M.

TECH DEGREE PROGRAM MANUFACTURING TECHNOLOGY TOTAL QUALITY MANAGEMENT

ASSIGNMENT NUMBER: 1
SUBMITTED BY

S.JEEVANANDAM Reg No: 6022510003

Date of Intimation: 16/02/2013 Date of Submission: 14/03/2013 Last date of Submission: 16/03/2013

PRIST UNIVERSITY, KUMBAKONAM CAMPUS

1. Describe the procedure for conducting work sampling in an organization. Also mention the advantages and disadvantages of this technique.

Work sampling is the statistical technique for determining the proportion of time spent by workers in various defined categories of activity. Work sampling was developed in England by L.Tippet in the 1930s.

Procedure for conducting work sampling: Stage 1: Preparing for work sampling

1. Specify the main objective and make statement 2. Obtain approval of the concerned departments supervisor 3. Identify quantitative measure of activity 4. Select and train personnel 5. Plan for the procedure of observations

Stage 2: Start work sampling

6. Get all details of jobs to be measured 7. Divide jobs into activity

8. Conduct pilot study to:

Determine number of observations Check methods Gain confidence 9. Describe and classify the elements to be studied 10. Design observation sheets 11. Identify the number of days/shifts for the study 12. Identify the scheme for properly randomized times of observations

13. Observe activity: record time for each shift/day/week 14. Summarize data

Stage 3: Evaluate and present results

15. Evaluate and validate data 16. Analyze data 17. Calculate proportion of time for each activity
18. Planning for future studies

Advantages:

1. Less expensive than time study 2. Observers need little training 3. Studies can be delayed or interrupted with little impact on results 4. Worker has little chance to affect results 5. Less intrusive

Dis Advantages:

1. Does not divide work elements as completely as time 2. Can yield biased results if observer does not follow random pattern
3. Less accurate than time study, especially when job element times are short

2. Define operating characteristic of curves and explain its significance.

Operating characteristic curves (OC curves): Graph used in quality control to determine the probability of accepting production lots when using different sampling schemes. It shows percentage defectives along the horizontal (X) axis and probability of acceptance along the vertical (Y) axis. Lots having more than the acceptable percentage of defectives are rejected. Significance of OC curves: The Operating characteristic curve is a picture of a sampling plan. Each sampling plan has a unique OC curve. The sample size and acceptance number define the OC curve and determine its shape. The acceptance number is the maximum allowable defects or defective parts in a sample for the lot to be accepted. The OC curve shows the probability of acceptance for various values of incoming quality.

An OC curve is developed by determining the probability of acceptance for several values of incoming quality. Incoming quality is denoted by p. The probability of acceptance is the probability that the number of defects or defective units in the sample is equal to or less than the acceptance number of the sampling plan. The AQL is the acceptable quality level and the RQL is rejectable quality level. If the units on the abscissa are in terms of percent defective, the RQL is called the LTPD or lot tolerance percent defective. The producers risk (a) is the probability of rejecting a lot of AQL quality. The consumers risk (b) is the probability of accepting a lot of RQL quality.

There are three probability distributions that may be used to find the probability of acceptance. These distributions were covered in the Basic Probability chapter and are reviewed here. The hypergeometric distribution The binomial distribution The Poisson distribution Although the hypergeometric may be used when the lot sizes are small, the binomial and Poisson are by far the most popular distributions to use when constructing sampling plans. Hypergeometric Distribution The hypergeometric distribution is used to calculate the probability of acceptance of a sampling plan when the lot is relatively small. It can be defined as the true basic probability distribution of attribute data but the calculations could become quite cumbersome for large lot sizes. The probability of exactly x defective parts in a sample n:

Binomial Distribution The binomial distribution is used when the lot is very large. For large lots, the nonreplacement of the sampled product does not affect the probabilities. The hypergeometric takes into consideration that each sample taken affects the probability associated with the next sample. This is called sampling without replacement. The binomial assumes that the probabilities associated with all samples are equal. This is sometimes referred to as sampling with replacement although the parts are not physically replaced. The binomial is used extensively in the construction of sampling plans. The sampling plans in the Dodge-Romig Sampling Tables were derived from the binomial distribution. The probability of exactly x defective parts in a sample n:

The symbol p represents the value of incoming quality expressed as a decimal. (1% = .01, 2% = .02, etc.)
Poisson Distribution The Poisson distribution is used for sampling plans involving the number of defects or defects per unit rather than the number of defective parts. It is also used to approximate the binomial probabilities involving the number of defective parts when the sample (n) is large and p is very small. When n is large and p is small, the Poisson distribution formula may be used to approximate the binomial. Using the Poisson to calculate probabilities associated with various sampling plans is relatively simple because the Poisson tables can be used. The Thorndike chart, which will be discussed later, is a valuable aid in the construction of sampling plans using the

Poisson distribution. The probability of exactly x defects or defective parts in a sample n:

The letter e represents the value of the base of the natural logarithm system. It is a constant value (e = 2.71828).

3. Define inspection. Analyze the essential elements of an inspection plan.

An inspection determines if the material or item is in proper quantity and condition, and if it conforms to the applicable or specified requirements. Inspection is generally divided into three categories: (1) Receiving inspection, (2) In-process inspection, and (3) Final inspection. In quality control (which is guided by the principle that "Quality cannot be inspected into a product") the role of inspection is to verify and validate the variance data; it does not involve separating the good from the bad.

What is an inspection plan: a. check machine tool for accuracy b. select the critical and important dimensions to inspect c. select the measuring instruments d. construct SPC charts for all dimensions

Essential elements of an inspection plan: Definition Describes how a quality inspection of one or several materials is to take place. The inspection plan contains information about the sequence of inspection operations and the range of specifications available for inspecting inspection characteristics. Use You use an inspection plan if you want to inspect materials using standard processes. You can inspect several materials with one inspection plan, or one material with several inspection plans. Structure The inspection plan has a similar structure to that of the routing. Inspection characteristics and test equipment (production resources/ tools) are assigned to one or more operations, which are in turn assigned to the inspection plan header. An inspection plan is identified by its task list group and group counter.

Inspection Plan Header

The structure of the inspection plan header is similar to that of the routing. The header contains information that forms the specification for the entire inspection plan. This information includes data that is important for inspection planning, such as:

Task list usage Inspection points Dynamic modification level and rule

Inspection operation The operations are assigned to the inspection plan header. An operation defines the activity that is to be performed at a work center. The structure of the inspection operations is also similar to that of the operations in a routing. The following assignment options are important for the quality inspection functions:

One or more items of test equipment that are used for the inspection (as production resources/ tools). Inspection characteristics

Inspection characteristic You can assign several inspection characteristics to the inspection operations. These characteristics describe what is to be inspected. The inspection characteristics are divided into quantitative (measuring) and qualitative (descriptive) characteristics. Integration You can integrate the following master data in your inspection plans and reference operation sets:

QM-specific basic data

Catalogs that store the codes for results recording and for making the usage decision. Inspection methods that store procedures for carrying out an inspection. Master inspection characteristics that simplify and standardize the inspection planning process and define what is to be inspected. Sampling procedure Dynamic modification rule

The dynamic modification of an inspection allows you to change the inspection scope dependent on the quality level that is expected.

General master data

Reference operation sets, Routings master recipes, from which you can copy operations and inspection characteristics if necessary and on which you can base the structure of your inspection plan. Work center at which the inspection takes place. using the work center. Appraisal costs. Are settled

o o

Production resources/ tools that are required for the inspection. Inspection planning must ensure that the test equipment required for an inspection is available or can be procured. Change Master Record with which you can manage various change statuses. Classes in the Classification System If you have large numbers of task lists, you can classify the inspection plan, to differentiate between them more easily. To do this you require the Classification System component (CA).

Scheduling You can control the lead times of an inspection plan more effectively by using the scheduling function. This allows you to check the expected lead time and to modify it, if required Refer to the documentation about routings (PP).

Integrating master data o Material Master for the material or materials that are inspected with the inspection plan. o Vendor master, with which you assign an inspection plan to a material in combination with a vendor. o Customer master, with which you assign an inspection plan to a material in combination with a customer. o Various info records for combinations of material and vendor, or of material, customer and sales organization or purchasing data.

4. Explain the characteristics of acceptance sampling.

Acceptance sampling uses statistical sampling to determine whether to accept or reject a production lot of material

C T I N T D A

C K S y p E

E E P e C TE C

T S

A A

N M S h N

C P A e

E L M r e E

C T t i t l e I S C I S I O T S I O T

T R D

LE O J E N

LA O M N IO N

T P

1 L 0O 0 T %

SS

PU

EP CP

T L I I OE

5. Write short notes: (i) Random numbers (ii) Sampling plan (iii) Sampling risk

(iv) Advantages and disadvantages for sampling inspection Random numbers:

A number generated for or part of a set exhibiting statistical randomness. A random sequence obtained from a stochastic process. An algorithmically random sequence in algorithmic information theory The output of a random number generator

Sampling plan: A sampling plan is a detailed outline of which measurements will be taken at what times, on which material, in what manner, and by whom. Sampling plans should be designed in such a way that the resulting data will contain a representative sample of the parameters of interest and allow for all questions, as stated in the goals, to be answered. Sampling risk: In inspection procedure, the probability, under the sampling plan used, that acceptable material will be rejected or that unsatisfactory material will be accepted. Advantages and disadvantages for sampling inspection: Advantages: More economical owing to fewer inspections. Less handling damages during inspection. Upgrading the inspection job from piece by piece decision to lot by lot. Disadvantages: There is a certain risk of accepting the bad lot and rejecting the good lot. More time and effort is devoted to plan the documentation. Less information is provided about the product.

6. Describe the procedure for sampling inspection. A sampling procedure contains rules that specify how:

The system calculates the sample size An inspection characteristic must be valuated

Structure The rules for determining the sample are stored in the sampling type. The sampling type and valuation mode for the inspection characteristic make up the sampling procedure. Sampling type The following sampling types are supplied in the standard system (among others):

100% inspection Fixed sample Percentage sample

Valuation mode You can adapt the valuation mode for the inspection characteristics to the sampling type (for example, for counting or measuring inspections). The following valuation modes are provided in the standard system (among others):

Attributive inspection Variable inspection

SPC inspection