is important to
provide some guidance to the groups to get started.
A company will often have one person who has become an
expert in quality circles and how they work attend meetings
with each circle for the first several times.
It is important to ensure that the expert doesn't try to take
over the circle, or have the circle become overly reliant on
them though, since this should just be a temporary thing to
get things up and running.
Quality circles should be measured based on their success in
improving the productivity of their department, eliminating
waste, and otherwise benefiting the company.
If the quality circles become unproductive, the expert in
this area can be brought back in to provide additional
direction to the group.
20. The most well-known example would be Toyota,
which helped to pioneer the concept decades ago.
These circles continue to meet on a regular basis
to identify potential problems and get them
resolved as efficiently as possible.
Another example would be Lockheed Martin.
Lockheed Martin began using quality circles in
their manufacturing facilities back in 1974.
Executives from this company learned of quality
circles when visiting Japanese manufacturing
plants, and saw how beneficial they could be.
Soon after Lockheed Martin, a number of other
US companies added them to their workplaces,
including GM, Northrop, and Westinghouse.
EXAMPLE
21. EXAMPLES IN INDIA
1.BHEL -1980 –Mr.S.R.Udapa (GM Operations) 1st Indian to start quality circle
1.Hero honda motors “Sunrise Quality circle”
1.Lucas TVS, Chennai “honey bee quality circle”
1.Tata Refactories (located in Orissa) “Niharika quality circle”
1.Kudhremukh –Iron Ore Plant (located in Karnataka) “Soorthy Quality Circle”
