Keeping You Safe Since 1970

1-888-326-9244

Favorites

Contact

Graphic Products
  • My Account
    No Account? Sign up
    Forgot password?
  • Cart ()
  • Printers & Supplies Printers
    Toro Max

    Toro Max

    NEW! portable all-in-one
    • Learn More
    • Toro Max Supplies
    Bronco Max

    Bronco Max

    NEW! reliable workhorse
    • Learn More
    • Bronco Max Supplies
    DuraLabel Kodiak

    DuraLabel Kodiak

    Multi-color, large format
    • Learn More
    • Kodiak Supplies
    DuraLabel Lobo

    DuraLabel Lobo

    Grab n' go labeler
    • Learn More
    • Lobo Supplies
    DuraLabel Toro

    DURALABEL TORO

    Mobile, stand-alone
    • Support
    • Toro Supplies
    DuraLabel Bronco

    DuraLabel Bronco

    Industrial, efficient
    • Support
    • Bronco Supplies
    DuraLabel Pro Series

    DuraLabel PRO 300

    Simple and reliable
    • Learn More
    • Pro Series Supplies
    Legacy Printers

    Legacy Printers

    Support and Supplies
    • Learn More
    • Shop All Supplies

    Quick Links

    All Printers

    Printer Kits

    Printer Supplies

    Printer Ribbons

    Accessories

    Printer Support

    Labeling Software

  • Safety Signs

    Compliance Signs

    • Chemical Signage
    • Confined Space Signs
    • Electrical Hazard Signs
    • Fire Signage
    • PPE Safety Signs
    • All Compliance Signs

    Facility Signs

    • Restricted Area Signs
    • Smoking Signs
    • Machinery Signs
    • Bathroom Signs
    • Clearance Signs
    • All Facility Signs

    Traffic Signs

    • Directional Signs
    • Exit Signs
    • Forklift Signs
    • Emergency Signs
    • All Traffic Signs

    Floor Signs

    • Blank Floor Signs
    • Exit Floor Signs
    • Fire Safety Floor Signs
    • First Aid Floor Signs
    • LOTO Floor Signs
    • All Floor Signs

    Related Resources

    PDF Icon EHS Manager's Guide
    PDF Icon OSHA Safety Signs Guide
    PDF Icon Labeling Your Facility for Safety
    PDF Icon Safety Labels vs. Signs
    SEE MORE
    Signs and Labels Banner
  • Floor Marking

    Floor Tape

    • 5S Floor Tape
    • Aisle Tape
    • Glow in the Dark Tape
    • Reflective Tape
    • Anti-Slip Tape
    • All Floor Tape

    Floor Signs

    • Blank Floor Signs
    • Exit Floor Signs
    • Fire Safety Floor Signs
    • First Aid Floor Signs
    • LOTO Floor Signs
    • All Floor Signs

    Floor Marking Shapes

    • Floor Marking Corners
    • Floor Marking T's
    • Floor Marking Footprints
    • Floor Marking Circles
    • Floor Marking Arrows
    • All Floor Marking Shapes

    Other

    • Discount Bundles
    • Floor Marking Accessories
    • Floor Laminate

    Lumen Projectors

    • Lumen Sign Projector
    • Lumen Line Projector
    • Lumen Accessories

    Related Resources

    PDF Icon Floor Marking Best Practices
    PDF Icon Floor Marking Color Chart
    PDF Icon What is Floor Marking?
    PDF Icon Floor Tape vs. Paint
    SEE MORE
    Floor Marking Banner
  • Pipe Markers

    Shop By Standard

    • ANSI A13.1 Pipe Markers
    • Ammonia (IIAR) Pipe Markers
    • Medical (NFPA 99) Pipe Markers
    • Marine (ISO 14726) Pipe Markers
    • European Pipe Markers
    • All Pipe Markers

    ANSI Pipe Markers

    • Fire Quenching
    • Flammable/Oxidizing
    • Toxic or Corrosive
    • Compressed Air
    • Various Water
    • All ANSI Pipe Markers

    Other

    • Pipe Marking Accessories
    • Valve Tags
    • Arrow Banding Tape

    Related Resources

    PDF Icon Pipe Marking Best Practices
    PDF Icon Facility Pipe Marking Guide
    PDF Icon Pipe Marking Basics
    PDF Icon Getting Started with Pipe Marking
    SEE MORE
    Pipe Marking Banner
  • COVID-19

    COVID-19 Solutions

    • Safety Signs
    • Printer Kits
    • Awareness Posters
    • A-Frame Signs
    • Sneeze Guards
    • All COVID-19 Solutions

    Social Distancing

    • Social Distancing Signs
    • Social Distancing Floor Signs
    • Social Distancing Floor Tape
    • All Social Distancing

    COVID-19 By Industry

    • Grocery & Retail
    • Medical & Healthcare
    • Office Settings
    • Restaurants & Food Service
    • Food Manufacturing
    • Construction
    • Manufacturing
    • Finance
    • Transportation
    • Education

    Related Resources

    Video Icon COVID-19 Safety At Work Webinar
    PDF Icon Social Distancing Reference Chart
    SEE MORE
    COVID Banner
  • Resources
  • Help
  • Free Samples
  • Quick Order
    Enter item SKU# and quantity
Graphic Products
  • My Account
  • Printers & Supplies
  • Safety Signs
  • Floor Tape
  • Pipe Markers
  • COVID-19
  • Resources
  • Help
  • Free Samples
  • Quick Order
  • Favorites
  • Contact Us
  • Back
  • MY ACCOUNT
  • Account
  • Orders
  • Track My Order
  • Addresses
  • Login & Security
  • Payment Methods
  • Carrier Accounts
  • Favorites Lists
  • Sign Out
  • Back
  • SIGN IN
  • No Account? Sign up
    Forgot password?
  • Back
  • Quick Order
Enter item SKU# and quantity
  • Back
  • Printers & Supplies
  • DuraLabel Toro Max
  • DuraLabel Bronco Max
  • DuraLabel Toro
  • DuraLabel Bronco
  • DuraLabel Kodiak
  • DuraLabel Lobo
  • DuraLabel PRO 300
  • Shop All Printers
  • Shop All Supplies
  • Shop All Ribbons
  • Labeling Software
  • Back
  • DuraLabel Toro Max
  • Toro Max Printer
  • Toro Max Supplies
  • Toro Max Ribbon
  • Toro Max Accessories
  • Toro Max Bundles and Kits
  • Toro Max Support
  • Shop All Printers
  • Shop All Supplies
  • Shop All Ribbons
  • Labeling Software
  • Back
  • DuraLabel Bronco Max
  • Bronco Max Printer
  • Bronco Max Supplies
  • Bronco Max Ribbon
  • Bronco Max Accessories
  • Shop All Printers
  • Shop All Supplies
  • Shop All Ribbons
  • Labeling Software
  • Back
  • DuraLabel Toro
  • Toro Supplies
  • Toro Ribbon
  • Toro Accessories
  • Toro Support
  • Shop All Printers
  • Shop All Supplies
  • Shop All Ribbons
  • Labeling Software
  • Back
  • DuraLabel Bronco
  • Bronco Supplies
  • Bronco Ribbon
  • Bronco Accessories
  • Bronco Support
  • Shop All Printers
  • Shop All Supplies
  • Shop All Ribbons
  • Labeling Software
  • Back
  • DuraLabel Kodiak
  • Kodiak Printer
  • Kodiak Supplies
  • Kodiak Ribbon
  • Kodiak Accessories
  • Kodiak Bundles and Kits
  • Kodiak Support
  • Shop All Printers
  • Shop All Supplies
  • Shop All Ribbons
  • Labeling Software
  • Back
  • DuraLabel Lobo
  • Lobo Printer
  • Lobo Supplies
  • Lobo Ribbon
  • Lobo Accessories
  • Lobo Support
  • Shop All Printers
  • Shop All Supplies
  • Shop All Ribbons
  • Labeling Software
  • Back
  • DuraLabel PRO 300
  • DLP 300 Printer
  • DLP 300 Supplies
  • DLP 300 Ribbon
  • DLP 300 Accessories
  • DLP 300 Bundles and Kits
  • DLP 300 Support
  • Shop All Printers
  • Shop All Supplies
  • Shop All Ribbons
  • Labeling Software
  • Back
  • Safety Signs
  • Compliance Signs
  • Facility Signs
  • Traffic Signs
  • Floor Signs
  • Shop All Safety Signs
  • Back
  • Compliance Signs
  • Chemical Signage
  • Confined Space Signs
  • Electrical Hazard Signs
  • Fire Signage
  • PPE Safety Signs
  • All Compliance Signs
  • Back
  • Facility Signs
  • Restricted Area Signs
  • Smoking Signs
  • Machinery Signs
  • Bathroom Signs
  • All Facility Signs
  • Back
  • Traffic Signs
  • Directional Signs
  • Exit Signs
  • Emergency Signs
  • Forklift Signs
  • All Traffic Signs
  • Back
  • Floor Signs
  • Blank Floor Signs
  • Exit Floor Signs
  • Fire Safety Floor Signs
  • First Aid Floor Signs
  • LOTO Floor Signs
  • All Floor Signs
  • Back
  • Floor Tape
  • General Floor Tape
  • Floor Signs
  • Floor Marking Shapes
  • Other
  • Shop All Floor Tape
  • Back
  • Floor Tape
  • 5S Floor Tape
  • Aisle Tape
  • Glow in the Dark Tape
  • Reflective Tape
  • Anti-Slip Tape
  • All Floor Tape
  • Back
  • Floor Signs
  • Blank Floor Signs
  • Exit Floor Signs
  • Fire Safety Floor Signs
  • First Aid Floor Signs
  • LOTO Floor Signs
  • All Floor Signs
  • All Floor Signs
  • Back
  • Floor Marking Shapes
  • Floor Marking Corners
  • Floor Marking T's
  • Floor Marking Footprints
  • Floor Marking Circles
  • Floor Marking Arrows
  • All Floor Marking Shapes
  • Back
  • Other
  • Discount Bundles
  • Floor Marking Accessories
  • Floor Laminate
  • Lumen Projectors
  • Back
  • Pipe Markers
  • Shop By Standard
  • ANSI Pipe Markers
  • Other
  • Shop All Pipe Markers
  • Back
  • Shop By Standard
  • Standard (ANSI A13.1) Pipe Markers
  • Ammonia (IIAR) Pipe Markers
  • Medical (NFPA 99) Pipe Markers
  • Marine (ISO 14726) Pipe Markers
  • European Pipe Markers
  • All Pipe Markers
  • Back
  • ANSI Pipe Markers
  • Fire Quenching
  • Flammable/Oxidizing
  • Toxic or Corrosive
  • Compressed Air
  • Various Water
  • All ANSI Pipe Markers
  • Back
  • Other
  • Pipe Marking Accessories
  • Valve Tags
  • Arrow Banding Tape
  • Back
  • COVID-19
  • COVID-19 Solutions
  • Social Distancing
  • COVID-19 By Industry
  • Shop All COVID-19 Solutions
  • Back
  • COVID-19 Solutions
  • Safety Signs
  • Printer Kits
  • Awareness Posters
  • A-Frame Signs
  • Sneeze Guards
  • All COVID-19 Solutions
  • Back
  • Social Distancing
  • Social Distancing Signs
  • Social Distancing Floor Signs
  • Social Distancing Floor Tape
  • All Social Distancing
  • Back
  • COVID-19 By Industry
  • Grocery & Retail
  • Medical & Healthcare
  • Office Settings
  • Restaurants & Food Service
  • Food Manufacturing
  • Construction
  • Manufacturing
  • Finance
  • Transportation
  • Education
  • Home
  • Resources
  • Articles
  • Quality Circles

Quality Circles

BY GRAPHIC PRODUCTS STAFF

minute read

The quality circle originated in Japan in the early 1960's. The objective was to give the responsibility for identification and resolution of quality problems to those working on the factory floor. This was in line with the basic philosophy of the Toyota Production System (TPS), that problem solving should take place on the shop floor where the work is done.

What is a Quality Circle?

A quality circle is a small group of employees who have volunteered to meet periodically to discuss quality problems. The groups usually consist of three to twelve individuals. Meetings typically last about an hour and are held during paid time, at least once a month but usually once a week. The exact timing and duration of meetings varies, depending on the type of problems being addressed.

The members of a quality circle typically come from the same department or work area, and the quality circle is led by their supervisor. However, successful quality circles often include some members from outside the area being targeted for improvement.

The person appointed to lead the quality circle runs the meetings in an orderly manner. Minutes are taken to document the discussions, creating a record of the problems identified and the solutions proposed. These notes provide the basis for proposals to be submitted to management.

Because most members of a quality circle come from the work area being examined, many changes can be implemented immediately. The underlying idea is to use the principles of Kaizen to generate a continuous stream of suggestions for small improvements that can be quickly applied.

Keys to Success: Training and Support

The goal of the quality circle is to identify quality problems and create solutions to those problems. To meet that goal, the members of the quality circle need training in a specific set of skills.

The training of circle/Kaizen leaders and members is the foundation of all successful programmes. The whole basis of the training operation is that the ideas must be easy to take in and be put across in a way that facilitates understanding. Simplicity must be the key word, with emphasis being given to the basic techniques. Essentially there are eight segments of training:

1. Introduction to quality circles
2. Brainstorming
3. Data gathering and histograms
4. Cause and effect analysis
5. Pareto analysis
6. Sampling and stratification
7. Control charts
8. Presentation techniques

This quote from Total Quality Management: Text with Cases, by John S. Oakland, mentions “circle/Kaizen.” Successful quality circles incorporate the principles of Kaizen as the basis for identifying and solving quality problems. This means that Quality Circle members must be thoroughly familiar with Kaizen and how to use Kaizen in the workplace.

In addition to training, the other key factor for success is management support. In some cases someone from management is assigned to be a part of the Quality Circle. However, this usually results in the manager dominating the quality circle meetings, when what is needed is input from the people actually doing the work. What is required from management is:

  • Take quick action on quality circle recommendations.
  • Provide an adequate budget for the quality circle.
  • Support the training of members of the quality circle.
  • Provide authorization to get assistance from other departments.
  • Facilitate communication between quality circles in different departments.
  • Pick significant projects with measurable goals.
Although the quality circle concept has gained considerable momentum in the United States, many organizations are finding that quality circles are not the panacea most people believed they would be. Quality circles offer a number of advantages, but they also have certain limitations. The problems most frequently encountered include a tendency for the quality circle concept to fade away if not nurtured in adequate training, nonparticipation, inadequate technical expertise for the problems taken on by the quality circle, and a lack of focus.

It is the job of management to “nurture” Quality Circles, and provide the resources, training, and support quality circle members need.

Quality Circle Training Topics

Let's take a closer look at the areas that need to be targeted for training.

What is Brainstorming?

Brainstorming is a technique used to generate ideas, allowing for free input even when that input is impractical or unorthodox. The goal is to generate ideas, without filtering, criticizing, or limiting those ideas in any way. After the ideas have been shared, they can be discussed and modified for eventual use.

Brainstorming may be done in a number of ways. For example, members of the Quality Circle may explain their ideas as they occur to them, speaking out as they have a thought. Brainstorming may be more structured, with the Quality Circle leader calling on each team member in turn, soliciting their ideas. The process can be used to identify possible causes of a problem. It is also used to develop suggestions for solutions to that problem. Whenever ideas are needed, brainstorming is a technique that can be used to generate those ideas.

Kaizen Best Practices Guide
A free guide to reducing costs and increasing productivity.

What are Data Gathering and Histograms?

In order to analyze a problem, data is needed. The more relevant information is available, the better the opportunity to come up with a good solution. Since members of a quality circle are the people doing the work, in many cases they can collect the needed data. However, collecting valid data requires familiarity with sampling techniques so that the data stays relevant and accurate. Data gathering is its own field of study.

A histogram, one central element of data gathering, is a graph showing the distribution of data. This visually presents the number of data points that fall within different ranges of values. For example, one quality circle is measuring the length of a product; the desired length is 15 inches, and the data collected for an 8-hour day of production shows that the system is producing an average length of 15 inches. But customers are complaining about quality. What is the problem? A histogram could show that, while the average output is correct, a large number of units are being measured at 13 and 17 inches — well out of specification.

What is a Cause-and-Effect Analysis?

Cause-and-Effect Analysis is a technique used to identify all the possible causes of a certain effect, not just the most obvious causes. The process creates a diagram, often called a fishbone diagram or an Ishikawa diagram, to visualize the connections and causes that are discussed. they begin with identifying the problem. The problem is written on the left side of a sheet of paper, and a horizontal line is drawn leading from that definition across the page. Possible causes of the problem are brainstormed and drawn as smaller lines connected to the horizontal line, creating a fishbone pattern. Contributing causes can then be added to each individual cause in the same way. This may be done several times, creating a final diagram three or four layers deep.

After the initial diagram is created, each cause can be investigated and analyzed. The result is that the quality circle can identify which cause or causes are actually contributing to the problem, so that those causes can be addressed.

What is Pareto Analysis?

Pareto analysis is a technique that helps to organize thoughts and ideas. It is used to identify the important problems and separate them from the trivial problems. Based on the “Pareto Principle” — the idea that 80% of the results are produced by 20% of the effort — the objective of Pareto analysis is to identify the few problems that, when resolved, result in most of the possible improvement.

Pareto analysis involves identifying problems and rating them based on the severity of their impact. Then the root cause of each problem is identified. The problems are grouped together based on their root cause, and the ratings for the problems in each group are totaled. The root cause with the highest total rating is the top priority.

The completed analysis is often presented using a bar graph with each column representing a root cause. The columns are arranged from the tallest to the shortest, making it easy to see the priority for addressing the root causes.

What is Sampling and Stratification?

At times it may be difficult to identify the cause of a problem, in particular if there are many possible contributing factors. In those cases it can be useful to use stratified sampling. Instead of measuring the total output of the process as a whole, samples (or measurements) are made at each step along the way. In effect, the quality circle is separating the problem into layers, and examining each layer separately.

For example, a product goes through five manufacturing operations in the course of its production, and the end result is not meeting quality specifications. Each of the five manufacturing operations can be examined separately. It may turn out that a small error in an early step of manufacturing the product is causing significant problems further down the line.

What is a Control Chart?

A control chart is a set of graphs that record the quality of a product or service. One line marks the average output of the process, and two additional lines mark the upper and lower control limits. When the process produces falls outside those boundaries, or meets certain other criteria that indicate inconsistency, then there is a problem that needs to be addressed. Often, one graph will show average measurements of a product, and a second graph will show the spread of those measurements within a test set.

Why are Presentation Techniques (Communication Skills) Important?

Communication skills are important. The quality circle may identify problems, and come up with excellent solutions, but if they cannot effectively communicate with those who approve budgets (management) and authorize changes to equipment and processes (engineering department), even the best plans are only wasted effort. The quality circle must be able to effectively communicate their findings and recommendations.

Looking at Labels and Signs

Labels and signs can be a forgotten aspect of quality. When they are properly used, they effectively deliver important information where and when it is most needed. But missing labels and signs may not be noticed, resulting in problems that can be difficult to diagnose. For example, when Joe is on vacation the defect rate goes up. Why? Because Joe knows to lubricate the machine every three hours. But the label reminding the machine operator about the lubrication times is missing, and the fill-in operator is not aware that there is a problem at all. Conducting an annual inspection to look for faded, damaged, peeling, or missing labels and signs should be a part of the normal maintenance routine.

To ensure labels and signs are long-lasting, a DuraLabel printer should be a part of every maintenance shop. With DuraLabel you get quality that can't be beat, and warranties that back up those claims. Call us today for more information about DuraLabel custom label printers and tough-tested supplies.

Leverage Quality Circles for Continuous Improvements

Utilizing the TPS, Kaizen, Lean and other organizational frameworks can help boost efficiency, productivity, morale, as well as reduce accidents. Get your copy of our free Kaizen Best Practice Guide below!

Kaizen Best Practices Guide
A free guide to reducing costs and increasing productivity.

Related Resources

What Is 5S?

What is 5S?

Get a breakdown of each step in the 5S system, a versatile approach to improve workplace efficiency.

Read
What Is Kaizen?

What is Kaizen?

Understand how the lean tool Kaizen works to reduce waste and eliminate overly difficult work processes

Read
Using Lean Kaizen Theory in Manufacturing

Lean Kaizen Theory in Manufacturing

See how Kaizen Theory is beneficial in a manufacturing environment by encouraging employee suggestions for improvements.

Read
  • A free guide to reducing costs and increasing productivity.
Get the latest deals straight to your inbox
Trusted by These Companies
Starbucks
GM
Du Pont
Amazon
Disney
3M
Pepsi
NASA
Chevron
AT&T
Toyota
Coca-Cola
UPS
Target
  • Graphic Products, Inc.
    9825 SW Sunshine Ct
    Beaverton, OR
    97005 USA

  • Business Hours:
    Monday - Friday
    5:30am - 5pm Pacific

  • 1-888-326-9244 (U.S./Canada)
  • +1-503-644-5572 (International)
  • Products
  • Printers
  • Printer Supplies
  • Safety Signs
  • Safety Labels
  • Floor Marking
  • Pipe Markers & Tags
  • Support
  • Shipping & Returns
  • Manage Account
  • Printer Support
  • Warranties
  • Content Usage Guidelines
  • Resources
  • Resource Center
  • Guides
  • Articles
  • Video Library
  • Safety Blog
  • Infographics
  • Webinars
  • Company
  • About Us
  • Careers
  • Become a Dealer
  • Find a Dealer
  • Press Room

Need Help?

Give us a call at 1-888-326-9244 and speak with an expert.

Customer Reviews
  • Copyright © 2023
  • All Rights Reserved
  • Terms and Conditions
  • Shipping and Returns
  • Privacy Policy
  • Do Not Sell My Personal Data