session-2 & 3 Quality- Evolution of quality

8/7/2019 session-2 & 3 Quality- Evolution of quality

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TOTALTOTAL

QUALITYQUALITYMANAGEMENTMANAGEMENT

By:By:Zahid HussainZahid Hussain

Quality TrainerQuality TrainerMSMS--Total Quality ManagementTotal Quality Management

IRCA Lead Auditor ISOIRCA Lead Auditor ISO--90019001--20002000IRCA Lead Auditor ISOIRCA Lead Auditor ISO--1400014000--20042004

B.Sc Engineering (Chemical)B.Sc Engineering (Chemical)

PCBAPCBAUCPUCP

SESSION 2 & 3


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What is Quality ?What is Quality ?

Fitness for purpose or useFitness for purpose or use

JuranJuran

Quality is conformance to theQuality is conformance to therequirements.requirements.

CrosbyCrosby

Quality should be aimed at the needs ofQuality should be aimed at the needs ofthe consumer, present and futurethe consumer, present and future

Dr. DemingDr. Deming


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What is GRADE?What is GRADE?

Category or rankCategory or rank given to differentgiven to different

quality requirementsquality requirements for products,for products,processes, or systems having theprocesses, or systems having thesamesame functional usefunctional use

(ISO 9000:2008)(ISO 9000:2008)


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5/20

Quality Improvement for CustomerQuality Improvement for Customer

ValueValue

CUSTOMER

PRODUCTDESIGN

Quality ofPerformance / Use

Quality ofConformance

Quality of

Design / RedesignPurpose:

Customer Value


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Quality ParametersQuality Parameters Quality is a composite of three parameters:Quality is a composite of three parameters:

Quality of Design / RedesignQuality of Design / Redesign

Quality of ConformanceQuality of Conformance

Quality of Use / PerformanceQuality of Use / Performance

Quality of Design:Quality of Design: (Product and User Based Quality) is(Product and User Based Quality) isthethe extentextent to which the design reflects a product or serviceto which the design reflects a product or servicethat satisfies the customer needs or expectations.that satisfies the customer needs or expectations.

Quality of Conformance:Quality of Conformance: (Manufacturing Based(Manufacturing BasedQuality) is theQuality) is the extentextent to which the product or service conformsto which the product or service conformsto the design standard expectations.to the design standard expectations.

Quality of Use:Quality of Use: (User Based Quality) is the(User Based Quality) is the extentextent toto

which a product is easy to use, reliable and maintainable.which a product is easy to use, reliable and maintainable.


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The Evolution of QualityThe Evolution of Quality

The evolution can be broadlyThe evolution can be broadly

classified into five phases:classified into five phases:

InspectionInspection Quality ControlQuality Control

Quality AssuranceQuality Assurance

Total Quality ManagementTotal Quality Management

Total Quality AssuranceTotal Quality Assurance


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INSPECTIONINSPECTION

It is the sorting of NonIt is the sorting of Nonconforming items fromconforming items from

the conforming itemsthe conforming items Means separation ofMeans separation of

Defective items fromDefective items from

the right itemsthe right items +Rework (IF NEEDED)


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Process

Inspection

Acceptance

Next Process

Reject,Scrap,Rework

No

Yes

INSPECTION (Acceptance Sampling)

Pass theInspection


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The Quality Control PhaseThe Quality Control Phase

It involvesIt involves analyticalanalytical andand diagnosticdiagnostic

techniquestechniques and activitiesand activities aimedaimed atatmonitoring a process and eliminatingmonitoring a process and eliminatingcauses of unsatisfactory performancecauses of unsatisfactory performancefor the prevention of defects.for the prevention of defects.


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What is Quality Control?What is Quality Control?

The operational techniques andThe operational techniques andactivities that are used to fulfill theactivities that are used to fulfill the

requirements for quality. (ISOrequirements for quality. (ISO9000)9000) This general area may be divided intoThis general area may be divided into

two main sub areas:two main sub areas:

Statistical Process ControlStatistical Process Control

Acceptance Sampling PlansAcceptance Sampling Plans

INSPECTION + Corrective actionINSPECTION + Corrective action


12/20

Comparison withRequirements

ProcessProcess Settings,

Specifications, etc.

THE QUALITY CONTROL MODEL

Next Process

CorrectiveAnd

PreventiveActions

Process inControl

Yes

No

Corrective Actions: Action takento eliminate the cause of a

detected nonconformity or other

undesirable situation.

(ISO 9000:2008)

Preventive Actions: Action taken

to eliminate the cause of a

potential nonconformity or other

potentially undesirable situation.

(ISO 9000:2008)


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Benefits of Quality ControlBenefits of Quality Control

The advantages of a quality control system,The advantages of a quality control system,however, become obvious in the long run.however, become obvious in the long run.

1.1. Improvement in the quality of products andImprovement in the quality of products andservices.services.

2.2. System is continually evaluated and modified toSystem is continually evaluated and modified tomeet the changing needs of the customer.meet the changing needs of the customer.

3.3. Improves productivity, which is one of the goalsImproves productivity, which is one of the goalsof all organizations.of all organizations.

4.4. With improved productivity, the lead time on theWith improved productivity, the lead time on theproduction of parts and subassemblies isproduction of parts and subassemblies isreduced, which may result in an improvement inreduced, which may result in an improvement inmeeting customer due datesmeeting customer due dates

5.5. Reduces costs in the long run.Reduces costs in the long run.


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What is Quality Assurance?What is Quality Assurance?

TheThe objective of the quality assuranceobjective of the quality assurancefunction is to have a formal system that willfunction is to have a formal system that willcontinually survey the effectiveness of thecontinually survey the effectiveness of the

quality philosophy of the company.quality philosophy of the company.

QualityAssuranceQualityAssurance:: All those planned and

systematicactivities implemented toprovide adequate confidence that an entitywill fulfill requirements for quality. (ISO 9000)


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The Quality Assurance ModelThe Quality Assurance Model

The emphasis is towards improvement ofThe emphasis is towards improvement ofthethe process capabilityprocess capability ,,detection anddetection andprevention of nonprevention of non--conformanceconformance..

Quality Assurance addresses theQuality Assurance addresses the entire lifeentire lifecyclecycle of a product, starting from the initialof a product, starting from the initialproduct identification to final inspection,product identification to final inspection,

reliability in use and customer satisfaction.reliability in use and customer satisfaction.


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Comparison withRequirements

Process

Process Settings,

Specifications, etc.

THE QUALITY ASSURANCE MODEL

Corrective &Preventive

Actions

Process inControl

Yes

No

Process inControl

No

Continuous Process Improvement

Perform Design Of Experiment,Reliability Engineering

Yes

Improved ProcessSettings, Alternative

Material


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DefinitionsDefinitions

Design of ExperimentDesign of Experiment(DOE)(DOE)

It is a structured andorganized method used

to determine therelationship betweenthe different factors(XS) effecting a processand the output ofprocess (Y).

10 -20 experiment relevant factors arevaried systematically results of experimentsare analyzed to identify

the optimum condition.

Reliability EngineeringReliability Engineering

It is the study ofIt is the study ofreliability, which isreliability, which is

thethe abilityability of aof aperson productperson productsystem tosystem toperformperformand maintain itsand maintain itsfunctionfunction in routinein routine

andand unexpectedunexpectedcircumstancescircumstances..


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QC Vs QAQC Vs QA

Quality ControlQuality Control

ProductProduct

ReactiveReactive Line functionLine function

Find DefectsFind Defects

Quality AssuranceQuality Assurance

ProcessProcess

ProactiveProactive Staff functionStaff function

Prevent defectsPrevent defects

Line function: Decision making areas of an organizationassociated with its daily operations.Staff Function: The advisory , analysis and support functionsprovided to line functions such as accounting , planning.


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Total Quality Assurance ModelTotal Quality Assurance Model

All the companies are dependent on theirAll the companies are dependent on theirsuppliers to provide:suppliers to provide: Cost reductionCost reduction

Joint innovationsJoint innovations-- Collaboration in setting of jointCollaboration in setting of jointbusiness objectives.business objectives.

Prompt response to design changesPrompt response to design changes

Reduction in duplicate efforts ( Quality checks etc)Reduction in duplicate efforts ( Quality checks etc)

Waste reductionWaste reduction

Short lead timeShort lead time

Informal alliances can reduce the likelihood of eitherInformal alliances can reduce the likelihood of eitherparty to unexpected switching businessparty to unexpected switching business


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Total Quality Assurance Model

QualitySystem

(ISO (9001)

+Tools

e. g SPC,DOEx

= TQMTeam Work+

Specification,

Feedback,

Training,

Seminars

Good QualityProducts

Prompt Delivery

Supplier's QualitySystem

(ISO 9001)+

Business

Alliance &TechnologySharing

Company

Supplier

Suppliers Management Commitment

Companys Management Commitment

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session-2 & 3 Quality- Evolution of quality

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