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By Marek Szwejczewski, Malcolm Jones (auth.)

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Learning from World-Class Manufacturers SPC AND SIX SIGMA This leads us into a discussion of Statistical Quality Control tools and Six Sigma. The QC Story approach initially focuses on data analysis, traditionally using the 7 QC Tools: 1. Check Sheet/Stratification 2. Pareto Diagram 3. Graphs 4. Histogram 5. Scatter Diagram 6. Cause and Effect Diagram 7. Control Chart We have re-ordered these to point out that the first five are effectively analysis techniques, the sixth a problem-solving approach and the last a means of control.

The precision of the customer rating can of course be questioned, but the orders of magnitude produced by such an approach are effective in focusing design efforts on customer preferences and in avoiding expensively engineered features which produce little benefit from a customer point of view, although to the design engineer it may be a particularly elegant part of the design. The standard value engineering approach looks at how to derive specific product performance in the most cost efficient way.

Each one had a specific owner, defined benefits and timescales. 4 Projects implemented in 2005–06 (4) Product Rationalisation (5) PVC Strategy (6) Metals Strategy (3) Increase Flat-packability (2) Lean Classic (Flat-pack) (8) Cost of Quality Reduction (1) Supply Simplification (7) Logistics Strategy (11) Glass Strategy & information flow improvement (10) Ultranet Order Manager/ Electronic Trading (9) Operating Times Redefinition (13) Outsource Polycarbonate (14) Outsource Windows (12) Accrington Site Consolidation Additional Projects Initial Projects Importantly each project had a cross-functional element, to help break down the silo mentality and help to change the culture.

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