Quality Control Circle Activities and Memories
As employees of EDS Manufacturing Inc., a Japanese wiring harness company, we often face the challenge of delivering high-quality products.
Our conveyor line had a high number of defective parts, which affected the line's quality and efficiency. By forming a Quality Control Circle group, we were able to lessen and eliminate defective parts and improve the quality and efficiency status of our production line.
I will share stories of our Quality Control Circle Activities in the 1990s, the group efforts, and our happy memories as a team. But first, basic information about QCC.
What is a Quality Control Circle?
A Quality Control Circle is a small group of employees who perform similar work and meet voluntarily or regularly to learn and apply basic quality circle tools and techniques to identify, analyze, and solve quality and other problems in the work area.
The major parts of a QCC group are collaboration and teamwork. Brainstorming ideas is the foundation for identifying problems and finding effective solutions. One must be familiar with the QCC Tools and Techniques to present your report effectively. It is best to understand a graphical presentation and to write the words in the report.
Quality Improvement Tools and Techniques:
- 5Ws and 2H
- Data Collection
- Graphs and Charts
= stand for What, Where, When, Who, Why, How, and How Much.
It is a systematic technique for brainstorming, analyzing problems, identifying the root causes, and generating solutions.
That was the reason why many employees were assigned to join QCC groups to generate as many ideas as possible.
= facts or figures which will serve as the basis of conclusions, decisions, and actions.
The Quality Control Circle Leader assigns members to collect the data from the previous three months to identify major problems encountered by their department. This is not an easy task and needs at least two or three employees to gather the necessary data needed for the report.
= These are pictorial or illustrative data presentations that provide an idea about the data at a glance without referring to the numerical results of data gathering.
A Quality Control Circle member must know which graph or chart best presents the data.
- A Line Graph = is good for indicating the progress of a process, depicting the trends in numerical data, and comparing one trend with another.
- A Bar Graph = is used for comparing variables; it can be either vertical or horizontal.
- Circle Graph/Pie chart = shows the proportions and percentages of variables used.
- Gantt Chart = a tool used to set timetables and to schedule planned activities. It can also be referred to as an Activity Plan to track the progress of your activities.
- Cause and Effect Diagram (Fishbone Diagram) = a relationship between the effects of a problem and the causes influencing them. Visually, the diagram's structure resembles a fish's skeleton. The ribs represent the causes of an event, and the fish head indicates the outcome.
- Pareto Diagram = a combination of a bar and a line graph. This graph compares the categories that contribute to a quality problem.
Quality Control Circle Memories
The first thing you need to brainstorm is the name of your QCC group. I have been fortunate to be included in 4 of the best Quality Control Circles. Here they are;
QCC Group Names:
- Forerunner - my 1st QCC Group as a leader in Production. It was the first time that I had completed a QCC report with the help of members and the support of immediate superiors. Teamwork makes the dream work.
- Rearviewer - my 2nd QCC group as a leader, and my first time joining the EMI Competition. The second QCC group was chosen to compete with other groups to present our reports and countermeasures to the Company Management. We didn't win in the competition, but the shared memories mattered more than the results.
- Charioteer - 3rd QCC group but as a member. Only 4 of the 10 members were included to compete in the Regional and International competitions. The challenge in big groups was that during competitions, only a few members were included to compete.
- Torchere - 4th QCC group I joined as a member of the Training Department, and they competed and won Regional and International Competitions. The group leader and 3 speakers competed in both Regional and International competitions.
Quality Control Circle Competitions:
- EMI Competition - within the company
- Regional Competition - competing with other companies
- International Competition - overseas competition
QCC Materials Needed During a Presentation (1990s)
- OHP (overhead projector) = is like a film or slide projector; it uses light to project an enlarged image on a screen, allowing a small document or picture to be shared with a large audience.
- Acetate sheets = are thin transparent sheets of flexible material onto which images or graphs can be printed and used for the OHP.
- Visual aids = are enlarged samples of actual small objects used to explain to a large audience.
- A microphone = is a handheld device used by a speaker to project their voice clearly and effectively.
- Podium = an elevated speaking platform that provides a surface for a speaker to place notes while reading.
The Results: What We Achieved
QCC activities were part of our professional growth; they developed our problem-solving, data analysis, critical thinking, and decision-making abilities. These activities allow rank-and-file employees to present their ideas to the Management Team for project approval.
Indeed, it has been a privilege to be a part of Quality Control Circle Activities. The various challenges and struggles that came with creating these reports and competitions were worthwhile once the goals were accomplished.
The technical terms in this blog are based on notes I have taken down during the QCC trainings and seminars I've attended within the company.
Credits are given to the owners of these terminologies.
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