Preparation for QC Certification Level 3. Summary of Basic Words and Phrases

Today, I am taking notes on "Preparation for QC Certification Level 3. Summary of Basic Words and Phrases" notes. I passed the QC Certification Level 3 exam on March 20, 2016 (a year when the exam content was difficult). Here I am uploading the content that I actually summarized as a QC Certification Level 3 Preparation, and I believe it is very effective in preparing for the exam, as I only summarized the important points to pass the QC Certification Level 3 exam and re-summarized them after the exam. As an idea, I think you can get more than 40 points in the basic words and phrases part by grasping the contents and their meanings.

Basic Knowledge of QC Certification Level 3

 

Outline of QC Certification

The QC certification test evaluates the level of knowledge of quality control, and QC stands for Quality Control, and the practical level of QC Level 3 is considered to be the ability to conduct basic management and improvement activities with support as needed.

 

About the QC Certification Examination

The duration of the QC Certification Level 3 exam is 90 minutes, and the ratio of the number of examinees taking the QC Certification Level 3 exam to the number of successful examinees is approximately 28,000 examinees to 14,000 examinees in the 2012-2014 fiscal year, a pass rate of approximately 50%.

 

Basic Words and Phrases of QC Certification Level 3

What is QCD and PSME?

Q=Quality (nonconforming product rate, number of occurrences by responsibility, etc.)
C=Costs (e.g., budgetary and actual variances)
D=Quantity and delivery date (delivery date achievement status, parts inventory trend, etc.)
P = Productivity (number produced per person, hourly production value, etc.)
S=Safety (number of accidents, number of accident-free operating days)
M = Morale (absenteeism rate, number of improvement proposals by individual, etc.)
E = Environment (e.g., carbon dioxide emissions)

What is Market-In?

Prioritize customer needs. We develop standards and products from the customer's point of view. We make only what sells.

What is Product Out?

The maker makes good products. The maker's theory should be prioritized and sold.

What is Win-Win?

You win and the other party also wins. A situation that benefits both parties involved.

What is Quality Priority/Quality First?

Priority should be given to providing good quality products and services, not to short-term profits or expanding market share.

Work Process

Front-end and back-end (next process)
The basic rule is not to inconvenience those working in the back-end process.

Process-oriented

The idea that the process to the result is more important than the result.
In quality control activities, it is fundamental to clarify the process and ensure that it is implemented.

First Aid, Recurrence Prevention, Proactive Prevention, Predictive Prevention

When a problem occurs, emergency measures should be taken to stop it for the time being, and preventive measures should be taken carefully to prevent recurrence. In addition, we will take advantage of our experience with problems to prevent similar problems before they occur. Predictive prevention is another way to identify problems early and prevent them from becoming serious problems.

Characteristics and Factors and Causal Relationships

Understanding the cause-and-effect relationship between quality characteristics is an effective method of QC, as it enables us to take the initiative in detecting signs of change and preventing defects.

Source control = source control as well.

Basic Quality Control Activity Policy: Take action against causes. When a defect occurs, go back to the source to find the true cause, and prevent recurrence by improving and managing the defect. The more the problem is at the source, the greater the impact, so quality control at the source is of utmost importance.

goal-oriented

QC's view and approach is based on a goal-oriented approach.

priority selection

It is important not only to place importance on the size of the effect, but also to start with what can be improved. In an environment with a limited number of participants and limited funds, it is important to give priority to those activities that are useful and effective for company management. Pareto analysis

the principle of see no evil, hear no evil, speak no evil

It is necessary to correctly grasp the facts as data and make objective judgments without relying on experience or intuition. Even if work is performed under the same conditions, the characteristics of the results will always vary due to various factors. It is important to examine realistically while looking at the actual products on site.

Visualization, manifestation of latent problems (Kenzaika)

To "visualize" the original state of a problem by visualizing it on a graph or by using sound or warning lights on equipment in order to detect, treat, and improve the problem at an early stage.

The idea of focusing on variation

Uneven work creates inconsistencies or "variations" in quality. The reason statistical thinking is important in quality control is that it is constantly changing. Variation has a statistical "regularity" that is the focus of attention.

Preparation for QC Circle Activities" and how to proceed

While policy management is carried out by senior management and daily management by supervisors, QC circle activities are also called small group activities and are "organizational revitalization activities carried out by general employees. Members consist of the head of the workplace and below

The following attitudes are considered: a place for self-development, respect for autonomy, group activities, participation by all, use of QC methods, activities closely related to the workplace, activation and permanence, a place for mutual enlightenment, never neglecting originality and ingenuity, and an awareness of quality, problems, and improvement. QC is a place for mutual learning, creativity, and awareness of quality, problems, and improvement.

Definition of quality

Degree" to which customer, social, and organizational requirements are met

Quality Requirements and Quality Elements

It is important to correctly understand and grasp the quality of customer requirements. It is generally more difficult because there are manifest and latent requirement qualities.

Quality and Substitution Properties

Quality characteristic: A property or performance that is the subject of quality evaluation and is a "component of quality". Quality characteristics are divided into "practical characteristics" and "substitute characteristics. For substitute characteristics, items that can be measured are selected.

Example I want a bright room.
Want a bright room: Practical characteristics
Measurement of illuminance, etc.: Substitute characteristics

Aimed quality (design quality) and finished product quality

Product design (target): Aimed quality
Manufactured products: quality of workmanship

Bland and Attractive Quality

of quality commonplace

Quality characteristics that are valued as "natural" when they are fulfilled, but cause dissatisfaction when they are lacking.

attractive quality

A quality characteristic that can give "satisfaction" if it is fulfilled, but can be accepted as inevitable if it is lacking.

Quality of Service and Quality of Work

Both service and work can be evaluated from a "quality perspective. The quality of work can also be said to be whether or not "QCD" has been achieved.
For example, if "service quality" is broken down, the six important "basic service qualities" can be captured as accuracy, promptness, flexibility, empathy, security, and good impression.

Customer Satisfaction and Customer Value

Customers will be satisfied (customer satisfaction) if the product fully answers their expected value (customer value) because they try to select the product with the maximum value within their limited budget, knowledge, and time.

social quality

The "degree of annoyance" that a product or service causes to third parties other than the manufacturer and its customers.

Maintenance and Improvement

In the process of maintaining and managing technology, we pursue the causes of abnormalities that occur and take fundamental measures to prevent their recurrence. Improvement is the process of raising the standard to a higher and higher level based on the basis of these measures.

Maintenance → Improvement (improvement) → Maintenance → Improvement (improvement) → ...

In addition, improvement activities that are systematically and illegally implemented under the "PDCA" cycle are referred to as "continuous improvement.

PDCA, SDCA, PDCAS

PDCA

P(Plan): Plan → D(Do): Do → C(Check): Check → A(Action): Action

SDCA

S(Standard): Standard → D(Do): Implementation → C(Check): Inspection → A(Action): Action

PDCAS

P(Plan): Plan → D(Do): Do → C(Check): Check → A(Action): Action → S(Standard): Standard

Difference between a problem and an issue

Problem: A gap between the goal and the current situation that needs to be resolved.
Issue: How to fill gaps and achieve objectives

QC Story

Problem-Solving QC Stories

Procedures for approaching the cause of a problem and taking action to resolve it.

1. Theme Selection
2. Setting Goals
3. Planning for Promotion
4. Current Status and Analysis
5. Development of countermeasures
6. implementation
7. Confirmation of results
8. brake
9. Reflection and future planning

Problem Solving QC Story

Procedures for accomplishing tasks by designing new ways of working and equipment, rather than problematizing the cause of the trouble.

1. Theme Selection
2. Clarify issues and set goals
3. policy making
4. Pursuit of optimal measures
5. Implementation of optimal measures
6. Confirmation of Effectiveness
7. brake
8. Reflection and future planning

Assurance of results and assurance through process

Quality assurance requires not only "assurance of the result" as a finished product, but also "assurance of the process" that the correct manufacturing process was followed until the product became a finished product. In order to do so, it is necessary to keep correct records of acceptance, process control, product inspection, etc., as well as shipment inspection records.

Warranty and indemnification

Guarantee: To undertake (promise) to do this or that in the future.
Compensation: making up for losses

Quality Function Deployment (QFD)

English: QFD (Quality Function Deployment)
Purpose: Quality function deployment is to establish design quality that satisfies the customer and to develop the design intent to the manufacturing process.

The quality function deployment table includes

Requirements Quality Development Table" that organizes market feedback in terms of linguistic information. The "quality characteristics development table" that develops technical characteristics related to the product. There is a "quality table," which is a dual table of requirement quality development table and quality characteristics development table.

Quality Assurance System Chart

A system chart that clearly defines "assurance tasks" and "assurance managers" to clarify how quality is realized and assured from product planning to sales and service.

DR and trouble prediction (FMEA, FTA)

DR: Design Review (Design Review Board)
A method in which related parties gather at each point in the product planning → basic design → prototype → detailed design → prototype → mass production process to evaluate items to be fulfilled from each perspective and confirm that the criteria are exceeded before proceeding to the next step. The purpose of this method is to avoid rework from the back-end process.

FMEA: Failure Mode and Effects Analysis

Bottom-up method. A technique that analyzes the failure modes of components and their effects on higher-level items in order to discover design imperfections and potential shortcomings.

FTA: Fault Tree Analysis
top-down approach

Quality assurance process, assurance network (QA network)

QA Network: Quality Assurance Network Quality Network
English: Qality Assurance Network
In order to guarantee product quality, defects that occur in the manufacturing process are predicted, and a process is created to prevent the flow of defective products to subsequent processes.
A network that has been formed to improve service readiness and to serve consumers anywhere.

Quality assurance throughout the quality lifecycle

A method that positions the improvement of quality in the planning, design, manufacturing, and after-sales service processes as the foundation of quality assurance activities, aiming to enhance customer satisfaction throughout the product lifecycle by providing not only the quality required by customers, but also attractive quality that anticipates customer needs.

Product Safety, Environmental Considerations and Product Liability

Three perspectives that need to be considered from a quality assurance perspective in DR

1. Product Safety: Products are safe.
2. Environmental considerations: No environmental impact
3. Product Liability: No damage to the life, body or property of the customer caused by a defect in the product.

Market trouble handling, complaints and their handling

Trouble in the market: apparent claims (repair, replacement, discount, cancellation)
Latent complaints (kept in the customer's chest) *Similar to complaints: grievances

Complaint Measures

Establishment of a feedback system for complaint information is necessary. A system that can trace lots and products back to the manufacturing process is necessary to meet the quality and speed requirements of information.

Process (step) concept

Converting inputs into outputs. Interrelated. Or a series of activities that interact with each other.

operation standard

The procedures for human and machine operations are defined so that the same results can be obtained regardless of who performs the work. There is no fixed form, but three items are required: work procedures, caution points, and reasons.

QC process diagram/flowchart
A QC process chart describes the inspections and checks at each step in the process sequence.

Concept of process abnormality, its detection and treatment

When a process abnormality is discovered

1. Remove the above causes
2. Return the process to normal
3. Clearly identify abnormal and normal production so that they do not flow to the back-end process and are not mixed.
4. Preventing recurrence of the problem
5. report

Process capability studies and process analysis

Process capability study: Sampling from the process and measuring quality characteristics. Also, process capability is estimated (evaluated) by using a process capability index that is compared to the standard.
Process Analysis: Pursuing the causes of defects. A method to reduce defects, to understand the true causes, and to find better conditions to improve quality.

Types and Methods of Inspection

Acceptance and purchase inspections

Inspection of incoming lots from external sources to determine if they are acceptable

In-process (interim) inspection

Inspection of semi-finished products in the factory as they are passed between processes. There is "self-inspection" by workers.

Final inspection and shipping inspection

Inspection to determine if the finished product meets the requirements. Packaging conditions must also be checked.

Types and Methods of Inspection

100% inspection
Inspect all inspection units in the lot

Non-test inspection and indirect inspection

Inspections that omit inspection of samples based on quality and technical information

sampling inspection

Samples are extracted from inspection lots using a predetermined "sampling inspection method" and the results are compared with the "lot judgment criteria" to determine whether the lot is acceptable or not.

sensory evaluation

Inspections that use human senses to evaluate quality characteristics and make judgments by matching them with judgment criteria.

Measurement Basics and Control

To measure product characteristics,

1. Select measurement equipment, facilities, and limited samples for inspection
2. Methods of connecting measuring instruments and preparation of character fools' answers for inspection
3. Inspection of measuring equipment
4. Connect, set up, and calibrate measurement equipment and facilities.

Evaluation of measurement error

Data are obtained by measuring samples from the population, but they are subject to measurement error. In order to minimize measurement error, it is important to consider measurement instruments and methods and conduct "daily management.
There are also "bias" and "variation" in measurement error.

Sensory testing and sensory quality
Sensory testing: In addition to instruments, tests rely on the senses, such as color, scratches, etc.
Inertial quality: Quality that appeals to people's emotions

Elements of Quality Management (Policy Management)

Policy development and alignment. Policy from top management: not presented in detail.

Policy Development

Break down the policy from the top down to the level of the person in charge to be specific and detailed.

policy alignment

Policy development is not a one-way directive from the top to the bottom, but a consensus-building process that both parties can agree on through the exchange of opinions.

Policies, Objectives and Measures
Policy: Used for 3-5 year mid-term plans
Goal: Used for 6 month to 1 year timeframe plan to achieve policy
Measure: Used to track progress of daily implementation achievement to meet daily to monthly timeframe goals.

Policy Management

Activities conducted with the cooperation of the entire organization to effectively and efficiently achieve "medium- to long-term plans" and "short-term plans" based on management policies.
*A characteristic of Japanese quality control.

Evaluation of policy achievement and reflection

Evaluate achievement at the end of the policy management phase

Segregation of duties, responsibilities and authority

Segregation of duties rules (segregation of duties chart) organize and distribute roles to clarify the authority necessary to fulfill the responsibilities and duties to be performed by each job in the organization, and define and clearly state the contents of each job and the scope of authority and responsibility.

List of control points, inspection points and control items

Control items: Refers to items subject to control in order to maintain product quality.
Control points: Result system items
Inspection point: Factor system items
If there is an anomaly in the results and it is unexpected, take action by tracing back the factor system.
Mainly control items related to the resultant system, and check and control of the causal system using inspection items are important for prevention.

Control items: control chart, etc.
Inspection items: checklist items, etc.

Abnormality and its treatment

Abnormality: Deviation from the stable state As a remedy

1. Remove the above causes
2. Return the process to normal
3. Clearly identify abnormal and normal production so that they do not flow to the back-end process and are not mixed.
4. Preventing recurrence of the problem
5. Report *Same as "Concept of process abnormality and its detection and treatment

Change points and their management

Most defects in the manufacturing floor occur when manufacturing conditions are changed.
4M: Man (Man), Machine (Machine), Material (Material), Method (Method)
Initial flow monitoring: 4M change and production start-up and restart should also be performed.
5M:Measure

Purpose, Significance, and Concept of Standardization

Standardization: To determine materials and parts in advance and to establish certain procedures.

In-house standardization and how to promote it

Standardization Activities

Aiming to improve the efficiency of the entire activity. Activities to create internal rules and standards that indicate work methods to be repeated to produce products of stable quality, etc.

industrial standardization

To contribute to the improvement of quality, increase in productivity, simplification and fairness of transactions, and promotion of public welfare by establishing and promoting appropriate and reasonable industrial standards.

international standardization

International agreements on product quality, performance, safety, dimensions, test methods, etc. An inevitable consequence of the fact that economic activities are no longer completed through domestic trade but have become dependent on international trade.

Eight Principles of Quality Management

1. Customer Focus
2. leadership
3. People Involvement
4. process approach
5. . Sysm Approach to Management
6. Continuous Improvement
7. Fact-based approach to decision-making
8. Reciprocal relationship with suppliers * Reciprocal relationship: A relationship in which both parties benefit or give benefits to each other.

Quality education and its system

In the 4Ms and 5Ms of quality control, "people" are the most important, and it is desirable to conduct education and training according to rank and function. In addition, "On the Job Training (OJT)" should be conducted through daily work.

ISO 9001

Quality management system" defined by the International Organization for Standardization, also called QMS (Quality Management System).

Introduce QMS within the company with the aim of providing good products and services and achieving customer satisfaction.
Receive certification or undergo periodic external audits with the help of an external auditing organization in the process of implementation and operation.
and so on to achieve continuous improvement.

Seven QC Tools

Pareto Chart: Identify the true problem from many problems.
*Clearly shows important phenomena and causes.

2. Characteristic factor diagram: Pick up and organize factors
*A tool for systematically organizing the relationship between specific results and causal systems.

3. Check Sheet: Easily take data and prevent omissions

4. Histogram: To grasp the distribution and compare it with the standard.
How to make a histogram

1. Gathering Data
2. Find maximum and minimum values
3. Determine the width of the interval
4. Determine the boundaries of the interval
5. Find the center value of the interval
6. Make a frequency table
7. Create a histogram

5. Scatter plots: Grasping the relationship between two pairs of paired data
The two variables are used as the horizontal and vertical axes to examine the relationship (trend) between the variables.

6. Graphs: Allow the eye to view the data.
7. Control chart: Examine whether the process is in a stable state.

How to read a histogram

The general type is a distribution formed when important factors are under control, the two-peaks type is a distribution formed when there are two peaks and different populations are mixed, the isolated-island type is a distribution formed when different materials are mixed, etc., the precipice type is a distribution formed when there is something out of the standard value and the user wants to selectively remove that portion, etc., and the missing-tooth type is a distribution formed when the measurement is poor or when the method of dividing the interval when drawing the histogram is not appropriate. A distribution with a cliff is formed when a part of the material is out of the standard value and the user wants to select and remove that part.

the Seven New QC Tools

1. Affinity Diagram Method

A method for "organizing," "classifying," and "systematizing" linguistic data by grouping them.
The "affinity" or "structure" of the issue can be organized.

2. linkage diagram method
A method of clarifying problems involving cause and effect, purpose and means, etc., by logically "connecting" the relationships between them. It can clarify the cause-and-effect relationship of a problem.

3. Systematic Diagram Method
A method of organizing measures by systematizing objectives and means.

4. Matrix Diagram Method
A method used to determine the weighting and division of roles for measures developed by the "phylogenetic charting" method.
The two elements can be arranged in "rows" and "columns" to clarify their correspondence.

5. Arrow Diagram
A method of clarifying the relationship between each task and the schedule.

6. PDPC method
A method to identify alternatives for unforeseen circumstances leading up to the achievement of the goal.
Anticipate the outcome in advance and steer the process in the desired direction as much as possible.

7. Matrix data analysis method
A method in which two or more data are analyzed to identify trends at a glance.
It is possible to sort out problems and find solutions.
That's it.

*This "Preparation for QC Certification Level 3" article is in two parts. Together with "Preparation for QC Certification Level 3. Summary of Basic CalculationsSee also.

 

QC Certification Level 3 Preparation Book for 2018

This is the 2018 edition of the book for the preparation of the 2018 edition of the book →.QC Certification Level 3 (2018 Edition) Learned by Past Problems [ Ken Nishina ].