10 Steps to Zero Defects

A Generic Problem-Solving Framework: A 10-Step Sure-Fire Approach

1. Define the Problem (the Green Y)

2. Quantify and measure the Green Y

  • - Measurement scatter plot
  • - Likert Scale to convert attributes into variables

3. Problem History (problem age, defect rate, cost)

4. Generate Clues:

Multi-vari (including concentration chart)

  • - Concentration Diagram
  • - Components Search
  • - Paired Comparisons
  • - Product / Process Search

5. Formal Design of Experiments:

  • - Variables Search
  • - Full Factorials
  • - B vs. C

6. Turn the problem on and off – ensuring permanence of improvement

  • - B vs. C

7. Establish realistic specifications and tolerances (optimize)

  • - Scatter Plots
  • - Response Surface Methodology (RSM)

8. “Freeze” the process improvements

  • - Positrol

9. Certify the process: Nail down all peripheral quality issues

  • - Process Certification

10. Hold the Gains with SPC

  • - Pre-Control

Acknowledgement: World Class Quality book by Keki R Bhote

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