Module-II bu pom notes

8/6/2019 Module-II bu pom notes

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Asst Prof Arvind Gajakosh

BE, MBA, NET


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Quality is the totality of features & characteristics

of a product or services that bear on its ability to

satisfy stated or implied needs.

In simple terms, quality means the satisfaction ofthe customer real or potential.

Quality of the product will also depend upon the

expectations of the customer.

Appearance, performance, life, reliability, taste,& maintainability etc are generally called as

quality characteristics.


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QCs are small groups of employees who meet

regularly for solving different problems related

mainly with cost, quality, efficiency, equipment,

tools, morale, process, control, missed work,safety, learning & maintenance etc.


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Quality control helps achieve the qualitativeobjectives of the production system by keeping a

check on all these parts of a production system

that may have an impact on the quality of

product.

Quality planning Quality control Quality improvement

Establish quality goals Choose control subjects Prove the need

Identify customers Choose unit to measure Diagnose the causes

Discover customer

needs

Create a sensor Provide remedies

Develop product

features

Measure actual

performance

Deal with the

resistance

Develop process

features

Interpret the

difference

Change & control


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The formation of International Standards

Organization (ISO) in Geneva in 1946, led to the

increased awareness amongst people regarding

quality.

It is an international body which consists of

representatives from more than 90 countries.

Bureau of Indian Standards is the Indian

representative to ISO.

ISO & IEC (International Electro Technical

Commission) operate jointly as a single system.


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Standard Objectives/Tasks

ISO 9000 This provides guidelines on selection & use of quality

mgmt and quality assurance standards.

ISO 9001 It has 20 elements covering design, development,

production, installation & servicing.

ISO 9002 It has 18 elements [it is same as ISO 9001 without the first

two tasks design & development]

ISO 9003 It has 12 elements covering final inspection & testing for

laboratories & warehouses etc.

ISO 9004 This provides guidelines to interpret the quality mgmt &

quality assurance.


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Prof. Karou Ishikawa, known as the father of

Quality Control Circles (QCCs), developed the

seven QC tools.

Pareto chart Cause & Effect Diagram

Histogram

Stratification

Scatter Diagram Controls charts

Check sheets


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Pareto diagram consists of two graphs. One is bar

chart in which the items are arranged in the order

of the no. of problems or the amount of money.

Another graph is line chart of accumulations ofbars.

If the bars show the amount of money, the line

shows the transition of the accumulated amount

of money. This line chart is also called as Pareto

Curve.


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Prof. Karou of Tokyo University of Japan developed

the concept of cause & effect diagram.

Due to its shape, this diagram is also known as the

fishbone diagram. The box represents the effect & the lines are the

causes.

CE diagram is a first step in problem solving.

CE diagram is a tool for discovering all the possiblecauses for a particular effect.


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Dispersion analysis type

(communication, skills, procedures transport

incorrect deliveries)

Production process classification type (order processing, picking, packing, dispatch

incorrect deliveries)

Cause enumeration type

(starting with the backbone deciding broad areas,then adding more & more branches)


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A histogram is a graphic summary of variation in a

set of data.

Histogram can be analyzed to draw conclusions

about the data set. Histograms are used to chart frequency of

occurrence.


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Histogram used two types of data that are variable

data & attribute data.

Variable data are continuous in nature & are

measurable on a sliding scale. Ex: dimension,voltage, weight etc.

Attribute data are discrete in nature & can be

binary. Ex: accept/reject.


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Stratification is stratifying or categorizing of data

in some meaningful categories.

Categories can be determined by equipment, by

operator, by operation method or by RM. Grouping of data by common element or

characteristic makes it easier to understand the

data & to pull insights from it.

Operators can be stratified by age, training,gender, marital status, experience etc.

Machines can be stratified by age, data of

maintenance, tools & location.


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Scatter diagram is a figure applied to visualize the

relation of two variables.

The scatter diagram is used to determine the

correlation b/n two characteristics (variables) One variable is scaled on X-axis (color) & another

on Y-axis (age of bread[days]).


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Control chart is an instrument to be used in theproduction, specification & inspection.

It tells us at a glance whether or not a process is

within the tolerance limits.

A typical control chart consists of a central line,upper control limit, & lower control limit. (ex:

room temperature)

Based on Variables Attributes

Control chart for Mean P (proportion)

Control chart for Range Np (no. of defectives)

Control chart for Std Deviation C (no.of defects per unit)


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Check sheet is a tool applied at the phase of data

collection.

The purpose of the check sheet is to make it easy to

collect for specific purposes & to present it in waythat if facilitates conversion from data to useful

info.

Defect factor check sheets (time, temp)


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Establishment ofpolicies regarding

quality desired inrelation to market,

invstmt reqmt, ROI etc

Quality & the

design of

prod/services in

relation to the

productive sys.

Quality stds for:

Materials,

Processes,

Performance of

Prod/services

Design ofproductive system

to be compatible

with quality, cost

& capacity

requirements

Inspection

& controlof

incoming

materials

Production

of goods &

services

Inspection

& control ofprocesses &

products or

services


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The QC process involves in general the following

steps:

Preparation of policies regarding quality

Fixation of quality stds relating to materials &processes.

Designing the productive system.

Inspection & control of materials.

Inspection & control of processes. Production of goods & services.

Inspection of the final products/services.


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Increased sales volume

Increased profits

Improving the company image

Improving the production system

Better procurement of materials

Analyzing & doing away with the deviations

To reduce the cost of inspection and loss


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Asst Prof Arvind Gajakosh

BE, MBA, NET


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In the mid 1980s Motorola engineer felt that thetraditional quality levels of measuring defects in

thousands of opportunities didt provide enough

depth of info.

They decided to measure the defects per millionopportunities.

Definition: six sigma is a disciplined data driven

approach & methodology for eliminating defects

which amounts to driving towards six standard

deviations b/n the mean & the nearer specification

limit in any process of products/services.


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General Electric(GE) Company, defined six sigma as itis a vision of quality which equates with only 3.4

defects per million opportunities for each

product/service transaction & it strives for

perfection. Six sigma level indicates that we are 99.99966%

confident that the product/service delivered by us is

defect free.

This means that only 0.00034% of the times the

product/service delivered is defect prone(3.4 defects

per million opportunities[DPMO]).


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There are two approaches for achieving six sigmawhich are as listed below.

DMAIC

DMADV

DMAIC: means Define, Measure, Analyze, Improve &Control. The six sigma DMAIC process is an

improvement system for existing processes falling

below specification & looking for incremental

improvement. DMADV: means Define, Measure, Analyze, Design, &

Verify. The six sigma DMADV process is an

improvement system used to develop new processes

or products at six sigma quality levels.


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DMADV: means Define, Measure, Analyze, Design, &Verify. The six sigma DMADV process is an

improvement system used to develop new processes

or products at six sigma quality levels.

Types of six sigma belts: Green belts

Black belts

Master black belts


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Green belts: six sigma green belts are six sigma teamleaders capable of forming & facilitating six sigma

teams & managing six sigma projects from concept to

completion.

It consists of five days of classroom training. Training covers facilitation techniques & mgmt of

meetings, project mgmt, qlty mgmt tools, qlty ctrl

tools, problem solving etc.

Black belt help green belts in choosing their projectsprior to the training.


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Black belts: six sigma black belts are leaders ofteams responsible for measuring, analyzing,

improving & controlling key processes that influence

customer satisfaction &/or productivity growth.

They should focus on 1 to 3 projects. Direction &leadership for them should come from a master black

belts.

Master black belts: these are the persons with

highest level of technical & organizational

proficiency. They train black belts.

They should be sound on mathematical theory on

which the statistical methods are based.


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It ensures enhanced product quality.

It enables predictable delivery of the products.

It helps to achieve productivity improvement.

It helps to have rapid response to changing needs of

customers.

It also facilitates the development & introduction of

new products into the marketplace.


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FMEA is a procedure for analysis of potential failuremodes within a system for the classification of thefailure effects upon the system.

Failure causes are any errors or defects in process,

design, or product. FMECA is a technique for assessing the risk associated

with defective products reaching the market.

The technique assesses the following three aspects ofthe system and optimizes them:

Every possible failure mode.

Effect of each failure mode on the product.

The critically of the effect of each failure mode onthe product.


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Poka yoke (mistake proofing) is a Japanese term

which was coined by a Japanese engineer named

Shingeo Shingo.

This was originally called as Baka Yoke (fool proofing)

during 1961.

Poka Yoke is a bunch of a small devices like fixtures,

jigs, gadgets, warning signals, paper systems and the

like which are used to detect or prevent defects from

occurring the first place.


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It is capable of being used all the time by allworkers.

It is simple to install which means that it is not

requiring continuous attention from the operator.

It is usually installed with low implementation cost. It provides instantaneous feedback, prevention or

correction.

If a component is not having the correct shape or

form, then the production process should detect itbefore performing any operation on it.


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Reduction in waste & associated machining as

nonconforming material is identified at each stage

rather than an inspection stage b/n several pairs of

stages.

Reduction of waste in the system leads to reductionin inventory holdings.

Improvements in customer satisfaction levels because

better quality product is delivered to them.

Improvement in employees relationships as itencourages more involvement of operators and team

members.


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It increases the time of inspection that the operatorwould spend on his job.

Increased time of inspection does not mean reduced

cost of scrap in the long run.

In short term, there will be a sharp increase in scrapmaterials cost.


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End please.!

Thank you..!

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