Professional Documents
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It is a relative term, used with reference to the end use of the product.
The word Quality have variety of meanings:
Fitness of purpose Grade Degree of preference Degree of excellence Fulfillment of the promise
Quality of design
Quality
Quality of conformance
Quality of performance
the product.
Factors controlling the quality of design:
Type of customers in the market Intended life, environmental conditions, reliability, importance of continuity of services. Profit considerations Special requirement of the product such as strength, fatigue resistance, life, etc. Economic considerations and feasibility.
of design.
Important factors:
Adequate quality and proper maintenance of raw material, machines, tools, measuring instruments. Selection of proper process and there should be adequate process control during manufacturing. Operators should be well trained and experienced Proper care for shipment and storage of finished goods Properly planned inspection programme.
QUALITY OF PERFORMANCE
Concerned how well the manufactured product gives its performance.
It depends upon:Quality of Design Quality of Conformance.
carried out.
Its a name of the department which devotes itself full time to quality
functions.
System, plan or method to solve quality problems.
Give assurance the only good quality products are sent to the
customers.
Standardizations of products according to quality specifications.
Try to curtail the effective over all cost by controlling the process and
Control chart for variables Control charts Control chart for attributes
X bar and R or X bar and Sigma charts are used in combination for the
control process. X bar chart shows the centering of the process i.e. it shows the average of the samples. R chart shows the uniformity or consistency of the process i.e. it shows the variations in the ranges of the samples. Sigma chart shows the variation in the process. Control charts are used to determine whether a given process can meet the existing specifications without a fundamental change in production process. To secure information to be used in establishing or changing production process. To secure information when it is necessary to widen the tolerance. To secure information to be used in establishing or changing inspection procedure or acceptance procedure or both. To provide the basis for current decisions on acceptance or rejection of manufactured or purchased part.
1)
Calculate the average X and range R for each sub group:X = X1+X2+X3+X4+X5/5
R = R/N
3) Calculation of 3 Sigma limits on control chart X chart. Upper control Limit X = X + 3 X
UCL R = D4R or D2
LCL R = D3R or D1
Plot the X and R chart :X chart, the central line should be solid horizontal line. The upper and lower limits line should horizontal dotted lines at the computed values. In R chart central line will indicate R control limits will be shown by dotted horizontal lines at computed values
Central Line for P chart, P = Number of defective articles/Total number of articles inspected. Control Limits for P chart are:-
Record the date for each sub group on number inspected and numbers
defectives.
Compute p ( Fraction defective) for each subgroup.
Central line = p
Plot each point as obtained, plot trial control limits as soon as
calculated.
Control limits:
p = np/n
VARIABLE CHARTS 1. 2. 3. 4.
Examples: X, R , charts
ATTRIBUTES CHARTS
P, np, C, u charts
Type of data required:- Variables data ( Attribute data ( Using Go-No-Go gauges) Measured values of characteristics) Field of Applications: Control of individual Control of proportion of defectives or number characteristics of defects or number of defects per unit. Advantages:a). Provides maximum utilization of information available from data. b). Provides detail information on process average and variation for control of individual dimensions. Disadvantages:a). Not easily understood till training is not provided. b). Can cause confusion between control limits and specification limits. c). Cannot be used with go-on-go type gauge inspection. a). Data required are often already available from inspection records. b). Easily understood by all persons. As more easier den X bar and R charts. c). It provides over all picture of quality history. a). They do not provide detail information for control of individual characteristics. b). They do no recognize different degrees of defectiveness. ( weightage of defects).
5.
If all the points in a chart lie within UCL and LCL , then the process
said to be out of control showing the presence of assignable caused and necessity of some remedial measures.
If points lie predominantly on one side of the central line then it
charts)
Bullets and shells ( attributes charts)
( attributes charts).
Punch press works, forming, spot welding, etc. ( attributes charts)
lot for the purpose of accepting or rejecting the lot as either conforming or not conforming to a quality specifications.
2 ways in which inspections is carried out:100 % inspection Sampling inspection
inspected, if the sample is good enough the lot is accepted otherwise entire lot is rejected.
Sampling inspection is more practical, quick and economical.
The cost and time required for sampling inspection is quite less.
Problem of inspection fatigue which occurs in 100% inspection is
eliminated.
Smaller inspection staff is sufficient.
are improved.
It exerts more effective pressure on quality improvement. Since, the
May not always represent the exact picture as only part is inspected.
Likelihood of making wrong decision in 2 ways :A really good lot may be rejected because of sample drawn may be bad. A really bad lot may be accepted because sample drawn may be good.
In the first case producer has to suffer the risk, associated risk is called
as producer risk.
In the latter case, consumer runs a risk of accepting bad lots, associated
Randomness of samples. Sample size Quality characteristic to be tested. Acceptance criteria Lot size.
Producers risk
Consumers risk
Sampling plans may be grouped in 3 categories:Single sampling plans Double sampling plans Multiple sampling plans
In Single sampling plan 3 numbers are specified:N = lot size from which the sample is drawn n = sample size c = acceptance number
Eg. N = 50, n = 5, c = 1
Take a sample of 5 items from a lot of 50, if the sample contains more than 1 defective reject the lot, otherwise accept the lot.
Exceed c
Double sampling plan:The decision of acceptance or rejection of lot is based on 2 samples. A lot may be accepted at once if the first sample is good enough or rejected at once if the first sample is bad enough. If the first sample is neither good nor bad enough, the decision is based on the evidence of the first sample and second sample combined.
Parameters:-
n1+ n2=
Doesnt exceed C1
C1<def.<= C2
Exceeds C2
No. of defectives in the first and second samples combined together ( n1 + n2)
Doesnt exceed C2
Exceeds C2
Multiple Sampling Plan:It is generally used when three or more samples of stated size are permitted and when the decision on acceptance or rejection must be reached after a stated number of samples. Phrase sequential sampling is generally used when a decision is possible after each item is inspected and when there is no specified limit on total number of units to be inspected.
COMBINED SAMPLES Sample Sample size Size Acceptanc Rejection e number number
c1 c2 r1 r2
First Second
n1 n2
n1 n1+n2
Third
Fourth
n3
n4
n1+n2+n3
n1+ n2+n3+n4
c3
c4
r3
r4
Fifth
n5
n1+n2+n3+n4+n5
c5
r5
Total quality control:Effective system of integrating quality maintenance and quality improvement efforts of the various groups in the organization, so as to enable production and services at the most economical levels, which allow full customers satisfaction. Stress on prevention of defects rather than setting it right by rectification. Total quality can be achieved only through total Employee Improvement.
Development of product specifications based on needs of users and economical considerations. Interaction with product design Reliability and development testing Process capability studies Quality planning for control of production process Quality control for incoming material Vendor quality control and vendor development Interaction with service engineering Training of staff and customers Quality audit, etc.
COMPREHENSION
CONTINUANCE
COMMITMENT
CORRECTION
COMPETENCE
COMMUNICATION
Challenges faced by business in todays time:Increase in product complexity and size of operations Stiff competition at national and international levels.
Survival of the fittest is the slogan now the company follow to stay
in business.
3 main pillars :Consumer awareness National and international legislations To strive for excellence and grow in business responsibility for product quality has shifted from operator to foreman to inspector to quality control deptt. and later on to Quality Management.
Cost of manageme nt
Business
Technical innovations
Staff expectation s
(both external and internal) by meeting their expectations on a continuous basis through everyone involved with the organizational working on continuous improvement in all products/processes along with proper problem solving methodology.
TO DELIVER HIGHEST VALUE AT LOWEST COST is the main
objective of TQM
It was first released in Japan.
It is a organization wide quality focused culture.
business no matter what their function. It recognises the necessity to develop processes across the business, that together lead to the reliable delivery of exact, agreed customer requirements. This will achieve the most competitive cost position and a higher return on investment.
Quality - The prime task of any business is to understand the needs of
the customer, then deliver the product or service at the agreed time, place and price, on every occasion. This will retain current customers, assist in acquiring new ones and lead to a subsequent increase in market share.
Management - Top management lead the drive to achieve quality for
customers, by communicating the business vision and values to all employees; ensuring the right business processes are in place; introducing and maintaining a continuous improvement culture.
transformation processes of an organization to best satisfy customers needs in the most economical manner.
TQM is a management approach of organization, centered on quality,
based on the participation of all its members and aiming at long term success through customer satisfaction and benefits to the members of organization and society. (ISO : 8402/IS 13999)
As per Sashkin and Kiser, TQM may be defined as creating an
organizational culture committed to the continuous improvement of skills, teamwork, processes, product and service quality and customer satisfaction.
As per Atkinson,
As a strategic approach to produce the best product and services possible though constant innovation.
Commitment, participation, motivation, education and training, organization development, quality system.
satisfying the customers requirement which never remain constant but keep on changing with the change in times, environmental circumstances, needs, fashions, standard of living, etc.
Suitability (Fitness for use)
Reliability ( It should give efficient and consistent performance) Durability, the life aspect of quality Safe and foolproof workability Maintainability
Aesthetic look
Good packaging Versatility ( Can serve number of purposes) Variety in products and services After sales service and support to customer
- Affordability - value of money spent by customers - Good image and customer confidence
TQM adopts the zero defect policy. Rigorous application of EPDCA approach i.e. Evaluate
Plan Do Check
Act
Continuous Improvement:
Organization has to cope up with the changing requirements of the customers. TQM strives for ever better quality, cost reduction to face competition and for the survival of the organization.
Employee Involvement:All employees working in the organization should be involved in TQM operation. Requires every member of the organization to accept quality as his major area of responsibility. A positive attitude towards customer and constant enhancement of quality must be ingrained in the minds of employees.
Empowering the Staff:Assist to accomplish optimal business results through team work. Empowerment occurs when employees are adequately trained, with relevant information and best possible tools and are fairly rewarded for best results. Result of empowerment, creativity, productivity, motivation, commitment and customer service.
Bench Marking:Its the practice of identifying, studying and building upon the best practices in the industry or the world. Companies keeps on updating themselves regarding external environment to compare their process, products and services with best industry practices. Establish quality targets which enhances the competitive strength.
Feedback Mechanism:Customer feedback and employee feedback, to create customer oriented quality culture Provide an accurate evaluation of operations of the company, internal and external. Information can be collected through questionnaire surveys, interviews, use of focus groups and field complaints , suggestion systems etc.
Customers
Staff
c)
d)
It makes the company a leader not the follower. Creates goal directed connection between customer, management and workers. Makes company more sensitive to customer needs. Makes company adopts more readily to change. Fewer problems with product or services. Better customer care. Greater satisfaction
B.
Benefits to Customers:a)
b)
c)
Better product quality Staff more motivated and quality conscious Product improvement Reduced quality costs. Increased market. Increased competitive position of the firm, improved profitability. Good public image Improved human relation and work area morale
D.
Benefits to Staff:a) b) c) d) e)
Empowerment Enhancement of job interest and security More training and improvement in skills More recognition Reduced employee grievances.