Documente Academic
Documente Profesional
Documente Cultură
Equipes de Melhoria
Contínua
Círculos de Controle da Qualidade
Gerisval Alves Pessoa
São Luís
Julho de 2008
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______________________________________________________________________________ Gerisval Alves Pessoa
Micro GAP – C:\CCQ\Curso CCQ.doc Revisão: 02 – 01/04/08
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SUMÁRIO
INTRODUÇÃO 3
OBJETIVO
4
PROGRAMA DO CURSO
4
TRANSPARÊNCIAS DO CURSO 5
EXERCÍCIOS
51
TEXTOS SELECIONADOS
63
REFERÊNCIAS
66
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INTRODUÇÃO
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OBJETIVO
PROGRAMA
*0 Conceitos de CCQ
*1 Objetivo do CCQ
*2 Como surgiram o CCQ
*3 CCQ x GQT
*4 Dificuldades de condução do CCQ
*5 Fundamentos do CCQ
*6 Estudo da motivação
*7 Práticas e desenvolvimento do CCQ
*8 Conceito de problema
*9 Conceito do ciclo PDCA
*10 Conceitos e utilização das ferramentas básicas do CCQ
*11 Aplicação das Ferramentas básicas do CCQ:
- Brainstorming
- Matriz de priorização
- Folha de verificação
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- Gráfico sequêncial
- Estratificação
- Diagrama de Causa e Efeito
- Tabela de descartes
- Teste de hipóteses
- Método dos "por quês"
- Plano de Ação - 5W2H
CONCEITO:
OBJETIVO:
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HISTÓRICO DO CCQ
50 60 70 80 90
50 GQT
62 CCQ
71 CCQ
83 GQT
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CCQ x GQT
GQT - É o compromisso
da empresa com a
qualidade e o seu sistema
gerencial, voltado para
satisfação de todos os
envolvidos.
CCQ’s - São importantes
espaços de atuação
para que os empregados
possam participar com
determinação de todo o GQT CCQ’s
processo.
COMPLEMENTARES
INTERDEPENDENTES
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FUNDAMENTOS DO CCQ
Extravazar capacidade Contribuir para o desenvolvimento
criadora: da Empresa:
• Autodesenvolvimento • Participar dos processos decisórios
• Auto-realização • Aplicar talento
• Estima
PRINCÍPIOS BÁSICOS:
• Autodesenvolvimento;
• Prazer em trabalhar;
• Participação;
• Aplicação de técnicas de controle de qualidade;
• Fortalecer atividades dos círculos;
BENEFICIÁRIOS:
• Desenvolvimento mútuo;
• Empregados;
• Usar criatividade;
• Grupo;
• Consciência;
• Empresa;
• Voluntariedade.
• Sociedade.
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MOTIVAÇÃO x INSATISFAÇÃO
Máxima motivação
Área de motivação
(presença de fatores de
motivação)
Área de insatisfação
(presença de fatores de
higiene)
Máxima insatisfação
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SATISFAÇÃO x MOTIVAÇÃO
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DIAGRAMA DE HERSEY
A COMPORTAMENTO D
O
COMPORTAMENTO P
GRAU DE G
E
DIFICULDADE R
S
U
ATITUDE P S
P
E O
O
S A
S L
HABILIDADE O
A
L
CONHECIMENTO
A
TEMPO
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EMPREGADOS EMPRESAS
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ESTRUTURA DE UM
GRUPO DE CCQ
FUNÇÃO PAPEL
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FREQUÊNCIA E DURAÇÃO
DAS REUNIÕES
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Divulga ___
e Arquiva
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PAPEL DO GERENTE
☞ Incentivar
☞ Respeitar a voluntariedade
☞ Aprovar o problema / trabalho
☞ Aprovar as propostas de solução
☞ Cuidar da padronização
☞ Reconhecer os grupos
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FLUXOGRAMA DE FUNCIONAMENTO
DOS GRUPOS DE CCQ
GERENTE COORDENAÇÃO EMPREGADO GRUPO DE CCQ
INCENTIVA ADERE
SOLICITA
DEFINE NOME E LOGOTIPO
REGISTRO
REGISTRA E
EMITE IDENTIFICA PROBLEMAS
CERTIFICADO
ENTREGA
CLASSIFICA OS PROBLEMAS
CERTIFICADO
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Multifuncional
Atuação Funcional
ou Funcional
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DIRETRIZES CCQ
GERENTE EXECUTANTE
PDC A
GERENCIAMENTO DA ROTINA
5S
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PROBLEMA
CONCEITO:
É O RESULTADO
● INDESEJADO DE UM
PROCESSO
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COMO DESCREVER UM
PROBLEMA / TRABALHO
A redação dos títulos de problemas e trabalhos dos CCQs poderá
ser realizada da seguinte forma:
PROBLEMA: EFEITO OBJETO LOCAL
EXEMPLO:
“Excesso de manutenção corretiva nas locomotivas série 900”
“Tempo elevado para montagem e desmontagem de truques de
três peças”
TRABALHO: AÇÃO OBJETO LOCAL
EXEMPLO:
“Redução de manutenção corretiva nas locomotivas série
900”
“Dispositivo para montagem e desmontagem de truques
de três peças”
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TIPOS DE ASSUNTOS
QUE INTERESSAM AO CCQ
FASE TIPO DE ÁREAS DE ABRANGÊNCIA
PROBLEMA INVESTIGAÇÃO
Problema simples e de Limpeza, registro, fluxo de informa- Locais de
relevância para os ções, desperdício, manuseio mate - Trabalho
01
grupos riais, ferramentas, máquinas, causas
de desconforto e insegurança
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ROTEIRO RESUMO DE UM
TRABALHO DE CCQ
Etapa Fase Ferram enta / Recurso sugeridos
1- a)Levantam ento de Brainstorm ing
Identificação problem as
do problem a
b) Escolha do Problem a Matriz de priorização (parâm etros
definidos) G ráficos, pesquisas,
votação, etc...
c) Mostrar a im portância de reunião
estudar o problem a (razão da
escolha)
d) Buscar aprovação do reunião
gerente
2 - a) Planejam ento da Brainstorm ing (quais inform ações)
O bservação observação.
do Problem a
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ROTEIRO RESUMO DE UM
TRABALHO DE CCQ
E tap a F ase F erram en ta / R ecu rso su g erid o s
3- A nális e do a) Levantar hipóteses de B rains torm ing (porquê), D iagram a
P roblem a c au sas de c aus a e efeito.
b) S ele c ionar as hipótes es de D iagram a de c au s a e efeito; D ados
c au sas m ais prováveis e fatos obtidos na fas e de
obs erva ç ão (para identific ar quais
hipótes es de c aus as s ão m ais
s ignific ativas ); E xperiênc ia do g rupo
c) B us c ar as c au s as U tiliza ç ão dos porquês
fundam entais do problem a
D iagram a de c aus a e efeito
d) R eflexão s obre a cau s a reun ião, anális e de relatórios,
fundam ental pes quis as
4- P lano de a) P ropor e s elec ionar B rains torm ing (co m o); A nális e de
A ção s oluç ões via bilidade da s oluç ão, votaç ão,
s im ulaç ão, fluxogram a do novo
proc es s o .
b) E labo rar o P lano d e A ção 5W 2H
c ) R ever c ronogram a inic ial e c ronogram a; relatório de c u s to
orç ar
d) O bter apoio gere ncial reun ião
5- Aç ão a) T reinar pes s oal que vai reun ião e treinam ento no loc al de
im plem enta r as aç ões (s e trabalho, etc ...
não previs to no plano de
aç ã o)
b) Im plantar pla no de aç ã o
c ) A c om p anhar im plantaç ão, relatórios , gráfic os , etc ...
efetua ndo os ajus tes
nec es s ários
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ROTEIRO RESUMO DE UM
TRABALHO DE CCQ
Eta p a Fa s e Fe rra m e n t a / R e c u rs o s u g e rid o s
6- Verificação a Verificar atingim ento das gráficos, relatórios, m edições,
m etas pesquisas, etc...
b) Identificar os benefícios
tangíveis e intangíveis
c) Identificar o aparecim ento
de efeitos colaterais
7- Padronizar a)Elaborar a proposta para
e Estabelecer criação de procedim entos
Controle padrões ou rever se for o
caso
b) Elaborar proposta de
m anual de treinam ento ou
rever se for o caso
c) Elaborar proposta do plano
de controle ou rever se for o
caso
8) Conclusão a) Refletir sobre as atividades gráfico radar; reuniões; plano de
do grupo considerando os ação para m elhorar os itens com
objetivos do CCQ m aior potencial de desenvolvim ento
b) Consolidar o aprendizado
do grupo de CCQ (lição que
ficou)
c) O rganizar e concluir o
relatório final
d) Elaborar planos para o
futuro
e) Apresentar o trabalho reuniões, sem inários, convenções.
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BRAINSTORMING
CONCEITO:
É uma técnica que visa desinibir os
participantes da reunião para que dêem o
maior número possível de idéias,
encorajando o pensamento criativo de todos.
UTILIZAÇÃO:
Utilizado para o levantamento de idéias
relacionadas a um determinado assunto ou
objetivo, como escolha de tema para
trabalho de CCQ, prováveis causas,
soluções de um problema etc.
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MATRIZ DE PRIORIZAÇÃO
CONCEITO:
É uma matriz especialmente construída para ordenar uma lista de
itens. É uma ferramenta para tomadas de decisões, já que
estabelece a priorização, que pode ou não ser baseada em critérios
com pesos definidos (Ex.: 5, 3 e 1).
UTILIZAÇÃO:
A matriz deve ser usada quando:
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MATRIZ DE PRIORIZAÇÃO
Modelo conceitual
PROBLEMAS
1.
2.
3.
4.
5.
6.
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FOLHA DE VERIFICAÇÃO
CONCEITO:
É a ferramenta da qualidade utilizada para facilitar e
organizar o processo de coleta e registro de dados, de
forma a contribuir para otimizar a posterior análise dos
dados obtidos.
UTILIZAÇÃO E ELABORAÇÃO:
• Defina o objetivo da coleta de dados.
• Inclua campos para a identificação da(s) pessoa(s)
responsável(eis) pelo preenchimento da folha de verificação (quem).
• Inclua campos para o registro da origem dos dados (turno, data de
coleta, turma, período da coleta, etc...).
• Instrua a todas as pessoas envolvidas na coleta de dados sobre a
forma de preenchimento da folha de verificação, e exatamente o
que, onde, quando e como será medido.
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FOLHA DE VERIFICAÇÃO
Modelo conceitual
PROBLEMA: Queima excessiva de lâmpadas
RESPONSÁVEL: Zé Coleta
LOCAL S T Q Q S S D S T Q Q S S D TOTAL
QUARTO
SALA
BANHEIRO
TOTAL
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GRÁFICO SEQUENCIAL
CONCEITO/UTILIZAÇÃO :
O gráfico seqÜencial é um instrumento utilizado para representar graficamente
uma determinada sequência de dados. Ferramenta utilizada para facilitar a
visualização dos dados da folha de verificação.
Re la tórios Em itidos com Erro
30
25
20
Nº d e r e l.
15
10
0
Jan Fev Mar A br Maio Jun Jul A go Set Out Nov Dez
M eses
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ESTRATIFICAÇÃO
CONCEITO/UTILIZAÇÃO :
Ferramenta utilizada para dividir o todo em partes (estratos),
facilitando a observação individual das mesmas.
EXEMPLO:
Estratificação da quantidade de conexões consumidas numa instalação predial.
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TABELA DE DESCARTES
Modelo conceitual
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FATORES DESMOTIVACIONAIS
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NÍVEIS DE DIFICULDADES
NA SOLUÇÃO DE PROBLEMAS
4 5
2 3
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REFLEXÃO SOBRE AS
ATIVIDADES DO GRUPO
Ao final dos trabalhos, AMBIENTE
é importante fazer uma reflexão 10
sobre o desempenho do grupo.
Para isso, pode ser usado um 5 MOTIVAÇÃO
gráfico radar, onde poderão ser PDCA
visualizado os pontos a ser 0
melhorados.
Como sugestão, podem
ser observados os seguintes REUNIÕES LIDERANÇA
quesitos: ambiente da área,
motivação do grupo, liderança,
reuniões, utilização do PDCA,
etc.
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CRESCIMENTO DO GRUPO
TEMPO
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EXERCÍCIOS
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EXERCÍCIO 01
*15 DESENVOLVIMENTO:
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EXERCÍCIO 02
VIVENCIAR O BRAINSTORMING
*17 MÉTODO:
Lembrar que:
*18 MATERIAL:
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EXERCÍCIO 03
*20 MÉTODO:
De posse de uma lista de itens, cada grupo deverá elaborar uma matriz de
priorização.
Lembrar que:
*21 MATERIAL:
- Folha de flip chart
- Pincel
- Lista de itens
EXERCÍCIO 04
*23 MÉTODO:
*24 MATERIAL:
- Folha de flip chart
- Pincel
- Caso com as questões
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EXERCÍCIO 05
*26 MÉTODO:
1- Título;
2- Média dos dados;
3- Indicador de orientação (melhor);
*27 MATERIAL:
- Folha de flip chart
- Pincel
- Tabela de dados
TABELA DE DADOS
Nº DE TROCA DE ALTERNADORES
PARADAS
MESES NÃO PROGRAMADAS PROGRAMADAS
JANEIRO/92 07 01
FEVEREIRO 05 01
MARÇO 03 01
ABRIL 03 01
MAIO 05 02
JUNHO 02 01
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JULHO 08 02
AGOSTO 04 01
SETEMBRO 02 01
OUTUBRO 03 01
NOVEMBRO 05 01
DEZEMBRO 06 01
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EXERCÍCIO 06
VIVENCIAR A ESTRATIFICAÇÃO
*29 MÉTODO:
*30 MATERIAL:
TABELA DE DADOS
06 de matemática
12 de português
07 de história
04 de geografia
19 de física e química
07 de outras cadeiras
EXERCÍCIO 07
*32 MÉTODO:
*33 MATERIAL:
- Folha de flip chart
- Pincel
- Comentários de uma situação
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- Eu acho que tem a ver, porque esta tampa empenada pode estar provocando uma
vedação deficiente.
SUPERVISOR DE MANUTENÇÃO:
- O problema não é esse. O caso é que o projeto deste tipo de alternador não traz o
regulador blindado.
PROGRAMADOR DE MANUTENÇÃO:
- Também! O pessoal que faz a lavagem dos caminhões não foram treinados!
SUPERVISOR DO LAVADOR:
- Pudera! Não tenho como treinar de maneira rápida o número de pessoas que passam
por lá. Todo dia sai e entra gente!
OPERADOR DO LAVADOR I:
- Será que o uso de água quente na lavagem não diminui a vedação dos alternadores?
SUPERVISOR DO LAVADOR:
- Acho que o sabão não interfere em nada. Talvez seja penetração de água das chuvas.
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OPERADOR DO LAVADOR I:
- Vocês estão falando de penetração de água nos alternadores, mas já viram como a
iluminação na área de lavagem é ruim à noite?
TÉCNICO DE PROGRAMAÇÃO:
- Não gente, pera ai! Será que as pessoas sabem que o problema ocorre? De repente
nem todo mundo tem conhecimento?
SUPERVISOR DE MANUTENÇÃO:
- Não, mas o problema já foi definido. Tá aí na cabeça do peixe! Inclusive acho que o
problema ocorre por causa do aumento de consumo de corrente elétrica.
- Não sei, mas pode ser também má distribuição das cargas das baterias.
SUPERVISOR DO LAVADOR:
- Ah... Eu acho que esses alternadores CEN é que são de má qualidade mesmo!
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EXERCÍCIO 08
*35 MÉTODO:
*36 MATERIAL:
SITUAÇÃO:
O grupo deverá fazer um Plano de Ação, para propor a forma adequada
para se
resolver um problema utilizando as ferramentas do CCQ (PDCA).
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TEXTOS SELECIONADOS
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Cia. Fazem parte de uma encomenda que a empresa está mandando para São
Paulo. Esta manhã, passaram outros dez caminhões com a mesma carga. O
carregamento é consignado à firma Zanon Oliveira Ltda. da cidade de Cascavel no
Paraná."
O diretor agradeceu Antônio e com um sorriso virou-se para o João e limitou-se a
dizer-lhe:
"- Entendeu porque o Antônio foi promovido?"
Sem comentários...
Levei meu velho terno para o tintureiro. Três dias depois ficava pronto. Volto
ao tintureiro para buscar meu terno e o tintureiro, depois de procurá-lo, voltou e disse:
"Desculpe-me Sr. Marins, nosso funcionário entregou seu terno por engano a
uma outra pessoa. Peço desculpas . O senhor tem duas opções: ou o
senhor
me dá o valor do terno agora e eu lhe faço, imediatamente, um cheque ou
o
senhor espera uma semana, pois quem levou seu terno por certo o trará
de
volta ao perceber o engano. Assim que o terno chegar eu o levarei pessoal-
mente ao senhor".
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Cada vez que me lembro desse caso, fico impressionado com a ATENÇÃO AOS
DETALHES que o tintureiro teve. Não ficou dando desculpas para perda do
terno.
Ligou-me um dia ANTES e não um dia depois como a maioria faz. Pagou o valor do
terno sem discutir se o valor dado era caro ou barato. Simplesmente assumiu
o
prejuízo e fez o cheque.
Sem comentários...
REFERÊNCIAS
BRASSARD, Michael, Qualidade - Ferramentas para uma melhoria contínua (the memory jogger),
Rio de Janeiro, Qualitymark, 1992.
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