Guest lecture on TQM tools (Unit IV - GSS 103)

Presented by :Prof. M. Balaji., M.E., M.B.A., M.I.I.E.,M.I.S.M.,

Senior grade assistant professor, Department of Mechanical Engineering,

Kumaraguru college of technology, Coimbatore – 641 049.

email to: balaji.m.mec@kct.ac.in

04/18/23

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Topics to be covered

1)Benchmarking2)Quality Function Deployment (QFD) 3)Taguchi quality loss function 4)TPM – Concepts, improvement needs 5)FMEA6)Quality circles 7)Cost of Quality – Performance measures

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1) Benchmarking • Benchmarking is a relatively expensive and time consuming process

in most industries against the critical Design Measures.• Criticality is defined by how important a particular Measure is to

the success of the product and whether there are special circumstances impacting a particular Measure.

• Benchmarking is able to determine what the market likes and dislikes.

• When a manufacturer captures the customer's perceptions of how well different products perform in the marketplace, they can better understand what is driving the purchase decision.

• Benchmarking is an attempt to correlate the actual performance with the perceived performance of the product attributes.

• Benchmarking all of the competitive products may prove a time consuming occupation, rather the best in trade.

• ex: Maruthi 800 for hatch back sedan cars

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2) Quality Function Deployment (QFD)

• QFD is a rigorous method for translating customer needs, wants, and wishes into step by step procedures for delivering the product or service tailored to customer needs.• QFD cuts the normal development cycle by 50%,

making faster moves into market.• QFD resembles a highway interchange between

the voice of the customer (VOC) and the Voice of the Engineer(VOE).• Demand characteristics are represented in rows

and quality characteristics in columns.4

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A sample QFD

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Four steps to QFD thinking• Product planning: ex- fuel efficient car

translating what the customer wants

• Part planning: ex- MPFI/CI/SI engine

translating product specifications• Process planning: ex-Pull/Push/Lean mftg.

translating part characteristics• Production planning: Loading/Sequencing

translating process characteristics

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3)Taguchi Loss function• Quality engineering should start with an

understanding of the cost of poor quality in various situations much beyond the number of items outside specification by the cost of rework or scrap to a broader horizon as cost to society.• According to Taguchi, the products that do not

match the target, even if within specified limits do not operate as intended and any deviation from the target, be it within the specified limits or not will generate financial loss to the customers, the company and to society and the loss is proportional to the deviation from the target.

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…contd…• The loss function is the square of the deviation

multiplied by a constant k, with k being the ratio of the cost of defective product and the square of the tolerance.• Loss function, L(y)= k (y-t) 2

were k = ∆ / m2

m = LSL – t or t – USL LSL = Lower specification limit USL = Upper specification limit

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Case study--- Taguchi loss function

A machine manufacturer specifies the target for the diameter of two rivets to be 6 inches and the upper and lower limits of 5.98 and 6.02 inches respectively. Two bolts measuring 5.99 inches and 6 inches were inserted in its intended holes of the machine and sold.The machine breaks down within 4 months as a result of loose parts. The cost of repair associated with 5.99 inches bolt assembly was estimated at $95, while the other still kept functioning !

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4) Total Productive Maintenance(TPM)• TPM is considered as the medical science of

machines.• TPM is an innovative Japanese concept and its

origin can be traced back to 1951.• The goal of the TPM program is to markedly

increase production while, at the same time, increasing employee morale and job satisfaction. • Down time for maintenance is scheduled as a

part of the manufacturing day and, in some cases, as an integral part of the manufacturing process.

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Objectives of TPM

• Avoid wastage in a quickly changing economic environment.• Producing goods without reducing product

quality.• Reduce cost.• Produce a low batch quantity at the earliest

possible time.• Goods send to the customers must be non

defective.11

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Pillars of TPM

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… contd…• 5S: Seiri (Sort), seiton (systemize), seiso (sweep), seiketsu (standardise) & shitsuke

(self discipline).

• Autonomous maintenance: operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value added activity and technical repairs.

• Kaizen: Small improvements on a continual basis.

• Planned Maintenance: trouble free machines and equipment producing defect free products for total customer satisfaction.

• Quality Maintenance: customer delight through highest quality defect free manufacturing.

• Training: multi-skilled revitalized employees with high morale and eager to perform all required functions effectively and independently.

• Office TPM: to improve productivity, efficiency in the administrative functions and eliminate losses through automation.

• Safety, Health and environment: focus is on to create a safe workplace and a surrounding area that is not damaged by our process or procedures aiming Zero accident, Zero health damage and Zero fires.

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Types of Maintenance1. Preventive Maintenance• It is a daily maintenance ( cleaning, inspection, oiling and

re-tightening ), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis.

• Can be further subdivided into periodic and predictive maintenance.

2. Breakdown Maintenance• Waiting until equipment fails to repair it.

3. Corrective Maintenance• It improves equipment and its components (calibration) so

that preventive maintenance can be carried out reliably.

4. Maintenance Prevention• Studying the weakness of current machines ( on site

information leading to failure prevention, easier maintenance, safety and ease of manufacturing ) and are incorporated(DFM) before commissioning a new equipment.

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5) FMEA• FMEA (Failure Mode and Effects Analysis) is a proactive tool,

technique and quality method that enables the identification and prevention of process or product errors before they occur.

• It is a systematic way to examine a process prospectively for possible ways in which failure can occur, and then to redesign the processes so that the new model eliminates the possibility of failure.

• Types of FMEA Process FMEA System FMEA Design FMEA 15

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Benefits of FMEA

• Captures the collective knowledge of a team • Improves the quality, reliability, and safety of the process • Logical, structured process for identifying process areas of

concern • Reduces process development time, cost • Documents and tracks risk reduction activities • Helps to identify Critical-To-Quality characteristics (CTQs) • Provides historical records; establishes baseline • Helps increase customer satisfaction and safety

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It is possible to fail in many ways...while to succeed there is possibly only one way. – Aristotle

Thank you……

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