TOTAL QUALITY MANAGEMENT

SEMINAR

BY-
SHOUTIK CHAKRABARTI ID-091020024
APURVA GHUTUKADE ID-091021064
OUTLINE
INTRODUCTION AND DETAILS OF THE MAIN & COLLABORATING
COMPANIES AND THE PRODCUT TO BE MANUFACTURED
PROFILES AND THE PROBLEMS PLAGUING THE FOUR COLLABORATORS
PROFILE AND PROBLEMS PLAGUING THE FIFTH COMPANY WHICH WILL
WORK WITH THESE FOUR COMPANIES TO MAKE THE FINAL PRODUCT.
SOME BASIC SOLUTIONS TO THE PROBLEMS FACED BY THE FIVE
COMPANIES
INTRODUCTION
Product to be manufactured- A hybrid car(parallel)


COMPANY PROFILE
TASKS ASSIGNED &
PRODUCTS PRODUCED
HYBRIDENERGY LTD. MAIN COMPANY
ENGINE MANUFACTURING,
ASSEMBLY
ACCUCONSULTING INC. CONSULTANT
CONSULTANCY AND
CONTINUOUS ASSISTANCE
MARKTECH LOGISTICS CORP. MARKETING & LOGISTICS
PROMOTION OF PRODUCT,
SUPPLY CHAIN
MANAGEMENT
BLAZETRICAL LTD.
ELECTRICALS &
ELECTRONICS
MOTORS, ELECTRONIC
CIRCUITRY
MAXDESIGN LTD. MECHANICAL COMPONENTS
CHASSIS, TRANSMISSION,
GLASS PANELS
Auto industry trends
Auto industry challenges
Global Warming
Air Pollution
Rising fuel prices
Declining fuel reserves

AUTO INDUSTRY CHALLENGES
WORKING PRINCIPLE
WHY HYBRID CARS
Fuel efficient
Ultra low emissions
Reduced Noise
Better Performance
Financial Benefits
Rated as highly reliable cars by J.D. Powers and consumer reports
Customer satisfaction rate among buyers of hybrid vehicles is 80 to 90
percent according to J.D. Power, and Polk Automotive data


WHOS MAKING HYBRIDS TODAY
Prius
Camry
Malibu
Silverado
& Sierra
Accord
Civic
RX400 h
SUV
Escape
Current Market Scenario
Toyota has an edge at the moment.
Honda, now in its second generation of hybrids, is improving in leaps
and bounds, but Toyota has expanded the technology into the luxury
car sector via Lexus.
When comparing the Prius to the current Civic Hybrid, Toyota's
technology is a bit more refined. Both have a similar function but the
Toyota, because it's had a head-start, has a more seamless transition
between the petrol and the electric motors.
Camry hybrid car has helped Toyota to win a Green Innovation Award
in 2011.

projected co2 reduction
UNTAPPED MARKET
Money doesn't grow on trees, but it does grow from something
else green HYBRID VEHICLES

WORKING PRINCIPLE

WORKING PRINCIPLE
Gasoline-electric hybrid cars contain the following parts:
Gasoline engine - The hybrid car has a gasoline engine much like the one
you will find on most cars. However, the engine on a hybrid is smaller and
uses advanced technologies to reduce emissions and increase efficiency.
Fuel tank - The fuel tank in a hybrid is the energy storage device for the
gasoline engine. Gasoline has a much higher energy density than
batteries do. For example, it takes about 1,000 pounds of batteries to
store as much energy as 1 gallon (7 pounds) of gasoline.
Electric motor - The electric motor on a hybrid car is very sophisticated.
Advanced electronics allow it to act as a motor as well as a generator. For
example, when it needs to, it can draw energy from the batteries to
accelerate the car. But acting as a generator, it can slow the car down and
return energy to the batteries.
Generator - The generator is similar to an electric motor, but it acts only
to produce electrical power. It is used mostly on series hybrids

WORKING PRINCIPLE
Batteries - The batteries in a hybrid car are the energy storage device for the
electric motor. Unlike the gasoline in the fuel tank, which can only power the
gasoline engine, the electric motor on a hybrid car can put energy into the
batteries as well as draw energy from them.
Transmission - The transmission on a hybrid car performs the same basic
function as the transmission on a conventional car. Some hybrids, like the
Honda Insight, have conventional transmissions. Others, like the Toyota Prius,
have radically different ones, which we'll talk about later.
GETTING TO THE PROFILES
The product would need the following things to be successful :
Initial thorough market survey{which has already been carried out}
Assistance of third-party consultants
Good promotion of the product
Reliable supply chain
Good quality vendors supplying all the necessary parts

As mentioned earlier, we will have four major associates providing
services such as consulting, marketing, supply chains, parts, spares etc.

CONSULTANT

Third party consultants are approached to examine the viability of the project
and how to go about the whole thing right from how to go about
manufacturing the product to what types of works to outsource and finally the
channels of distribution.
CONSULTANT
The consultancy firm is ACCUCONSULTING INC.
Some of the suggestions offered by them are:

Establish concrete short term goals as such projects usually get lost in
the maze of long term goals and commitments
Ensure willing venture capitalist. Capital is of the essence
Hire a marketing agency
Hire a logistics agency
Try using best quality material and implement various green measures
such as Green PLM in order to obtain licenses soon and also to establish
oneself as the best in the business
Lay down very strict guidelines for the vendors. Include them in the
quality control process as well




Managing
Director
Client
Partner 1
Associate
Director
Client
Manager
Senior
Consultants
Associate
Consultants
Associate
Director
Client
Manager
Senior
Consultants
Associate
Consultants
Client
Partner 2
Associate
Director
Client
Manager
Senior
Consultants
Associate
Consultants
Associate
Director
Client
Manager
Senior
Consultants
Associate
Consultants
ORGANISATIONAL STRUCTURE
CONSULTANT
Problems faced by the consulting firm:

Poor channels of communication internally and externally
Late delivery of reports and suggestions
Poor soft skills of some of the junior level consultants
Arrogance on the part of the senior level consultants
Poor risk analysis at times
Very high expenses on the employees which in turn raises their
companys consultancy fees.
MARKETING & LOGISTICS
MARKETING & LOGISTICS
Enough stress cannot be laid on the importance of a good marketing strategy
and on the availability of good quality supply chains. Our company co-
ordinates with one company which provides both marketing expertise as well
as logistics support
C.E.O.
PRESIDENT(LOG)
Associate
Director
Client
Manager
Logistics Exec
Associate
Director
Client
Manager
Logistics Exec
PRESIDENT(MAR)
Associate
Director
Client
Manager
Marketing
Exec
Associate
Director
Client
Manager
Marketing
Exec
ORGANISATIONAL STRUCTURE
MARKETING & LOGISTICS
The marketing and logistics firm chosen is MARKTECH LOGISTICS CORP.

Some of the problems plaguing this company are:

Slightly laid back attitude while promoting the product especially in
sections of the society they feel will not buy this product
Lack of consistency in brochures distributed amongst various potential
clients such as the common people and corporate houses
Less focus on online promotion of the product
Lack of enough skilled personnel for loading and unloading goods from
their trucks
Many cases of defective products reaching our company

ELECTRICALS & ELECTRONICS
For the hybrid car, electrical components are very important. They
range from the motor, batteries to the various circuitry involved.
C.E.O.
PRESIDENT(ELECTRICALS)
Associate
Director
Client
Manager
Exec
Associate
Director
Client
Manager
Exec
PRESIDENT(ELECTRONICS)
Associate
Director
Client
Manager
Exec
Associate
Director
Client
Manager
Exec
ORGANISATIONAL STRUCTURE
ELECTRICALS & ELECTRONICS
The firm chosen for electricals and electronics is BLAZETRICAL LTD.

Some of the problems plaguing this company are:

Non compliance of ISO standards while making motors in spite of repeated
requests
Way too many defects in electronic circuits
Poor shelf life of batteries
Delay in response to orders
Poor communication internally and externally


MECHANICAL COMPONENTS
MECHANICAL COMPONENTS
No chassis, no body = No vehicle!
No vehicle would function without the basic components such as the
transmission system.
Hence finding the right vendor for such crucial components is important.
The company approached is MAXDESGIN LTD.

MAXDESIGN LTD. has been entrusted with the responsibilities of
manufacturing the following :

Chassis
Body
Drivetrain/transmission
Glass panels
Seats
Entire interiors



C.E.O.
PRESIDENT(TRANS)
Associate
Director
Client
Manager
Exec
Associate
Director
Client
Manager
Exec
PRESIDENT(ACCESSORIES)
Associate
Director
Client
Manager
Exec
Associate
Director
Client
Manager
Exec
ORGANISATIONAL STRUCTURE
We see that MAXDESIGN LTD. Is a very crucial associate as it has been
handed over a number of tasks and hence it is imperative that it meet the
highest quality standards in every single aspect.

Some of the problems plaguing them are:

Many cases of cracks on the body of the car
Poorly finished gear boxes , inaccurately machined and lack of proper fit
Noisy gear boxes
Short shelf life of clutch plates
Chassis unable to withstand slightly rough terrain
Glass panels not toughened enough
Poor quality material used for interiors



HYBRID CAR MANUFACTURER
The company which will co-ordinate with the previously mentioned four
companies and some other companies and small vendors is HYBRIDENERGY
LTD. This is a start up founded by us and it is our desire to break into the
field of hybrid vehicles. It has been already explained that this is a lucrative
field.

The company will perform the following tasks:

Manufacture the C.I. engine
Assemble the whole car
Co-ordinate with its four most valued associates and a host of other
suppliers and vendors
Implement quality control measures itself and also assist its vendors
implement quality control measures as well

Some of the other suppliers would include those needed for the wheels,
various lubricants, oils, nuts and screws and small peripherals.
PARTNERS 1 & 2
PRESIDENT(HR)
Associate
Director
Exec
Engineers
Associate
Director
Exec
Workers
PRESIDENT(OPS)
Associate
Director
Exec
Engineers
Associate
Director
Exec
Workers
ORGANISATIONAL STRUCTURE
HYBRID CAR MANUFACTURER
With such big names in the field of hybrid cars, it is imperative for us to
provide good quality cars at affordable prices. The dilemma of every
manufacturer! Hence we are constantly working towards trying to improve
ourselves
Some of the problems plaguing HYBRIDENERGY LTD. are:

Shortage of skilled labor
Shortage of personnel to oversee the day to day operations
Many defects in the engines produced
Low productivity
Poor co-ordination with the numerous vendors
Not yet obtained all green certifications
without which we cannot charge our customers a
premium for our products
Lack of enough quality checks for the incoming goods
Not enough training programs
Lack of good quality after sale service
INTEGRATED WORKING
HYBRIDENERGY
LTD.
MARKTECH
LOGISTICS
CORP.
BLAZETRICAL
LTD.
MAXDESIGN
LTD.
OTHER
VENDORS
ACCUCONSULTING INC.
Having seen the problems plaguing each of the five companies, lets
look at some of the quality control measures already accepted by
the industry and which we plan to implement as well.
Prepare Future State
Solution draft
Identify Action Plan
Implementation of
Future State Solution
and Measure Impact

Collect & Analyze Data
for Benchmark Item
Conduct Internal
interviews & Surveys
Conduct Reverse
Engineering
Identify What to
Benchmark
Obtain top management
support
Identify Benchmarking
Metric
Develop the Data
Collection Plan
Plan Do
Check Act
Benchmarking
Quality Control Measures
Kaizen
Strategic action plan
Hybridenergy Ltd aims to provide the best services to consumers by
quantifying gaps between the benchmarker's performance and
world-class performance and by adopting the best in class practices
through commitment to quality and sustainability.
Overseas markets