- Cost of Quality
- Customer Satisfaction and Value
- Design of Experiments
- Engineering
- Environmental Manag. and Sustainability
- Global Quality
- Human Resources
- Innovation
- Inspection
- ISO 14000
- ISO 9000
- Leadership
- Lean
- Problem Solving
- Process Management
- Product Development and Recall
- Project Management
- Quality Assurance
- Quality Control
- Quality Function Deployment
- Quality Management
- Quality Tools
- Reliability
- Six Sigma
- Social Responsibility
- Standards
- Statistical Process Control (SPC)
- Statistics
- Supplier Quality
- Teams
- TL 9000
- ISO/TS 16949
- Risk Management
- Customer Requirements
- Economic Case for Quality
- Continuous Improvement
Expert Answers: November 2009
The TOPS way of getting to the root cause ... Repair vs. rework...
3.4 per Million: Digging the Holistic Approach
Few will argue we live in a dynamic world where change is accelerating. What often goes unnoticed is that along with this rapid change, there is the opportunity and the need to improve....
Tune Up
Six Sigma has many meanings. In its simplest context, Six Sigma can be defined statistically as the attempt to achieve near-perfection by having no more than 3.4 errors per million opportunities, or being 99.997% correct (or defect-free)....
3.4 per Million: It’s a Marathon, Not a Sprint
Six Sigma practitioners like their successes swift, large and final. Nature and circumstance, however, are rarely that kind. Normally, success is secured one step at a time....
Standards Outlook: Major Upgrades
The new fourth edition of the Chrysler, Ford and General Motors (GM) Potential Failure Mode and Effects Analysis (FMEA) Reference Manual, which was released last year, is a significant upgrade from the third edition published in 2001....
Keeping Score
Like most of you, I’ve seen the “latest, greatest thing” introduced in organizations — repeatedly. We observe initial excitement for the new strategy, bursts of employee training, spotty implementation and eventual abandonment of the new approach....
Standards Outlook: Dynamic Duo
Lean and Six Sigma are two methods aimed at improving the quality of an organization’s operations and its financial results. Both concentrate on customer satisfaction and improved business performance....
Building From the Basics
Quality control is about models, methods, measuring and managing. It’s about uncovering a problem and finding the solution. It’s about using the right techniques at the right time to make things better....
Online Sidebars Sanders
Increasing movement from quality of product to quality of management and the organization. The systems approaches the quality profession has evolved through ISO 9000 and other management system standards will be valued by organizations looking to bring qu...
What's Up?
Study participants outlined the forces, four scenarios in which they might play out, and the implications to quality, organizations and the profession. Study participants were asked to envision the implications of the key forces and scenarios for quality ...
Futures Study
Forces of Change From All ASQ Futures Studies Table 1 1996 1999 2002 2005 2008 Changing values Partnering Quality must deliver bottom- line results Globalization Globalization Globalization Learning systems Management systems will increasingly absorb the...
Who's Keeping Score?
There’s one tool you won’t find for sale at Sears. One of the retail giant’s divisions has started using a quality management tool extensively to maintain and improve its own quality management system....
Expert Answers: May 2008
Government and cost of quality ... Understanding the slack factor....
Standards Outlook: Hazardous to Your Health
One hospital chain in my area has a snappy ad saying your selection of a hospital could be the most important choice you will ever make. This might be true—going into the hospital these days can be hazardous to your health....
3.4 per Million: Test Drives and Data Splits
Prediction models are one of a Six Sigma practitioner’s best friends for improving processes. The more complicated and persistent the quality problem, the more useful prediction models can be....
Standards Outlook: How to Manage Risk in a Global Economy
The global economy has provided opportunities that didn’t exist just 10 years ago. But the flattening of the Earth via the internet and extensive outsourcing to countries such as China and Mexico have also presented organizations with many risks....
Classroom Lessons Learned
Public education often tries to emulate the successful methods of industry. However, the experience of a school district in California offers several lessons about achieving continuous improvement in the corporate world....
Ghysels Online Sidebar: What Students Think
Jan. feature/SD EDUCATION School District Offers Ideas for Continuous Improvement by Maurice Ghysels In 50 Words or Less In implementing a process of continuous improvement, a California school district learned lessons that are applicable to industry. M.G...
Lean Six Sigma's Evolution
When Motorola rolled out its initial Six Sigma system in 1987, there were no Green Belts, Black Belts, Master Black Belts, Champions or any of the infrastructure or focused training we have come to associate with modern practices in Six Sigma....
Quality Tools, Teamwork Lead Boeing Team to a System Redesign
A team from Boeing, as well as members of the Air Force and suppliers, worked to fix the C-17's inert gas generating system that previously needed constant repairs. Using quality tools, the team identified cause and came up with the best solution for...
Improving the Internal Audit Experience
Employees don’t always understand how audits relate to ensuring the use of good business processes. Many don’t realize the significant process improvement benefits that can be achieved from an internal audit experience. Cerner Corp. developed...
ASQ Team Says QMS and EMS Standards Support SOX
The intent of the Sarbanes-Oxley Act (SOX) was to make the financial system of control more transparent and to reduce the incidence of corporate fraud. It soon became evident, however, that compliance with the law’s auditing requirements would be...
Living Inside China's Quality Revolution
Quality processes in China today continue to be influenced by remnants of ancient policies and practices. When Huawei Technologies, one of China’s largest telecommunications manufacturers, recently declared its intention to become the Toyota of the...
Quality Glossary
Five years after it published its first glossary of quality terms, ASQ has revised that glossary with updated definitions and new entries, many from the lean glossary published in 2005. This reference of terms, acronyms, and prominent figures in the...
Six Sigma at Cigna
In 2002, Cigna Corp., a provider of employee healthcare and insurance benefits, launched a grass-root driven quality program based on Six Sigma. Leadership made it clear that the approach would be holistic and would require behavioral changes and a...
Standards Outlook: Six Lessons Learned From QS-9000
The sun sets on QS-9000, the U.S. automotive standard.
My version of the old joke goes: "When’s your birthday?" "Dec. 15." "What year?" "Every year, so far."...
Statistics Roundtable: Turning Shewhart?s Challenge Into Opportunity
Statisticians must step forward and lead management to become more statistically minded.
Nearly 70 years ago, quality pioneer Walter Shewhart threw down the gauntlet: "The long-range contribution of statistics depends not so much on getting a lot of highly trained statisticians into industry as it does...
Lean Lessons: Using Lean to Meet Quality Objectives
For many years, proponents of lean and Six Sigma methodologies have worked to achieve a marriage of convenience. For the most part this has fared well....
Quality Goes to College
Higher education is seeing increased interest in quality management methods in response to the federal government's recommendation that they embrace the culture of continuous innovation and quality improvement. An overview is given of the types of...
Caring Culture and Results Focus Lead to Baldrige Award
For many years Mississippi ranked near the bottom of health status rankings, but now the North Mississippi Medical Center (NMMC), the largest rural medical center in the country, is the recipient of the 2006 Malcolm Baldrige National Quality Award in...
Statistics Roundtable: Design of Experiments: A Single Experiment or Sequential Learning
Sequential experimentation lends itself to more efficient and precise answers....
Career Corner: Get Rid of Clutter
Futurist John Naisbitt focused on 11 purposeful cognitive tools that contribute to successful anticipation of and adjustment to change. No. 10 is about leveraging quality: "Don't add unless you subtract," Naisbitt says....
Apply Six Sigma To Sales and Marketing
A common misconception regarding Six Sigma is that it applies only to manufacturing processes and that its fact-based problem solving methodology doesn't transfer to business processes such as marketing and sales. These people believe that a...
3.4 per Million: Six Sigma in Everything We Do?
I was lucky to work for Motorola in the 1980s and early 1990s - right in the middle of the company's transformation. Motorola was at risk as were many U.S. businesses....
Switching From Improvement to Innovation on the Fly
Proceeding with an improvement methodology when it becomes obvious the process lacks the potential to achieve the desired capability can be damaging to an organization's continuous improvement initiatives. Goals will not be reached, and the resulting...
Hospital Reduces Medication Errors Using DMAIC and QFD
The medication error rate at Illinois' Alton Memorial Hospital was low when compared to national statistics, but the hospital knew cost savings would be significant if this statistic was lowered even further. A multidisciplinary team sought the help of...
The Science in Six Sigma
The structure Six Sigma provides for managing an organization's improvement initiatives is more important than its conformance quality target. It also guides project leaders and offers an array of analysis tools. In addition to Six Sigma's DMAIC...
You Can Go Home Again
Jamie Houghton's love for Corning brought him out of retirement and back to the company when it was fighting for survival, due to the decline of the telecommunications industry and decreased demand for Corning's fiber optics. When Houghton returned to...
Salary Survey – 2006
Full Survey
44 Section 6. Salary by Number of Work Hours Online Section 7. Salary by Nonexempt vs. Exempt Status Online Section 8. Salary by Number of Years' Quality Experience and Highest Level of Education Online Section 9. Salary by Number of Years in Current Pos...
3.4 per Million: Control Charting at the 30,000-Foot-Level
In my "3.4 per Million" columns past, I first described a traditional and a 30,000-foot-level procedure for creating control charts and making process capability/performance assessments for a continuous response with multiple sampled subgroupings....
Getting Credit for Service
Experian Marketing Services (EMS) considers quality management a critical part of its commitment to its clients. Last year EMS looked to ISO 9001 certification as a way to extend its established project management program. EMS identified more than 100...
Climbing the Career Ladder: It's Up to You
With as much information on the subject of career development as there is available today, the real challenge is recognizing that you, not your employer, are responsible for your own career development, and then finding a structure to guide your plans....
Uniform Maker Sews Up Success With Scorecard
Operadora Ganso Azul S.A. de C.V. is an ISO 9001 sewing factory in Mexico facing growing competition for China. In 2000 when the company began operating as a maquiladora producing uniforms for police officers and firefighters, rapid expansion created...
Building Quality at Veridian Homes
Veridian Homes in Madison, Wisconsin uses several quality methods to improve productivity while reducing impact on the environment. To achieve its goal of promoting and coordinating quality throughout the company, the company employed the National...
3.4 Per Million: The Hard Part: Holding Improvement Gains
You've overcome the obstacles to launch your latest improvement initiative: scarce resources, time pressure, unforeseen glitches at every turn. Now comes the hard part--sustaining the gains....
Measuring the Cost of Quality for Management
Over the years, few organizations have adopted a reliable method for measuring and reporting cost of quality (COQ) and used it to improve operations. Since the avoidance of reduced profits from quality initiatives is seldom measured or reported by...
Emotional Intelligence and Six Sigma
Emotional intelligence (EI), the ability to perceive, assess, and manage one's own emotions and the emotions of others, is vital to a project team environment and fits well with Six Sigma methodology. When time is limited, Six Sigma Black Belts must...
Standards Outlook: Increase ISO 9001's Value
ISO 9001 describes a basic, effective quality management system (QMS). Compliance to it is the starting point toward achieving excellence in an organization. Additions to an ISO 9001 compliant QMS can act as the first steps toward excellence....
New Frontiers in the Design of Experiments
Statistically designed experiments enable businesses to reduce time to market while achieving quality product performance that is critical to survival and success. R.A. Fisher first introduced them in the early 20th century to evaluate the results of...
Beyond PDCA - A New Process Management
The ISO 9001 quality management standard calls for the use of the plan-do-check-act (PDCA) model for managing processes. The author questions why check is included in the cycle when the goal is to reduce the need for verification activities. Current...
Make Healthcare Lean
The principles of lean manufacturing are as applicable to healthcare as they are to the automobile industry. However, unlike manufacturing, healthcare management structures are not usually hierarchical, and hospitals generally are not-for-profit. Value...
3.4 Per Million: Deploying the 'D' in DFSS
As Six Sigma initiatives at many organizations have matured, the switch from reactive improvement - based on the DMAIC methodology - to proactive improvement - based on design for Six Sigma (DFSS) - has become pervasive....
The Histogram for Complex Parts
In the aerospace industry, production and procurement usually consists of infrequent lots of complex parts with relatively small lot sizes. Data are often insufficient to implement standard process assessment techniques. In these situations, a percent...
Use SPC for Everyday Work Processes
Despite the advantages of statistical process control (SPC), many organizational implementation efforts have not been successful or self-sustaining. This has nothing to do with the methodology, but is a case of using the right toolbox but the wrong...
Career Corner: Use DMAIC to Enhance Your Career
Attend an ASQ section meeting or conference, and if you didn't already know it, you'll quickly learn Six Sigma is still one of the hottest methodologies in the quality profession today....
Bridging the Gap Between the Classroom and Real World
Two of the courses in Scott Hiler's business education classes at Paramus High School in New Jersey specifically cover international business and management systems that include lessons on the Sarbanes-Oxley Act, total quality management, and ISO 9000....
Promoting Quality In Your Organization
A 2004 survey of industry executives showed that while nearly all agreed that quality favorably influences profits, few had actually used quality methods. Quality professionals can play a significant role in supporting performance management initiatives...
Statistics Roundtable: Monitor Your Industrial Processes.
Models are often developed in industry to characterize and explain a process because they can show how process variables are interconnected and interrelated. Historically, two particular methods have been used to construct models to...
Steady Does It For DynMcDermott
DynMcDermott Petroleum Operations (DM) holds the maintenance and operations contract for the Department of Energy's strategic petroleum reserve. High DOE expectations prompted DM's Malcolm Baldrige National Quality Award journey ten years ago when DM...
Detect Financial Problems With Six Sigma
An organization's financial decline is often impossible to detect from the few financial measures investors or creditors typically examine. While the Sarbanes-Oxley Act should help improve the quality of data available to the public, it has drawbacks...
Career Corner: Your Future in Risk Management
Our engineering company conducts risk analyses and assessments in cyber security, infrastructure security, operational integrity and business continuity planning. And, business is booming. Why?...
Your Customers Are Talking, But Are You Listening?
Few companies have a process to listen to their customers and act on the information. Without a method to measure how satisfied customers are, the door is left open to the competition. The listen, collect, analyze, learn, improve (LCALI) process can...
Statistics Roundtable: Data Mining for Quality
Allen, I. Elaine; Seaman, Christopher A.
In a 1996 Quality Progress article, Bert Gunter urged caution in the use of data mining based on the extraordinary amount of hype and false promises it was receiving at the time....
Standards Outlook: Clarifying the Intent of ISO 14001.
Are you in the process of upgrading your organization’s environmental management system (EMS) to the revised ISO 14001 standard and stumped on the meaning of the new language or a new requirement in the standard?...
Project Teams: How Good Are They?
Project teams have become the basic work units for most enterprises, but there are tough challenges, as illustrated by notable project failures featured in the media in recent years. A recent Quality Progress survey revealed a conflicting picture of...
TRIZ: A Creative Breeze for Quality Professionals
TRIZ, a systematic approach to creative thinking originating in Russia, can help quality professionals develop new approaches and solutions to quality problems. Its creator, Genrich Altshuller, wanted a systematic approach based on the rules of...
3.4 per Million: Put the Pieces Together
The whole is greater than the sum of its parts. This isn't a particularly new idea; it has been around for years. We even have an entire profession built around it....
The House That Fraud Built
The downfall of several seemingly strong companies has recently occurred after the discovery of extensive and long-running management fraud. While the fraud may not have been readily apparent, certain key indicators act as early warning signs that can...
Are You Making Decisions in a Fog?
Just as water makes up two thirds of the world's surface, measurement constitutes an enormous part of the scientific method and scientific problem solving....
Big Improvements for Small Parts
National Semiconductor Corporation is a process-driven manufacturer looking for additional ways to cut costs. Having experienced dissatisfaction with an earlier continuous improvement program, it became clear that reducing costs while maintaining...
Control Charting at the 30,000-Foot-Level, Part 3
In my November 2003 "3.4 per Million" column (p. 67), I described a traditional and a 30,000-foot-level procedure for creating control charts and making process capability/performance metric assessments for a continuous response....
Feigenbaum on Quality: Past, Present, Future
In an interview held at the ASQ World Conference on Quality and Improvement in Seattle this year, quality pioneer Armand V. Feigenbaum shared his views on the current status and future of quality. Feigenbaum notes that quality has always been a cyclic...
QFD in a Managed Care Organization
The application of quality function deployment (QFD) in the healthcare industry has been limited because the healthcare product is intangible and ill defined. Recently, however, a managed care organization used QFD to redesign its member handbook. QFD's...
How to Choose the Appropriate Design
When planning an experiment, you can consider many possible sets of observations. Choosing the combinations of factors at which to collect data to make up the best design involves balancing multiple goals and objectives....
Lead To Succeed
It seems at times that the quality profession is not as valued as it once was. The solution is to offer a unique service the corporation and its managers are willing to pay for. To sell yourself and your product, people must notice that you are...
When Worlds Collide: Lean and Six Sigma
Facing unprecedented pressure to improve performance across the board, organizations cannot afford to forego the benefits of either Six Sigma or lean....
Does Six Sigma Work in Service Industries?
Service and manufacturing organizations have much to learn from one another when it comes to serving customers. While in manufacturing the focus on product quality distracts employees from customer service quality requirements, in the service sector the...
Axiomatic Design and DFSS
In the last few years, design for Six Sigma (DFSS) has gained much popularity due to the widespread application of Six Sigma principles outside the operations environment, particularly in new product development....
Time Management Using Quality Tools
Quality tools are useful in personal life. The Six Sigma concept of process improvement, specifically the DMAIC tools, has been moved from product to process, and is now applicable for personal performance improvement. Random time checklists, frequency...
Improve Profits With Standards
The goal of CEOs and business managers is to make products that please customers and produce a profit. The International Organization for Standardization (ISO) provides a roadmap for profit gains through its standards and technical reports. Used in...
Genentech Error Proofs Its Batch Records
Like other firms subject to Food and Drug Administration (FDA) regulation, Genentech must provide complete and accurate documentation of processes. In September 2003 an error-proofing project was launched by the good manufacturing practices core team at...
What Do Online Customers Value?
Burgeoning e-commerce sales point to the pivotal role of the Internet as an effective marketing tool. An online survey was used to determine which website design features have the strongest consumer appeal. One section of the survey gathered background...
Lean Thinking for Knowledge Work
Productivity in the service sector trails manufacturing by a wide margin. Since the early 1990s, the Toyota Production System (TPS) has been heralded as the standard for manufacturing environments, but early attempts to apply it to nonproduction work...
Lean Glossary
A glossary defines terms commonly associated with lean...
Ghosts in Your Process? Who Ya Gonna Call?
Even when using the DMAIC process, root causes of poorly performing processes can be extremely difficult to find and eliminate. In his book Manufacturing Solutions for Consistent Quality and Reliability, Robert Traver proposes a nine-step process for...
Cumulative Meta-Analysis
Meta-analysis is a set of statistical procedures designed to integrate and synthesize experimental results across independent studies into an overall summary statistic....
The Human Side of Change Leadership
Even carefully planned efforts to introduce change can be short lived if the human element is neglected or left to chance. When planning a change it is important to identify potential resistance to the changes and then design motivation into the...
Lean Six Sigma Reduces Medication Errors
Medication errors are a serious threat in the healthcare industry. One mid-sized hospital interested in quality management in several areas undertook a Six Sigma project to determine what policy and practice changes might be needed to remedy the...
Back to the Future at Ford
The U.S. automotive industry, and U.S. industry in general, have seen significant change over the past thirty years, and the results haven’t always been positive. While specific details differ, Ford Motor Company's experience with the major system...
Compliance and Ethics Group Formed
Recently I learned about a new organization, the Open Compliance and Ethics Group (OCEG). I immediately found its website (www.oceg.org) and was impressed....
TS 16949 – Where Did It Come From?
TS 16949 is an international fundamental quality management system specification for the automotive industry based on ISO 9000. It was developed at the request of automotive suppliers from the Big Three automakers' quality system assessment manuals,...
Training : It's Not Always the Answer
Employers need employees who perform well, and while training is one way to achieve this goal, it isn't the only way. A training needs analysis assesses current performance and defines desired performance, with the gap between the two states...
Driving Organic Growth at Bank of America
The American Customer Satisfaction Index has shown that customers view banks and other financial institutions as a commodity, and consequently, they have no reason to establish a relationship with any one bank. In 2001 executives at Bank of America saw...
Are Your Hearing Voices?
For a company to succeed in today's marketplace, it must listen to the voice of the customer (VOC) so it can provide the products and services that inspire an enthusiastic customer response. One effective way to collect VOC input is through a customer...
A Roadmap For Change
This excerpt is from the book Juran Institute's Six Sigma Breakthrough and Beyond. The book is available from Quality Press, item P1089. Copyright restrictions do not allow its individual sale or its placement on My ASQ....
A Midstream Career Change
I began my life in the real world with a new engineering degree, a new job with a major aircraft manufacturer and a new baby. My first brush with the quality industry was after two years as an intern for the Boeing Co....
A Solid Foundation
Any discussion of implementing Six Sigma is typically accompanied by a conversation around top management buy-in and the fiat that it is a top-down initiative. They are independent issues, so I'll separate them for discussion and clarity....
What's Wrong With Six Sigma?
Many organizations experience disappointment with the results of their Six Sigma deployment efforts. This is because they may be applying Six Sigma on too grand a scale, when, in fact, its tools may be used separately or combined with other techniques....
How To Analyze a Split-Plot Experiment
Quality improvement projects frequently require experimentation on a process. In many real experimental situations, a restriction is placed on the randomization of runs that affects the statistical analysis. A split-plot experimental method involving...
Beyond Sample Size
As a statistical consultant who works with scientists and researchers in a number of areas, the question I have answered most frequently is, “How big a sample do I need?”...
