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Continuous Quality Improvement Dashboards in Manufacturing—What's the Big Deal?


The whole Performance Improvement or Continuous Quality Management dashboard space has been gaining significant traction lately as more and more organizations are recognizing the need to monitor their business performance and proactively make strategic and tactical decisions rather than becoming reactive to situations.

The mantra for quality improvement can be categorized into one simple statement: predictable quality at a predictable cost. With so many dashboards available today, what's the big deal? All reporting platforms provide us with the needed information to "predict quality." Pick one and you're good to go…right? Not so fast…

Dashboards include images to help us easily understand our "current reality." These images include stop lights, gauges, etc. and generally report on "averages." Are we performing well against our internal and/or external benchmarks? Continuous quality improvement (CQI) is an approach to quality management that builds upon traditional quality assurance methods by focusing on the "process" and the type of variation that exists within the process. The primary threat to our business survival comes not from events (budget cuts, new hires, downsizing, credentialing, internal/external requirements, etc.) but from slow gradual processes to which we are 90 percent blind. Inadvertently, we often times perpetuate this gradual decline by utilizing a wrong approach for the desired result. I think we all would agree that one would not use a screwdriver to pound nails! Why then, do we permit the use of Excel, report writers or other like "tools" to help us understand a "process?" The answer may be in our lack of understanding of CQI.

A process is a series of actions or operations conducting to an end. Every process contains some degree of variation. For example, when I sign my name, the resulting output is never exactly the same as the one before or the one after. Explanations for these variations include being in a hurry, feeling fatigued, the quality of the writing instrument, etc. We call this "common cause variation." The bank will still cash my check with a signature that shows common cause variation. If only common causes of variation are present, the output of a process forms a distribution that is stable over time. Now let's say I fall off my skateboard (yes, I can shred with the best of 'em!) and break my writing hand and am in a cast. The cast doesn't allow me to grip a pen correctly and therefore, I sign my name with my non-writing hand. The variation in this signature is called "special cause variation", as it is created by a non-random event leading to an unexpected change in the process output. The process output is not stable over time and is not predictable. The bank probably holds my checks until it ascertains why my signature has changed so drastically (or at least I hope they do!).

OK. So we have common cause and special cause variation. We expect common cause but not special cause. How do we tell the difference? This is where CQI technology comes to your rescue.
Let's use an example of HF Composite Scores. The Composite Score is the sum of the numerators for each HF measure divided by the sum of the denominators for each measure times 100. First, let's look at the HF Composite Score for an 18 month period through a bar chart.


Figure 1. Bar Chart of HF Composite Scores

The height of each bar represents the percentage by month of the HF Composite Score. As shown, we can see a low month of June 06 and a high a year later in June 07. We can make some inferences of the process with the early months showing a gradual decline and then a "general" increase from June 06. What we don't see is the volume for each month, an explanation as to why we began an improvement in the process or which months exhibited common cause variation and which showed special cause variation. Now, contrast this same data with a P chart and add corrective action and begin a new "phase."


Figure 2. P Chart of HF Composite Scores

Through the use of the P chart and CQI technology, we now see additional information including sigma limits, a corrective action plan and a vertical line dividing the pre- and post-corrective action plan process metrics. We also see "red" data points. The red data points indicate special cause variation. These data points violated established Statistical Process Control Rule sets such as:

  • Western Electric / AT&T Rules
  • Ford Rules
  • Nelson Rules

We can determine how stable and predictable our process is through the use of CQI techniques, providing us with opportunities to intervene where necessary. We also can initiate a new process based on a corrective action and determine if the desired results or outcomes are taking place.

Next time you hear, "all dashboards are created equal," respond with "your thinking processes are broken!" Stop lights, targets and scorecards are very important to your understanding of what is taking place in your organization. Yet, if the dashboard does not include CQI techniques, your processes may be exhibiting special cause variation without your awareness. Your report is merely "average."

Focused organizations are providing their leadership with continuous feedback on critical organizational metrics. Move away from simply generating reports to supporting analyses for informed decision making.

Statit Software has more than 25 years of experience in helping our customers recognize the difference between common and special cause variation and then to make corrections to improve the process. Shouldn't you be practicing predictable quality at a predictable cost? Your customers will be glad you are!

Statit Software is here to help. If you would like to learn more about this functionality, give us a call at (541) 752-4500 or send us an email at info@statit.com. We will show you how easy it is to create these reports while we are on the phone together.

If you would like additional information, please call our Sales staff at (541) 752-4500 or send email to .