Quality……
Management……
CU-MHROM
3rd Sem 305-2
July-Dec 2010
Syllabus For MHROM ( CU ) : Paper 305 Module 2
Total Quality Management
• Competition intensifies
• Environmental concerns
Coping with :-
External • uncertainty
Developments • variations
Requirements • complexity
• shorter response times
• improved quality & reliability
Performance
levels
Criteria
Measured by performance criteria
o effectiveness
o efficiency
o flexibility
o innovation
o quality
o cost
o productivity
o delivery
Coping
Copingsuccessfully
successfullywith
withExternal
ExternalDevelopments
Developmentsdepends
dependson
on
Organizational
OrganizationalCharacteristics
Characteristics
External
Developments
Requirements Adaptability
Performance Organisational
Criteria Characteristics
Degree of success
Is Quality absolute ?
bodies etc )
retailers etc. )
At all time
•Man
feedback •Goods
•Machine
•Services
•Material
•Info
•Method
Target
•Money
•Info
Controls,
Procedures
Input Output
Material, Process Material,
Information Services
Mechanisms Information
People,
Machines
Noise variables causing
the process to vary or
destabilise
Slides by : Anjan Ghosh
What is a process ?
A Process Is...
suppliers customers
Main Process
Sub-process
Work Process
Support Processes
Slides by : Anjan Ghosh
Functions ( in departments .) vs. Processes
P4
P1 P2 P5 P6
P3
S1
Robust : Mistake-Proof
• owned
• documented
• measured
• designed
• controlled
• improved
• Manufacturing process
• Logistics process
Examples:
• operating a machine
• testing a product
• typing letters
• contacting customers
• storing material
P-D-C-A
Feedback
Time Time
Previous best
incremental Not an improvement.
deterioration Trying to go to normal
breakthrough
state or previous best .
Time Time
Slides by : Anjan Ghosh
Small Steps & Big Strides
Breakthrough
Performance of best competitor
improvement
Value
Incremental improvement
(Kaizen)
Time
• Incremental • Breakthrough
Triggered by work experience Triggered by business strategy
No new technology Innovation
Gradual - Several in short time
Few in long span of time
Anybody can contribute
Low resources Require technical expertise
Large resources
Slides by : Anjan Ghosh
P-D-C-A Cycle for Improvement ( Deming Wheel )
Continual
Improvement
Replan new target • Objectives / targets
• Strategies
• Activities
• Standardize the • Responsibilities
new process after A ct P lan • Resources
taking corrective • Time frame
actions
Business Strategy
check check
Rigid - Flexibility
Examples:- Examples:-
Small ambient changes Temp set point changes
Material Tolerence Out-of-spec materials
Shift operators Untrained operator
Left to itself a process will drift from its set-point due to the chance
and assignable causes . If the drift is too much the process may
go outside the tolerance limits or target values . So there is a need
for controlling the process by means of continuous feedback and
corrections – either manual or automatic .
The ability of a process to stay within the tolerance limits ( and hence
In control ) is called its stability
• TC-176 set up in 1975 . ISO 9001 - 1st edition 1987 , 1994 , 2000 , 2008
“Leadership”
“Involvement of People”
“Process Approach”
“Continual Improvement”
Continual improvement is a
permanent objective of the
organization.
Responsibility
Customers satisfaction
Measurement
Resource
Analysis &
Management
Improvement
Product
Realisation Product
input output
Organisation
• Scope ( clause 1)
• Normative References ( clause 2 )
• Terms & Definitions (clause 3 )
• Quality management System ( clause 4)
General requirements, documentation requirements , Q.Manual ,
Control of documents & records
• Management responsibility ( clause 5 )
Commitment, Customer focus, Policy, Planning, Responsibility,
Communication, Review
• Resource management ( clause 6 )
Human resources, Infrastructure, Work environment
• Product realization ( clause 7 )
Customer Processes , Design, Purchasing, Operations, Calibration
• Measurement, analysis and improvement ( clause 8 )
Customer satisfaction, Audit, Process / product control, Non-conforming
product, Data analysis, Improvement
Slides by : Anjan Ghosh
Scope ( clause 1) ( where ISO-9001 can be applied )
a) needs to demonstrate its ability to consistently provide product that meets customer
and applicable statutory and regulatory requirements, and
b) aims to enhance customer satisfaction through the effective application of the system,
including processes for continual improvement of the system and the assurance of
conformity to customer and applicable statutory and regulatory requirements.
All requirements of this International Standard are generic and are intended to be
applicable to all organizations, regardless of type, size and product provided. Where any
requirement(s) of this International Standard cannot be applied due to the nature of an
organization and its product, this can be considered for exclusion.
Improvement Problem
SDCA
Defreeze Freeze
Data
• Primary Data - Collected for specific purpose directly from field of enquiries and
used by same person.
• Secondary Data - Compiled from some other source by persons who have not
collected the original data.
Whole Sample
Population
• More time, costly. • Less time, less money.
• Large number of investigators.
• Trained investigators.
• Supervision difficult.
• Intensive data collection.
• Data in some cases doubtful.
• No sampling errors. • Better control, supervision.
• Not practically feasible always. • Practically feasible.
• More accurate if done properly. • Less accurate, more
precise.
magnitude.
Dispersion
Absolute Relative
Measures Measures
• Quartile Deviation = Q3 – Q1
2
2
• Standard Deviation = 1/n (xi – x)
The two most important with which we work are Range & Standard Deviation
For a factory making light bulbs – the breakup of type of defects for one week
Is there any pattern ?
Filament fused 8 9 8 7 6 5
Pole disconnection 6 16 28 5 17 22
Low wattage 28 27 25 28 33 28
Vital few
approx 80%
Parameter
Being
Measured
Example :
A B C D E F G H
Type of Defect
Slides by : Anjan Ghosh
Cause And Effect Diagram Example
People
New joinees Material
Untrained
operator
Frequent change Too high
W.I. Not displayed dross Alloy not proper
of operator
Too thick
High
High Fe Content
absenteeism Cork spray
Does not follow P.I. Cooling fluid
Carelessness inconsistent
Method /
Machine
Process
80
60
40
20
4.5 4.5
4.0 4.0
3.5 3.5
x x
150 400 650 150 400 650
Plotting Data
(y axis)
Average
Measurement
(x axis)
Time or sequence
3.0
3.5
4.0
4.5
5.0
.2
.4
.6
.8
1.0
1.2
1.4
1.6
1.8
2.0
1
1.01 3.76 2
1.27 4.21 3
0.48 4.29 4
1.32 4.36 5
1.52 4.13 6
1.03 3.77 7
1.15 4.17 8
1.07 4.21 9
0.70 4.22 10
2.05 4.00 11
0.95 4.30 12
0.99 4.20 13
1.06 4.32 14
1.21 4.18 15
1.33 4.02 16
0.78 3.71 17
1.21 4.08 18
1.23 4.23 19
1.08 3.98 20
X & R Chart
1.64 4.46 21
1.20 3.96 22
0.98 3.63 23
0.91 4.48 24
1.19 4.30 25
1.03 4.29
Control Charts
LCL
UCL
LCL
UCL
• Tree Diagram
• Relations Diagram
• Matrix Diagram
• Matrix Data Analysis Method
• Affinity Diagram
• Arrow Diagram
• Process Decision Program Chart
Technique used to achieve objective (target ) by systematically breaking down an effect into
its causes by asking "why" at each step ; so as to see a whole problem at a glance .
Budget
constraint Political
Less govt. instability
orders Economic
External slowdown Bad monsoon
factors
Cheaper
Imports
WTO
Internal
factors High cost Low
productivity
Spares not
Breakdown of available
mc/s
Overloaded
mc/s Suppliers not
Material not paid
available
Unable to meet
target production
Planning faulty Funds crisis
Unable to clear
excise
Product
Characteristics Head Room Container & Alloy & Separator
Plate Design
Customer Lid Design Oxide Purity Quality
requirements
Long Life
Aesthetics
Low Maintenance
Positive Attitude
+5
Mrs G Mr A
+4
+3
Mr B
+2
Mr F +1 Mrs C
Cheerfulness
-5 -4 -3 -2 -1 +1 +2 +3 +4 +5
-1
Mr H
-2
-3 Mr D
Mr E
-4
-5
Factory
Start
End
So Final action :-
Add lubricating point in Preventive Maintenance Schedule
Slides by : Anjan Ghosh
Control Charts
Step 1: Select the process to be monitored. ( take one parameter of the process
eg length , mass , temp …… )
Step 2: Determine the sampling method and plan. ( who , when , how …..)
Step 3: Collect data. ( eg. 5 consecutive samples at one time …..repeat…. repeat
Step 5: Calculate the Mean and control limits. ( X(double bar) , UCL & LCL )
Step 6: Construct the control chart. ( Draw X(bar),UCL,LCL lines , plot points )
A2 D3 D4
2 1.880 0 3.267
3 1.023 0 2.574
4 0.729 0 2.282
5 0.577 0 2.114
6 0.483 0 2.004
7 0.419 0.076 1.924
8 0.373 0.136 1.864
9 0.337 0.184 1.816
10 0.308 0.223 1.777
Parameter being
measured (length,
mass….) also
Mean Called the variable
µ or X(bar)
Mean+1σ (68.26%)
Mean+2σ (95.46%)
Mean+3σ (99.73%)
Target Value
Process Capability Ratio = Cp
Cpk can never be higher than Cp . Only can be equal to Cp when K is zero , that is
When process is centered and process mean is on target value
Slides by : Anjan Ghosh
Alternate Formula
This can be used for one-sided tolerences also , When either USL or LSL is given
Cp value for one –sided tolerences does not exist .
Numerical Example
USL = 12.8 LSL=8.4 , Target value = 10.6 , process mean 9.8 , S.D = 0.2. Find Cp & Cpk
Cpk is much lower than Cp because the process is shifted to the left of centre
Cpk can be negative if the process mean falls outside the tolerence limits
Slides by : Anjan Ghosh
6 Sigma : A Methodology to reduce rejection & variation
• In many cases these are not possible due to high rate of defects ,
scrap and waste in products and services due to deficiencies in
design , incapable or unstable processes , deviations in materials ,
weak measurement systems , etc .
• If the root causes can be detected and actions taken , the defects
can be brought down and ultimately eliminated .
• Over the past decades quality engineers have been trying different
tools and techniques to reduce variation .
• 3 Sigma process has 66807 PPM reject level in the long run ( Cpk = 1 )
6 Sigma process has 3.4 PPM reject level in the long run ( Cpk = 2 )
WHY -
1. early identification & elimination of potential product / process failure modes
2. Improve product / process quality & reliability
3. Document risks and actions taken to reduce the risk before product fails
4. Minimise changes to products due to failures which will add costs
WHO - Done by a Cross functional team of people from R&D , Materials Mgt.
Production , Quality Assurance and Maintenance
HOW –
1. Brainstorming, assessment, testing, learning, analysis , by using standard tables etc.
2. Filing up standard format
• chance of occurrence ( what is the possibility that the failure can occur )
- more the possibility of failure higher is the number scale
• severity of the failure ( what will be the effect if the failure happens )
- more the seriousness of the failure higher is the number scale
Cut off score ( say 125 ) is set by the organisation depending on product type
and Quality / Business strategy and any score above that requires redesign
Of product or process . Cut off score is gradually lowered .
• Forgetfulness / Inattention
• Misunderstanding
• Wrong identification
• Lack of experience / training
• Willful (ignoring rules or procedure)
• Inadvertent or sloppiness
• Slow reaction time
• Lack of standardization
• Surprise (unexpected machine operation, etc.)
• Intentional (sabotage)
Anybody can and should practice poka yoke in the workplace. Poke
yoke does not necessarily require any complicated science or
engineering - sometimes it just needs common sense and the
appropriate poka yoke device – and the will to do zero defects .
1) useable by all ;
2) simple to install;
3) does not require continuous attention from person (ideally, it
should work even if the person is not aware of it);
4) low-cost;
5) provides instantaneous feedback, prevention, or correction.
3) Electrical plugs that can only be inserted into the correct outlets
5) A flip-type cover over a button that will prevent the button from
being accidentally pressed
6) Sounds alarm and does not start car if doors are not locked properly
• Housekeeping
While many people may consider housekeeping an unappealing
topic, we should realize that housekeeping is closely tied to many
important aspects of running a world-class organisation. For
example, there is a strong linkage between the level of
housekeeping and the level of scrap, machine breakdowns,
accidents, absenteeism, inventory and improvement suggestions.
• Workplace Organization
Housekeeping is tied closely to better workplace organization.
The value of clean floors and machines is not simply a pleasing
appearance. Clean surfaces expose problems such as oil leaks
and cracks so that corrective action can be taken as early as
possible.
• High obsolescence •
BUSINESS EXCELLENCE
SELF-DISCIPLINE
STRUCTURISE
STANDARDISE
SYSTEMATISE
SANITISE
Seiri (Structurise) - Take out unnecessary items and dispose them away. Keep only
essentials.
Seiton (Systematise) - Arrange necessary items in a proper order so that they can be
easily located and picked up for use.
Seiso (Sanitise ) - Clean the workplace thoroughly using proper tools & equipment.
Lean is about doing more with less: such as less time, inventory, space,
labor, and money. "Lean manufacturing", aims at eliminating waste,
simplifying procedures and speeding up production.
Also known as Toyota Production System (TPS) as its principles were first
proposed and put to use in Toyota by Taiichi Ohno during the 1970’s .
This system, more than any other aspect of the company, is responsible for
having made Toyota the respected company it is today. Toyota has long
been recognized as a leader in the automotive manufacturing and production
industry.[
5. Motion - Unnecessary or awkward operator motions put undue stress on the body
and cause waste.
7. Waiting time– People and machines remaining idle between operations is wasteful.
Small everyday maintenance can be done by the operator of the machine like lubricating ,
cleaning , tightening , inspecting etc . The change of parts or CBM or TBM or BM can be
done by specialist maintenance people.
By doing proper maintenance the productivity and life of machines can be increased with
Improvement in quality and decrease in cost .
A lot of training and involvement of people are reqd. to ensure that proper maintenance is
done . Proper records of the maintenance and history cards of the machines has to be
kept . For each breakdown and failure analysis needs to be done to find the root cause of
the failure . These learnings will help in designing of better machines .
This whole methodology is called as TPM because it involves many people & depts.
• Comparison with other functions/ depts within the organisation at same location.
Benchmarking is not spying or blindly coping others . Understanding & learning reqd.
In many cases there is collaboration between organisations for mutual benefit .
Benchmarking is a dynamic exercise and not one-time , because by the time the
Improvements are done the best being benchmarked would have improved further.
• warranty
External Failure • travel & other expenses of service personnel
cost • consumer forums / legal cases
• cost of service centres
• equipment & instruments for testing
• transportation of defective replacements
• Documentation / records
• Training of service people
• Cost of analysis of rejects
•
Slides by : Anjan Ghosh
Economics
WHERE IS THE POINT OF OPTIMUM
Of Quality QUALITY COST ?
Total Cost
Cost per good unit of product
Internal Prevention
+ +
External Least cost Appraisal
failures
100 % 0%
Defectives
The full potential of people needs to be harnessed and people motivated to contribute towards
improvements in a voluntary way . The aim would be to make jobs , enjoyable and satisfying .
Management needs to provide training and development and provide support for ongoing
improvements both for individuals and teams . Also give due rewards & recognition to keep
motivation high . In most cases the rewards are non-monetary .
Suggestion Box : Employees can give suggestions ( dropped in a box ) . Which are
evaluated by a committee and if found suitable are implemented .
Small Group Activities (SGA’s) : Work like QC’s but members can be from other depts also .
After problem is solved SGA is disbanded . May include mgt staff
Cross Functional Teams (CFT’s) , Self Directed Teams (SDT’s ) , Task Forces are other types
of improvement teams
Slides by : Anjan Ghosh
SUCCESS FACTORS for PEOPLE INVOLVEMNNT
Thru Training
Necessary
conditions
for
Success Success
Process Result
Ability of personnel Standardi-
( how to
zation
achieve?)
( how to
maintain
what has
Motivation of Opportunity to been
personnel personnel achieved? )
• Implement changes.
Workforce spend most time on control , then improvement , very low planning
Supervisors spend equals amounts on control and improvement , less planning
Middle mgt spend equal amounts of time on control , improvement and planning
Top mgt spend most time on planning , some improvement , but mostly planning
All other models are derivatives of these three . These models are
Much higher than ISO 9001 or ISO 14001 or OHSAS 18001
And looks at Ladership , Strategy , People Involvement , Products ,
Processes , Customer Satisfaction , Social Responsibility ,
Financial and non-Financial Results over a period of at least 3 years
how results are being achieved what the orgn. has achieved
Key
Performance
Leadership Policy & Strategy Processes Customer Result Results
10% 10% 10% 15% 15%