1. You do not become an expert driver overnight. You have to learn the skill to drive and constantly practice and put yourself in the situations where these skills are put to test in a variety of situations by practicing and practicing and thus refining and honing these skills to excellence. The same applies to intuitive quality control decisions. You have to learn this skill and then to make better intuitive quality decisions you have to improve the quality your intuition. It also important that you constantly challenge your intuitive decisions, learn from the results and constantly strive to make an experienced data base. You master the technique only when you start placing value to your skill to see things in a different way, in a way you would not have accepted otherwise.
2. There are five instruments of knowledge, viz, the sense of sight, smell, hearing, taste and touch and five instruments of action, viz, the abilities to procreate, excrete, talk, walk and exercises manual skills. These ten instruments helps us to form patterns about what is good for us to eat and what is not, what smells good and what does not, what is good to touch and what is not, what is good to hear and what not to hear, what is good to eyes and what is not. We have been storing these information in our subconscious for years. The only requirement is to access this information and decide what is right and what is not right for us. By using these ten instruments we can also store information about the parameters of the product in our brain, create a data bank and experience base and use it to decide what is right product and what is not good and is to be rejected. More are the patterns and scripts available to us more expertise we will have in making a better decision.
3. The intuitive quality control can be brought into the system by implementing the following steps:-
(a) Training the persons in forming patterns and the signals about the various aspects and parameters of quality. These can be done by giving the person product which conform to the specification and letting him use the ten instruments to form and store a pattern in his brain.
(b) Letting the person test these patterns in deliberate experimental manner. This can be done by introducing deliberately faulty products in the process to test his decision making ability by using constant feed backs. This will not only test the man but also the machine. The product initially should be faulty in one parameter at a time and later as he gains expertise then subjecting him to faulty product in a number of parameters.
(c) Step two is to performed under a controlled environment initially and then as he gains expertise and as his confidence and faith in his abilities in gained , then in a stand alone environment.
(d) Keep repeating the deliberate experiments at a random interval so that the patterns and signals are constantly being challenged, updated and refined.
(e) Institutionalize the system.
4. Merely having the experiences or forming the patterns is not enough. The experience will have to be turned into a skill and to utilize the skill effectively one has to has expertise. To have an expertise one has to concentrate on the feed backs which he gets from these deliberate experiments or experiences. What is needed is:-
(a) Deliberate and constant feedback on your actions not only when you make a correct decision but also when you make an incorrect decision.
(b) Analyze and interpret these feed backs correctly.
(c) Repeat these experiments in a regular but random manner to validate these feed backs.
5. What I am not saying is, that this intuitive quality control replaces the statistical quality control. Statistical quality control and parameters are required to develop the intuitive quality control. Both should support each other and are to be used as complimenting each other. As one gains expertise in intuitive version then he will use less and less of statistical quality control methods and will rely more on intuition and the patterns and signals available to him. But the statistical controls are required to keep testing his patterns and intuition. The advantages that the organization gains from this are:-
(a) Quality checks can be done on line, thus saving time, less inventory cost and more production.
(b) Saving in time as these decisions are instantaneous.
(c) allows check on machines.
(d) Cost saving.
(d) Forms a habit of intuitive decision making
(e) Development of faith and trust in one's own abilities.
6. Intuitive quality control when implemented does not in any way changes the way one does things in your organization nor it forces you to adopt new ways of doing things. It only encourages you to look at quality control the way you have always been looking but the only difference now is that you have a very comprehensive , experience base to base your judgments upon and the judgments are done in a fraction of second.