Assured Quality - Our Approach

Our Approach

Between 1910 and 1920 variation was identified as a key source of product defects. By the 1960´s, when Shigeo Shingo developed the concepts of mistake–proofing known as poka–yoke, it is likely variation related defects had been reduced through statistical process control to the point that mistakes were already a significant fraction of production defects. Dr. Hinckley´s work in the 1990´s was the first to quantify the relationship between product complexities and defect rates. This research also demonstrated for the first time that variation, mistakes, and complexity were different sources of nonconformities requiring distinctly different control methods.

Assured Quality has also shown that the most efficient and effective way to eliminate defects is the reverse of the order of discovery: first reduce complexity, then mistake-proof, and finally implement control of variation with settings rather than adjustments. This process is applied first to the product use, then to the assembly and fabrication, and finally to the tools and equipment.

At every stage, we follow a simple six step process derived from Toyota as shown here. Since improving quality is an opportunity rich environment, in the first step, the highest priority problems are identified and selected. After analyzing the problem, multiple solutions are always generated. This step is the key to finding less complex products and processes that provide more sophisticated results. The alternative concepts are then compared and the best option is selected. After implementation, the solution is evaluated. If effective, the use of the concept is standardized throughout the organization.