Introduction to Quality Control

TO QUALITY CONTROL 3A CORPORATION Originally printed in Japan as "Dai-3-pan Hinshitsu Kanri Nyumon" (Introduction to Quality Control 3rd Edition) by Kaoru Ishikawa. ©Kaoru Ishikawa 1989, published by JUSE Press Ltd. Softcover reprint of the hardcover 1st edition 1989 Distributed outside Japan and North America by: CHAPMAN & HALL 2 -6 Boundary Row, London SEl 8HN, UK. ISBN-13: 978-94-011-7690-3 e-ISBN-13: 978-94-011-7688-0 DOl: 10. 1007/978-94-011-7688-0 All rights reserved. No part of this book may be reproduced in any form or by any means, without permission in writing from the publisher. First Printing . . . . . October 1990 Translated by J. H. Loftus Contents Preface XVII Acknowledgment XIX CHAPTER 1 WHAT IS QUALITY CONTROL? 1 1. 1 What is Quality Control? 1 1. 1. 1 The Definition of Quality Control 1. 1. 2 Some Misunderstandings about Quality Control and Total Quality Control 1. 1. 3 The Benefits of Companywide Quality Control 1. 2 The History and Current Status of Quality Control 7 1. 3 Advances in Quality Assurance 13 1. 4 What is Quality? 15 1. 4. 1 Quality to Satisfy the Consumer 1. 4. 2 True Quality Characteristics and Substitute Characteristics; Product Research 1. 4. 3 Quality Analysis and Product Research 1. 4. 4 Clarifying Definitions Concerning Quality 1. 4. 5 What are Good Quality and Good Products? 1. 5 What is Control? 36 1. 5. 1 The Old-Fashioned Approach to Control 1. 5. 2 Control Methods and Philosophy 1. 5. 3 Action for Recurrence Prevention ("Permanent Fix") 1.

Inhalt
1 What is quality control?.- 1.1 What is Quality Control?.- 1.2 The History and Current Status of Quality Control.- 1.3 Advances in Quality Assurance.- 1.4 What is Quality?.- 1.5 What is Control?.- 1.6 Controlling Quality.- 1.7 Quality and Process Improvement.- 1.8 Statistical Quality Control, Total Quality Control and Technology.- 1.9 The Ends and Means of Business Management.- 1.10 QC Circle Activities.- 1.11 The Introduction and Promotion of TQC.- 1.12 Methods of Promoting TQC in Individual Departments.- 1.13 Quality Diagnosis and TQC Diagnosis.- 1.14 The Role of Executives in TQC 85 Some Quality Control Maxims.- 2 The Statistical Approach, With Some Simple Statistical Tools.- 2.1 Statistical Methods Used in Quality Control.- 2.2 The Statistical Approach.- 2.3 The Different Types of Data.- 2.4 Expressing Distributions Quantitatively.- 2.5 Interpreting and Using Frequency Distributions.- 2.6 Pareto Diagrams and Pareto Curves.- 2.7 Check Sheets.- 2.8 Process Capability Diagrams.- 2.9 Scatter Diagrams (Correlation Diagrams).- 2.10 What is Error?.- 3 The Preparation And Use Of Control Charts.- 3.1 What are Control Charts?.- 3.2 Types of Control Chart.- 3.3 Preparing Average and Range $$(\bar x - R)$$Control Charts.- 3.4 Preparing Control Charts for Fraction Defective (p).- 3.5 Preparing Control Charts for Number of Defectives (pn).- 3.6 Preparing Control Charts for Number of Defects per Unit (u).- 3.7 Preparing Control Charts for Number of Defects (c).- 3.8 Interpreting Control Charts.- 3.9 Using Control Charts.- 4 Process Analysis and Improvement.- 4.1 Process Improvement and Control.- 4.2 Improvement Types and Procedures.- 4.3 Problem-Finding Investigations.- 4.4 Deciding What Problems to Tackle.- 4.5 Organization for Process Analysis and Improvement.- 4.6 Analyzing Problems and Preparing Improvement Plans.- 4.7 Examining Process Analysis and Improvement Methods.- 4.8 Some General Hints on Analysis.- 4.9 General Procedures for Statistical Analysis.- 4.10 Performing Factory Experiments.- 4.11 Process Analysis with Scant Data.- 4.12 Preparing and Implementing Improvement Plans.- 4.13 Checking Results: Control and Further Improvement.- 4.14 Preparing Reports.- 5 Process Control.- 5.1 What is Process Control?.- 5.2 Quality Design and Process Design.- 5.3 Action.- 5.4 Work Standards and Technical Standards.- 5.5 Control Levels.- 5.6 Causes of Abnormalities and Control Standards.- 5.7 How to Check Whether Good Process Control is Being Implemented.- 5.8 The Benefits of Control Charts and the Controlled State.- 5.9 Setting Adjustment Criteria.- 6 Quality Assurance and Inspection.- 6.1 What is Quality Assurance?.- 6.2 The Principles of Quality Assurance.- 6.3 Quality Assurance Methods and Systems.- 6.4 Why are Defectives Produced? Some Suitable Countermeasures.- 6.5 Reliability.- 6.6 Quality Assurance and Social Responsibility (Product Liability and Environmental Disruption by Product).- 6.7 What is Inspection?.- 6.8 Inspection Type.- 6.9 What is Sampling Inspection?.- 6.10 100% Inspection or Sampling Inspection?.- 6.11 Process Control or Inspection?.- 6.12 The Inspection Department.- 6.13 Inspection Standards and How to Set them.- 6.14 Complaints Handling and Special Acceptance.- 6.15 Conclusions.- 7 The Systematic Implementation of Total Quality Control.- 7.1 Total Quality Control.- 7.2 The TQC Organization.- 7.3 TQC Promotion Programs.- 7.4 Design Control.- 7.5 Raw Material Control, Subcontractor Control, and TQC for Small and Medium-Sized Enterprises.- 7.6 Equipment Control, Jig and Tool Control, and Measurement Control.- 7.7 TQC in Marketing, Sales, and Service.- 7.8 TQC and Distribution Organization.- 7.9 Research and Development Control.- 7.10 Quality Audits.- 7.11 Quality Control Audits and TQC Audits.- 7.12 Policy Management.- 7.13 Conclusion.