Revelations of a QCC Research Survey in Japan ICQCC 2009, Cebu, - PowerPoint PPT Presentation

Revelations of a QCC Research Survey in Japan ICQCC 2009, Cebu, Philippines October 23, 2009 Ichiro Kotsuka Executive Director Union of Japanese Scientists & Engineers 1

QC Circle Headquarters We began the QC Circle Activities Hokkaido Region in Japan, in April, 1962. The activities spread rapidly in Tohoku Region subsequent years. In Japan, the Hokuriku Region activities have been practiced throughout many industries from Kanto Region manufacturing to services. QC Circle Globally, more than 70 countries Headquarters Tokai Region and regions have introduced and (JUSE) promoted QC Circles. Kinki Region The QC Circle Headquarters of Japan is Chugoku-Shikoku located within the Union of Japanese Region Scientists and Engineers (JUSE). There are 9 regional offices throughout Kyushu Region Japan as shown on the right, to Okinawa Region facilitate and assist QC Circle activities. 2

What is the “QCC Research Survey”? • The QCC Research Survey is a nation-wide survey of QCC activity status in Japan. • The survey started in 1979, is conducted every 4 to 8 years and this is the 7 th survey. • The survey was conducted respectively, to QCC promoters who help promote QCC activities, and QCC leaders who take charge of actual QCC activities.

Part 1. Promoter Results

1. Department/ Section that introduces small group activities 84% Manufacturing 86% 59% Materials 65% 58% Administrative affairs 69% 57% Maintenance 72% 51% Design, technology 63% 34% Marketing 35% 31% R&D 45% 14% Service 14% 2009 8% Sales 10% 2004 10% Other 13% 0% 20% 40% 60% 80% 100% 5

2. Participants in small group activities Full ‐ time, part ‐ time, and temp ‐ workers all participate Full ‐ time workers all participate Full ‐ time, part ‐ time, and temp ‐ workers voluntarily participate Full ‐ time workers voluntarily participate Other 2009 53% 29% 7% 3% 8% 2004 47% 46% 5% 2% 0% 20% 40% 60% 80% 100% 6

7 3. Promotional body of small group activities

4. Promotion of e-QCC activities Promotes e ‐ QCC concious circle activity Promotes circle activity without e ‐ QCC in mind Not aware of e ‐ QCC Other 32% 46% 18% 37% 0% 20% 40% 60% 80% 100% 8

5. Participants in the promotional body of QCC activities 23% President 24% 48% Executives 50% 70% Managers 75% 78% Deputy Managers 84% 60% Chiefs 71% 2009 53% Supervisory staffs 52% 2004 57% General staffs 64% 0% 20% 40% 60% 80% 100% 9

6. Objectives to introduce small group activities To contribute to the company's business 35% result 35% 35% To enhance circle member's skill 35% To create fullfiling and cheerful work 27% environment 27% 2009 3% 2004 Other 3% 0% 10% 20% 30% 40% 10

7. Composition of small group activities 89% Departmentally organized 96% 40% Organized for specific themes 32% 33% Cross ‐ departmentally organized 33% 23% Group includes mamagers 24% 2009 3% 2004 Other 4% 0% 20% 40% 60% 80% 100% 11

8. Meeting time of small group activities During office hours During Off ‐ hours Both 2009 50% 16% 34% 2004 31% 29% 40% 1996 53% 40% 7% 0% 20% 40% 60% 80% 100% 12

9. Allowance for small group activities 100% 1% 2% 5% 10% 29% 31% 27% 34% 80% 30% 20% No response 13% 60% Not provided 18% 40% Provided depend on the 70% 70% 69% 66% activity 57% 47% 20% Provided 0% 1983 1987 1991 1996 2004 2009 13

10. System of internal presentation opportunity by small group activities 14

11. Participation of the top management in internal presentations 1% 1% 1% 1% 2% 100% 2% 2% 4% 2% 3% 2% 3% 5% 4% 6% 6% 6% 80% 60% Other Participate rarely 94% 93% 92% 91% 90% 90% Participate occasionally 40% Participate 20% 0% 1983 1987 1991 1996 2004 2009 15

16 12. Outcome of small group activities

17 13. Evaluation of small group activities

14. Reward system of small group activities Established Not established Unknown 2009 82% 13% 6% 2004 89% 8% 3% 0% 20% 40% 60% 80% 100% 18

15. Support/ guidance by seniors or managers for small group activities 19

16. Problems/ Issues when promoting small group activities 55% Level disparity among small groups 41% 46% Fostering a leader 46% 33% Saving time 39% 28% Training 20% 27% Understanding from top/senior managers 33% 27% Promotion activity 25% 22% Not being able to achieve result 28% 12% Presentation, award, evaluation system 7% 2009 2% Labor issue 1% 2004 7% Other 10% 0% 20% 40% 60% 20

Part 2: QCC Leader Results

17. What are the contents of your business operation? 22

18. What are the objectives of practicing small group activities? 71% To enhance the ability of members 73% To contribute to the company's business 68% performance 76% 52% To create fulfilling workplace 50% 2004 7% Other 2009 6% 0% 20% 40% 60% 80% 100% 23

19. What motivates you to participate in small group activities? 24

20. Who participates in your small group activities? Full ‐ time, part ‐ time, and temp ‐ workers all participate Full ‐ time workers all participate Full ‐ time, part ‐ time, and temp ‐ workers voluntarily participate Full ‐ time workers voluntarily participate 4%3% 34% 58% 25

21. When are small group activity meetings held? During office hours During off ‐ hours Both 2009 52% 22% 26% 2004 37% 29% 34% 0% 20% 40% 60% 80% 100% 26

22. How long is the average meeting time? 0 ‐ 10 min. 10 11 ‐ 20 min. 11 21 ‐ 30 min. 66 31 ‐ 60 min. 164 61 ‐ 90 min. 20 91 ‐ 120 min. 18 121 ‐ 150 min. 0 151 ‐ 180 min. 1 Number of circles 181min.+ 1 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 27

23. How many themes have been solved in the past one year? 120 2009 109 2004 100 85 81 Number of groups 80 65 60 35 40 21 20 17 20 14 11 8 7 5 5 5 5 3 3 2 2 2 1 1 1 1 1 1 0 Number of themes solved per year 28

24. How much time is spent to solve one theme in general? 16+ 2 15 ‐ 15.9 0 0 14 ‐ 14.9 0 13 ‐ 13.9 18 12 ‐ 12.9 1 11 ‐ 11.9 10 ‐ 10.9 10 Months 9 ‐ 9.9 1 5 8 ‐ 8.9 1 7 ‐ 7.9 114 6 ‐ 6.9 5 ‐ 5.9 21 4 ‐ 4.9 45 48 3 ‐ 3.9 9 2 ‐ 2.9 8 1 ‐ 1.9 Number of circles 2 Less than 1 month 0 10 20 30 40 50 60 70 80 90 100 110 120 29

25. What is the level of cooperation provided by your senior/ manager? 30

26. Are the themes related to your upper policy? Related Not related Other 2009 96% 4% 2004 93% 5% 2% 0% 20% 40% 60% 80% 100% 31

27. How are the themes decided? Assigned by manager Discussed among managers, staff, leaders Requested from other departments Discussed among members 2009 3% 40% 1% 51% 2004 7% 46% 1% 45% 1996 4% 30% 5% 60% 0% 20% 40% 60% 80% 100% 32

28. What are the main aims of setting themes? 29% To enhance quality 30% 17% To reduce cost 16% 12% To enhance efficiency 14% 5% To save cost 6% 4% To enhance CS 8% 4% To avoid mistakes 2% 3% To improve equipment 5% 3% To enhance service 3% 2009 3% To enhance working environment 2% 2004 2% To enhance management level 2% 0% 10% 20% 30% 40% 50% 33

29. What is the procedure used to solve themes? 86% Problem ‐ solving procedure 86% 37% Task ‐ achieving procedure 50% 16% Measure ‐ implementing procedure 13% 2009 1% Other 0% 2004 0% 20% 40% 60% 80% 100% 34

30. Is it useful to listen to presentations by other circles in different organization? 100% 1% 1% 2% 7% 12% 9% 13% 18% 22% 80% 60% Not useful 93% Neither 88% 84% 86% 82% 40% 77% Useful 20% 0% 1983 1987 1991 1996 2004 2009 35

31. What are the outcomes by playing the role of QCC leader? 36

32. What are the outcomes of small group activities as a circle? Raised more awareness toward problems Increased knowledge Higher motivation toward one's work Established better communication Enhanced teamwork Other No specific outcome 2009 47% 11% 3% 2% 34% 1% 1% 2004 49% 24% 5% 4% 17% 1% 2% 0% 20% 40% 60% 80% 100% 37

33. What are the outcomes of small group activities for business operation and the environment? Improved workplace environment Enabled to work smoothly with less burden Enhanced productivity Improved quality Reduced cost Prompted better collaboration with other departments Other No specific outcome 2009 18% 26% 17% 19% 10% 5% 3% 2% 2004 17% 32% 11% 20% 11% 4% 2% 4% 0% 20% 40% 60% 80% 100% 38

34. Are there any issues/ problems in promoting small group activities? 100% 14% 17% 18% 21% 23% 26% 80% 60% There are no issues 86% 82% 82% 40% 79% There are difficulties 77% 74% when promoting activity 20% 0% 1983 1987 1991 1996 2004 2009 39

35. What external education and training would you like to attend? 35% Problem ‐ solving 26% 32% Leadership 33% 31% Task ‐ achieving 29% 28% Fundamental of QC tools(e.g.Q7, N7) 32% 28% Promotion of small group activity 26% 23% Fundamentals of QM 22% 22% Coaching 14% 20% Statistical method, DOE 25% 2009 16% Safety management 7% 2004 5% Other 3% 0% 10% 20% 30% 40% 50% 40

36. Do you intend to continue small group activities? 41