Supply Chain Quality Management (SCQM) : Measuring and Controlling Quality in The Supply Chains
Supply Chain Quality Management (SCQM) : Measuring and Controlling Quality in The Supply Chains
Module 07
Introduction
Control Charts
Summary
References
Lesson 1 of 9
Introduction
In the last few modules of this unit, we emphasised a process approach to Supply
Chain Quality Management. In module five, we used the three major activities of
process management; process design, process control and process improvement,
as a focus for optimising product and service quality. In module six, we narrowed
our scope to explore supply chain design for quality and product excellence. In
this module, we will explore the topic of measuring and controlling quality in the
supply chain to focus our learning on the two other major activities of process
management; process control and process improvement.
Learning Outcomes
Interpret a control chart and identify the various elements and patterns
View 1 video
Work on 2 activities
- (Vardeman 2016, 5)
Click the link to read the BBC News article about the complexities of measuring.
CLICK HERE
The article that you have just read demonstrates the complexities of measuring.
Now let’s think about measurement from a manufacturing versus services
perspective. Can measurement be approached the same way for these two
business functions or do we need to distinguish between quality measures in
service organisations and those involved in the manufacturing of products? Let’s
look at some common quality measurements to find out.
Unit of Work
–
“A unit of work is the output of a process or an individual process step. A unit of work might be a
completed product ready to be shipped to a customer, or the delivery of a package to a customer.”
(Evans and Lindsay 2017, 377)
Non-conformance
–
This is any defect or error associated with a unit of work. In manufacturing, the term defect is
usually used, while in service applications, the term error is used. Therefore, a non-conforming
unit of work is one that has one or more defects or errors (Evans and Lindsay 2017).
As you can distinguish from the common quality measurements that we have
just described, both products and services are broadly measured in a similar
way.
Measures in quality control fall into one of two broad categories.
Attribute Measures
–
“Characterise the presence or absence of non-conformances in a unit of work, or the number of
non-conformances in a unit of work. Attribute measurements are often collected by visual
inspection and expressed as proportions and counts.” (Evans and Lindsay 2017, 377)
Variable Measurements
–
“Applied to dimensional quantities such as length, weight and time, or any value on a continuous
scale of measurement. Variable measurements are usually expressed with statistical measures
such as averages and standard deviations.” (Evans and Lindsay 2017, 377)
Let’s use a simple example to show that both attribute and variable measures
can sometimes be dually applied. For example, we could determine whether a
part meets a specification of 1.60 ± 0.01 millimetre (an attribute measurement),
or measure and record the actual value of the diameter (a variable
measurement) (Evans and Lindsay 2017).
In this first part of the module, we have introduced some of the main terms and
definitions in measuring and controlling quality in supply chains. We have also
identified some of the complexities of attempting to measure and control the
quality of products and services in the supply chain. In the next part of the
module, we will discuss how the measurement and control of quality comes at a
cost for any organisation. However, these costs can be surpassed by benefits if
the right strategies to improve quality are put in place.
Lesson 3 of 9
While organisations have tried to measure and report quality costs as a basis for
process control and improvement, many have not fully understood the full range
of quality costs. Traditionally, the focus of the COQ has been limited to more
easily identified quality and inspection costs, which could be easily recorded
through financial cost accounting. More recently, terms such as finance
improvement have been applied to more accurately describe the COQ and
include a more complete supply chain focus.
“the sum of the costs incurred across a supply chain in preventing poor quality
of product and / or service to the final consumer, the costs incurred to ensure
and evaluate that the quality requirements are being met, and any other costs
incurred as a result of poor quality.”
Supply chain strategies that consider the COQ have vital to help better
understand the trade-off between cost and quality. Businesses are considering
not just the COQ, but also the Cost of Poor Quality (COPQ). This increased
understanding of the importance of quality to business success can be
highlighted by the following points:
Quality related costs are not only related to manufacturing operations, but
can equally affect the provision of services and even other ancillary
functions such as procurement and customer service departments.
Measuring and controlling quality in the supply chain is vital to balancing the
trade-off between cost and quality. SCQM has a vital role to play in selecting
suitable strategies to maximise opportunities for business and add value for
customers.
Let’s take some time to learn more about COQ and some SCQM strategies that
can be used to calculate the COQ for business.
CLICK HERE
Answer the following questions that are based on the journal that you have just
analysed.
popularise the Cost of Quality (COQ) concept beyond the quality profession and
Feigenbaum
Crosby
Juran
Taguchi
SUBMIT
Based on the literature survey COQ has focussed on the supply chain and not
True
False
SUBMIT
measurement system.
SUBMIT
Let’s briefly summarise what we have discussed in this part of the module. There
is an inevitable trade-off between cost and quality that requires SCQM
strategies that can measure and control quality to benefit business and the
customer. Quality costs can be segregated into four major categories; prevention
costs, appraisal costs, internal failure costs and external failure costs. There are
significant advantages in establishing a COQ SCM measurement system which
involves identifying the activities that generate cost, measuring those costs and
analysing them in order to identify areas for continuous improvement to the
product or service system.
In the next section of the module, we will identify the various methods for
measurement system evaluation.
Lesson 4 of 9
Let’s think about how we can control these important interrelated processes.
First, we need to review what we learned about control in an earlier module.
“long term improvements cannot be made to a process unless the process is first
bought under control”
Therefore, in order to control and improve our supply chain system we require
strategies to measure and evaluate our system. In the next part of the module,
we will identify various methods of evaluating a measurement system.
Stable: When applied to the same items the measurement system should
produce the same results in the future as it did in the past and would
provide in the present.
“Accuracy is defined as the difference between the true value and the observed
average of measurement. Accuracy is measured as the amount of error in a
measurement in proportion to the total size of the measurement ”
2. An error caused by the person using the equipment e.g. failing to correctly
seal the tyre pressure gauge on the tyre valve.
Figure A
In Figure A, the average measurement is not close to the true value. Additionally, a
wide range of values fall around the average. Thus, the measurement is neither
accurate nor precise (Evans and Lindsay 2017, 387).
Figure B
In Figure B, even though the average measurement is not close to the true value, the
range of variation is small. Thus, the measurement is precise but not accurate (Evans
and Lindsay 2017, 387).
Figure C
In Figure C, the average value is close to the true value, so the measurement is
accurate but not precise (Evans and Lindsay 2017, 387).
Figure D
In Figure D, the average value is close to the true value and the distribution is narrow so
the measurement is both precise and accurate (Evans and Lindsay 2017, 387).
At the start of this section of the module, we identified that measuring quality
performance usually requires the collection of data from several sources,
especially if it involves the measurement of complex processes or whole SC
systems. We also highlighted that some measurements involve human senses
and experiences which by their very nature may be quite subjective. Other data
may be derived from measurement devices.
So far in this part of the module we have identified various methods for
measurement system evaluation without mentioning the key influence that we
are trying to control. Think back to earlier modules particularly those with a
process focus and answer the following question.
approach. Deming ultimately synthesized his 14 points for quality into four
singled out one of these elements as the chief culprit of poor quality. Review
Deming’s System of Profound Knowledge, listed below and select the element
that provides the best strategy to measure and control quality in a supply chain
Appreciation of a system
Knowledge of variation
Theory of knowledge
Knowledge of psychology
SUBMIT
“Observed variation in a process output stems from the natural variation that
occurs in the output itself as well as the measurement system.”
Therefore, total observed variation = true process variation PLUS variation due to
measurement.
Throughout this part of the module, we have identified many of the concepts
around measurement systems evaluation. We have highlighted that the value of
measurement systems evaluation is a function of up to date, valid, reliable
information in SCQM.
We also identified that measuring quality performance requires a measurement
system containing key measurement characteristics as well as an
understanding of the difference between accuracy and precision. Finally, we
exposed the importance of knowledge of variation in measuring and controlling
quality in the supply chain.
In the next section of the module, we will use a control chart to provide an
example of a method for measuring and controlling quality in a supply chain.
Lesson 5 of 9
Control Charts
Let’s continue our learning on measuring and controlling quality in the supply
chain by exploring the use of control charts. If you remember back to module 5,
on achieving quality through a process focus, we explained that a control chart is
a statistical tool that can be used to analyse how a process changes over time.
While control charts are a valuable tool to measure and analyse variation in
processes, the overall methodology that focuses on measuring and controlling
quality in the supply chain is known as Statistical Process Control.
Statistical Process Control
The Statistical Process Control (SPC) methodology provides the dual benefits of
not only monitoring a process to identify different causes of variation, but also
provides information about the process to help make corrective actions to
control and improve process performance. In addition, SPC also provides the
opportunity for a business to demonstrate evidence of its quality capabilities
and is particularly useful for measuring and controlling processes that are in the
early stages of quality assurance.
Let’s look at a simple example to highlight why SPC is important for any
businesses aiming to meet customer requirements and at the same time keep
their bottom line healthy.
As we have mentioned previously, SPC relies on the use of control charts that
were first proposed by Walter Sherwart in the 1920s. In a control chart, upper
control limits (UCL) and lower control limits (LCL) are identified to provide a high
probability (generally greater than 0.99) that data points will fall between these
limits if the process is in control (Evans and Lindsay 2017).
Let’s review an example of the structure of a control chart.
Next let’s view an example of a process that can be described as being in control.
The task of analysing a control chart is a more complex challenge. This can be
done by examining the chart and comparing the information to prescribed
criteria. The most common use of a control chart is to identify if the process,
(over the time period measured) is in control (or not in control).
In this example, the criteria for determining a control chart and therefore the
process it is measuring, could be;
The number of points above and below the centre line is about the same
The data points seem to fall randomly above and below the centre line
Most points, but not all, are near the centre line and only a few are close to
the control limits. (Evans and Lindsay 2017, 404)
Control charts can offer a great deal of knowledge to help measure and control
quality in supply chain processes. One way to analyse control charts is to look
for easily identifiable patterns that can often appear. Let’s look at some typical
out of control patterns that can be observed in control charts and see how these
patterns can be interpreted to tell us about what is happening in the process.
When an unusual number of consecutive data points fall on one side of the
centre line, as highlighted in the circled area above, this is an indication that the
process average has suddenly shifted and may be the result of some change in
the process. These changes could be a new process operator, new inspector or a
new machine. This shift in process average will not identify the root cause of the
change to the process, but will act as a red flag to indicate that some sort of
follow up investigation is required. An investigation can then be undertaken to
identify the cause and develop a strategy to bring the process average back
towards the centre line. For example, this could be further operator training or
recalibration of the machine.
A trend is the result of some cause that gradually affects the measurement and
causes the points on a control chart to gradually move up or down from the
centre line.
We have learnt a little about the structure of control charts and the types of
patterns that may occur in the measurement of control processes. We will now
learn more about the two sources of variation in processes and the eight rules
that can be used to help interpret the information from control charts.
Click the link to read more about Control Chart Rules and Interpretation (Bill McNeese, 2016).
CLICK HERE
Answer the following question to test your knowledge on process variation and
control charts.
Process variation comes from two sources. Select the option with the two
correct causes.
SUBMIT
True
False
SUBMIT
In the final part of this module, we turn our focus to strategies that can provide
more detailed measurement and control data to help improve process quality.
Lesson 6 of 9
In the process for the manufacturing of a steel bushing that supports a steel
shaft (see image to the right), the inside diameter of the bushing has a Lower
Specification Limit (LSL) of 1.498 mm and an Upper Specification Limit (USL) of
1.510 mm. If the diameter is too small it can be enlarged through a rework
process.
However, if the diameter is too large, the part must be scrapped.
A process where most of the measurements fall within the specification limits is
a capable process. Understanding the capabilities of its processes is important
for any business. Especially for those seeking to design, measure, control and
continuously improve their process capabilities. Process capability focuses on;
The relationship between the process capability specifications and the natural
variation of the process is often quantified by a measure known as the process
capability index.
(Joyner 2014)
Select the capability index that best matches the scenario below
In this final section, we have discussed the importance of process capability and
indexes to measuring and controlling quality in the supply chain. We promoted
the use of a customised process capability study as a way of focussing process
design, measurement, control and improve the quality performance goals of the
business.
To integrate the knowledge that we have gained throughout this module, let’s
look at a case study example of a supply chain that has performed its own
capability study to measure the behaviour of its processes and create strategies
to improve process performance and improve quality for its customers.
CLICK HERE
01/04
Applies to dimensional qualities such as length, weight and time or any value on a continuous
scale of measurement.
Is the act of collecting data to quantify the values of product, service, process and other
business metrics.
Question
02/04
monetary language that every stakeholder can understand. COQ concepts affect operating
True
False
Question
03/04
Select all correct responses to the following statement. A lack of accuracy reflects a
04/04
No one table or set of rules to analyse variation in control charts can give you the reasons
for out of control points in your process. You have to use your knowledge (and that of those
True
False
Lesson 8 of 9
Summary
In this module, we have explored the topic of measuring and controlling quality
in the supply chain. In the first part of the module, we introduced some
important definitions and concepts in measuring and controlling quality.
Throughout this module we revisited a recurring theme in this SCQM unit, the
influence of variation, on this occasion, as it relates to measuring and controlling
quality in the supply chain. We identified that control charts can offer a great
deal of knowledge to help measure and control variation in supply chain
processes.
In the final part of the module, we turned our focus to strategies that can provide
more detailed measurement and analysis of data to help improve process
quality, such as the study of process capabilities and indexes.
Lastly, we used a case study to integrate the knowledge gained throughout the
module and to promote the use of a customised process capability study as a
way of focussing process design, measurement, control and to achieving the
quality performance goals of organisations.
Lesson 9 of 9
References
Evans, James R. , and William M. Lindsay. 2017. Managing for Quality and
Performance 10th ed, Managing for Quality and Performance Excellence.
Boston, Massachusetts: Cengage Learning.
Joyner, Helen. 2014. Process Capability Index Lecture. YouTube Video. 11:16.
https://www.youtube.com/watch?v=RXsvGe-6dYw
McNeese,Bill. 2016. "Control Chart Rules and Interpretation". 2016. SPC for Excel
https://www.spcforexcel.com/knowledge/control-chart-basics/control-chart-
rules-interpretation
Pyzdek, Thomas author. 2014. Six Sigma Handbook : A Complete Guide for Green
Belts, Black Belts, and Managers at All Levels / by Thomas Pyzdek and Paul Keller.
Edited by Paul A. author Keller. 4th ed.. ed. Chicago, Ill.: Chicago, Ill. : McGraw-Hill
Education LLC.
Srivastava, Samir K. 2008. "Towards Estimating Cost of Quality in Supply
Chains." Total Quality Management & Business Excellence 19 (3): 193-208.
doi: 10.1080/14783360701600605.
Yee, T. M., S. Ahmed, and M. A. Quader. 2014. "Process Behaviour and Capability
Analysis for Improvement of Product Quality in Car-Door Glass Manufacturing"
5th Brunei International Conference on Engineering and Technology (BICET
2014), doi: 10.1049/cp.2014.1059.