Quality Management Systems (QMS) Lessons PDF

1.2Pr ocedur esandMat hinAppl icat ionofQC Designofexper iment. I finmos trealli fesit uati...

1.2Pr ocedur esandMat hinAppl icat ionofQC Designofexper iment. I finmos trealli fesit uati ons,thenumberoft heinputismorethan j ustaf ew,thenumberofexperimentsneces s arytot es tallcombinati onsoft hesefactor sat di fferentlevelsi sveryhugeandtheappr oachconsequentlyisnolongerfeasi blyThi siswhere st atist icalmethodscanbeappli edusingdes i gnofexpei mients,f oranexper i mentdesignedto gi veamaxi mum ofexperi mentrunsthatistheoptimalcost. DOE mus tcome up wi t hi nnovat ive waysofdefi ning and organi zing t he experi ment/ sand analysi ngtheresul ts,s ot hattheeffectofeachcausat ivefactorcanbeeval uatedint hemost effi cientmanner.Todot his,someoft heDOEmaintechniquesappliedure 1. Methodsf ort he economi c pl anni ng and des ign ofexper iment s(e g,f act or l ayoutmethods) 2. Methodsforanal yfi ngexj hui ment alr esul tss tat ist ical lyandr eachi ngconcl usi ons ( des isi onanal ysi smet hods ) Multi vari ateAnal ysis : Mostoft hepr oblemst hatallofusdealwi thinourdai lywor k have multi faceted char acteri sti cs.The us ualcas ei sthat (hose char acter ist ics mus t be consi deredinr especttovar i ousr efer ences,andt huscanonl ybeunderstoodbyexami ni ng vari oustypesofdat as uch dat aiscalled multivari ant( mult icharact eri sti c)dat a.Exampl e. Productqualit y ofan engi ne block,ithasmul t ivari ate dat as uch asdimensi ons ,haidncss, materi alcharacter ist ics ,andpr ocessi ngcondi t ions. Multi variateAnalys i sMet hodi satechniquef ors i mul taneousanal ysisofdat at hathave cros s -corr elation,whil et akingintoconsi derati ont hecoef ficientsofcor rel ati on,i tisimport ant thatt he concl us ions gained through t his analysis met hod be compr ehensi vel y evaluat ed consideri ngavar i etyofr elatedtechni calfactors ,s uchast heor i esofthespeci f i cf ieldandt he experience and knowledge ofper sondoing theanal ysi s.Thi swayt he mult ivariate analys t s method s ummar i zesdat aon manychar acteri sticsand pr ovi desusabl e materialf ormaki ng overallj udgment s. TypesofMul ti var iat eAnal ysi sMet hodsandThei rSpeci alFeat ures : 1.Mult ivar iat eanal ysi smet hodsthatareusedtof i ndoveral lcharacter ist icvaluesThesear e methodsfors ummar i zingthedi spers ionandcovar iancer elati ons hips,aswellasthecorrelat ion ofone mul t ivari ate datainthe for m ofas mallnumberofi ndependent( non-corr elated^ gener alcharacteri sti cvalues. 2.Multivar iat eanal ysi smet hodsusedf orf or ecasti ng,wit hthesemethods.Thecharacteris tics underexami nation are di vided i ntotwo groups-obj ect(tar get)var iables,and descripti on vari ables.Thesemet hodsar eusedtof orecasttar getvari abl es,bas edoni nformat iongat hered regar dingdes cr ipti onvariables. Quali tyEngineeri ng.In quali tyengi neer ing,qual it yu,defined asthe l ossesthataproduct caus est ocus tomersaftershipping.Thesel oss esmayincl ude( I )lossescausedbyvar iat ionin thefuncti oni ngoft hepr oduct,and( 2)lossesduetovari oustroubl escaus edI atheproduct (i ncl udingexcessappl icati oncos ts). Goodqual it yr equir est hatther ebenovanat ioni ntheint endedfunct ionandthatl ossescaus ed bypr oducttroubleasr efl ectedinappl icat ioncos ts(i e.negat ivesi deeffect s)be mini mal. Quali ty Problems.Mostqual i ty pr oblemsar e problemsofvar iat ion Inst abi li ty off unct ion occursduetovar i ati onindifferentfact ors.Thesevari ationsmaybel i kenedt o“noise"whichin mathematicalsense,consi stst ounwantedvar i ati onsi mposedont hedes ir edwavef orm.This "noi se"maybeduet o:envir onment alcondit ion(externalnoi se) ,det er iorat ion(i nteri ornoise" andproducttopr oductdi fferences. Countermeas urestoSolveQual i tyProblems.Tos olvetheprobl em ofvari ati on,whichisthe rootofquali typrobl ems ,i tisneces s aryto “stabi li ze desi gnand pr oducti ont echnol ogyor eli minatethe pot enti alinfl uence of noise.Qual i ty engi neeri ng s olves qual it y problems i ntroduci nganewwayoft hi nking:“desi gnforstabi li ty""par ameterdesi gn. TheCompar isoni sasf oll ows : 1)Convent i onalapproach.Bas edoni nt endedproductfuncti ons,parametersarechos enand charact eris ticval uesarees t abl ishedwhi chexactl ymat chtargetval ues.Asar es ult ,af terthe productiscompletedtheprobl em ofvar iat ioni nfuncti on(charact eri sticval ues)mayoccur 2)Par amet erDes ign.Fi rst ,a“par amet ers tudy"i sdonet obui ldi nthef unct ionr equi redof t he product.Second,fort he sel ected des ign,par amet eropt imizati onisdone t hrought wo s tagesstabi li zat ionoff unct ionandadjus tmenttoachievetar getvalues. I napar amet erdes ign,t hef act orst hataf fectt hei ntendedf unct ionofapr oduct 1. Cont roll ablefact ors-Thesearecall eddesignconstant sordesignpar amet ers. Thecent reval ueorleveli sdetermi nedbythedes ignerorproduct ionengi neer 2. Tol erancef act ors- Thes ear ecal lednoi se,andt heyar eacaus eofvar iat ionsi n t hei ntendedf uncti onsofaproduct 3. Adjus tabl ef act ors- Among the cont rol labl ef act ors,the adj ust ablef act ors mpactthe s ize ofoutput-r elat ed char act eri sti cs val ues.They can be adj usted t o bring char act eri sti cval uesi ntoal ignmentwi tht argetval ues. 4. Si gnalf act ors - Relat edtoi nputandout put s,t hes ear einputval uest hat canbesett ochangeanout putt argetval ue. Thef oll owi ngbenef itscanbegai nedbyi ntr oduci ngpar amet erdes ign: Qual it y level i mpr oves by r educt ion of var iat ions i n pr oduct f unct ion ( char acter ist icval ues). Cos treduct iont hroughqual it yenhancement Stabi li zat ion of f uncti on becomes pos sibl eint he ear lys tages of pr oduct devel opment ,anddevelopmenteffi ci encyincr eas es. 2Met hodsEngi neer ing MethodsEngineering. Asyst emat i ctechni quef orthedesi gnandi mprovementof workmet hods.Itprovi desauni fi edandt horoughsystem for(1)anal ysingthepresentwor k si tuati on,identi fyi ng problems ,bri ngi ng outimprovement sideas,and sel ect iont he bestof t hos e'(2)alterimplement ati on ofimprovements,standardi zi ng the new methods,insuri ng t heiradaptati on,andmeas uringandevaluati ngthei rimpact. Met hodsengi neeri ngi sthet echni quet hats ubj ectseachoperati onofagi venpieceof workt ocloseanal ys istoel i-mir rateever yunneces sar yel ementoroperati onandt oapproach thequickestthebes tmet hodofper for mi ngeachneces s aryelementoroper at ion,i tincludes the improvement and s tandar dizati on of met hods,equi pment ,and wor ki ng conditi ons: operator trai ning: the det erminati on of s tandard t i me; and occasional ly devis ing and administ eri ngvar iousincent i veplans. ProcessCharts. Pr ocesschar tsgraphi cal lypr esenttheeventswhi choccurduri nga seri esofact i onsoroper at ionssot hatt heycanbeeas il yvisual izedandanalys ed,ther ear e dif ferentclas sif icat ion ofthisli ke:operat ion pr ocesschar ts,fl ow processchart s,multi ple acti vit ycharts. Moti udy.Mot onSt ion s tudy cons ist sofdi vi ding wor ki ntothe mostbasi c elements pos sibl e and st udyi ng t hese elementssepar ately and i nr elat ion t o one another,bot h quali tat ivel y and quanti tat ivel y.The mot ion s tudy anal ystisgoverned and gui ded by t he pri ncipl esofmot i oneconomy,whichhavebeenestabli shedasaresultofthor oughstudythe motioncapabil it iesofthebody. Wor k Sampli ng.One. of t he mos t ef fecti ve and mos tfr equent l y us ed methods engineeri ngtechni quesisworksampli ng.Thewor ks ampl i ngprocedureisbasedont hefactt hat as mallnumberofchance obs ervat ionstend tof oll ow the same dist ri but i on patt ernthat actual lyoccursinthesit uati onbeings t udi ed,Wor ks ampli ngenablest heobs ervertocoll ect factsaboutanoperat ion,pr ocessorotheracti vit yinexpensi velyandaccurately. Work Measur ement.Onl y af t er s tandardi zat ion and met hods i mpr ovement wer e compl etedwasast artmadeont heactualmeasurementofthework Val ueEngineeri ng.Val ueengi neer ingisamor erecentaddit iontothegener alareacf methodsengineeri ng.I thast wo uni quecharacter ist icsthatmakei tpar ti cul arl yvaluabl efor r educingthe,cos tsofprocess es,proceduress yst ems ,andservi ces. Quali tyControl-ist heuseoft echni quesandacti vit iestoachievesust ainandImprovethe quali ty ofpr oductofser vice.I tinvolvesi ntegr ati ng the f oll owing r elated t echni quesand acti vit ies. 1.Speci fi cat ionofwhati sneeded 2.Des ignoft hepr oductands ervi cet omeett hes peci fi cat ion 3.Pr oduct ionori nst all ati onst omeett hef ulli ntentt hes peci fi cat ions. 4.I nspect ingt odet ermi neconf ormancet ospeci fi cat ions. 5.Revi ewofus aget opr ovi dei nfor mat ionf ort her evi si onofs peci fi cat ioni fneeded Stat ist icalQuali tyControl(SQC)-isabranchoft otalquali tymanagementiti sthecollecti on, anal ysisand inter pret ation ofdataforusei n quali ty contr olacti vit ies.Stat ist icalProcess Control(SPC)andacceptancesampl ingar et hetwomaj orpartsofSQC. Allt hepl annedors ystemat i cact i onsneces sar ytopr ovi deadequat econfidencet hataproduct orservicewi l lsat isfygivenr equir ement sf orqual ityiscall edqualit yas s ur ance.Apr ocessisa setofinterrel atedacti vitiesthatusess peci fici nputstopr oducespecif icout puts.Theout putof onepr ocessi susual lyt heinputt o another.Processreferstobot hbusines sandpr oducti on acti vit ies.Cus t omer sreferst o bothinternalandext ernalcust omer sands uppli ersrefersto bothinternalandexternalsuppliers. Hi stor icalRevi ew I n1924,W.A Shewhar tofBel lTel ephoneLaborat ori esdevelopedast atat ist icalchart fort hecontrolofpr oductvar iabl es.Thischar tiscons ider edtobet hebegi nni ngofs tati sti cal qual it ycontr ol. I n1 946,An Ameri can Societ yf orquali tywasf ormed.Thi sorgani zati on t hrough i ts publi cat ion,conf erenceandtrai nings es sionhaspr omotedtheuseorqual it yofal lt ypesof product ionandservi ce. I n1 950,W.Edwar dsDemi ngwholear neds t ati sti calquali tycontr olfr om shewhartgave aseri esofl ectur esonstati sti calmethodstoJapaneseengineersandonquali tyresponsi bil it y t ot hechiefexecuti veof ficer s( CEO)ofthelar gestor ganizati oninJapan. I n1 960,the f irstqualit ycontrolci rcl eswer e perfor med forthe purpose ofquali ty i mpr ovement.Bythelate1 970’sandear ly1980’s ,USmanager sweremakingfrequenttr ipsto Japant olearnabouttheJapanes emir acl es.Nevert heless,aquali tyr enai ssancebegant ooccur i nUSpr oductsandservicesandbyt hemiddleof1 980t heconceptofTQM wer ebegant o publi cize. Inthe late1980’sthe automot ive i ndust ry began to emphasize s tat ist icalpr oces s cont rol.Suppl iersandthei rsuppl ier swererequi redtouset hes etechniques. Byt heyear2000,thequal ityfocuswass hif tingt oinf ormat iont echnol ogywi thi nan or gani zat ionandext ernal lyvi atheInter net. Res pons ibi li tyf orqual it y Areasresponsi ble-Qualit yisnottheresponsi bil it yofanyoneper sonorfunct ionalar ea:iti s everyone’sj ob.Ther es ponsi bil it yforquali tybeginswhenmarket ingdeter minesthecustomer quali tyrequi rementsandconti nuesunti ltheproductisus edforaper i odoftimebyas ati sfi ed customer. Cus tomer s ervi ce mar ket ing Packagi ng& Desi gn Qual it y st orage engi neeri ng Pr oductor Ser vice I nspect ion& pr ocur ement tes t Pr oduct ion Pr ocess Desi gn Mar ketinghel pstoeval uat e-t hel evelofpr oductqual it ythatt hecus tomerwant s,needsand i swil li ngtopayfori t. Desi gn Engi neering- t r anslat e t he cust omer’s qual it y requi rements int o operat ing char acteri sti cs,exactspecif icati onsandappr opri atet oler ancesf oranewpr oductors ervi cesor therevi si onofanes tabl is hedpr oduct. Concur r entengineeri ng-ast hecompl exi tyofthepr oductors ervi cesincreasesthequal it y andrel iabil it ydecreases.Ear lyinvolvementofmarket ingpr oducti on,qual ity,procur ementand thecus t omerisessenti altopreventprobl emsbeforetheyoccur. Tol erance-istheper missi blevar iat ioninthes izeoft hequal it ychar act eri sti candt hes elect ion oft olerancehasadualef fectonquali ty. Procurement - us ing the qual it y est abli shes by desi gn engi neer ing,procur ementhas the responsi bil it yf orprocuri ng qual itymateri alsand componentsand est abli shi ng al ong-t erm rel ations hip. Var iat ionandpr oces scont rol Var iat ion-Exi stsi nthewor ldar oundus...Inal lthi ngs. -Notwoproduct sorchar act eri sti csar eident ical … Becaus epr oces sescont ainmanys our cei f var iat ion -Thi sres ult sini ncons ist enci esordi ffer encesamongpr oduct sorpr oces sout put. -Somedi ffer encesmaybequi tel argewhi leot her smaybei nfi nit esi mal. -Thi ngsar eneverexact ly“al ike’. -Ever ypr oductvar iess li ght lyf rom ever ypr oductmadef rom t hes amepr oces s. -Result sf r om mat eri als ,meas urement sormet hods ,machi ne,manpower ,envi ronment ,and ot herfactors. -Keyt oqual it yIt oreduce,orcont rolt heamountofvar iat ionamongt hes epr oduct s. Sour cesofVar iat ion - Materi als - Equi pment - Method/procedur e - Manpower - Envi ronment - Managements tyl e Caus esofVar iat ion Commoncauses-aresourceofvari ati ont hatisal wayspresent ,par toftherandom var iat ion i nheri tint heproces sit sel f,it sori gincanus ual lybet r acedtoanelementoft hes ys tem which onl ymanagementcancorr ect. Speci alCauses-isasourcevari ati onthati sint ermit tent ,unpredi ctabl e,unst abl e,s omet imes cal ledanass ignabl ecause.I tiss ignal ledbyapoi ntbeyondthecontr olli mits. As signabl ecaus es-caus ethepr oces stof luct uat einanunnat ural ,non-r andom manner -Foundpr oces sesoper ati ngoutofcont rol. Stat ist ics-t hesci encet hatdeal swi thcol lect ion,t abul ati on,i nter pret ati on,andpr esent ati on ofquanti tat ivedata. Col lect ion-meas uri ng,det ermi ning Tabul ati on-paper ,penci l,comput er Anal ysi s-vi sualexami nat ion,cal cul ati on Dat a-col lect edbydi rectobs ervat ion -col lect edt hroughwr it tenorver balques tion Var iabl es-t hos echar act eri sti cswhi char emeas urabl e.Ex.Wei ght ,Lengt h,di amet er,r esi stance Obj ect ives Becomef ami li arwi thSPCmet hodsandt erms Under standourr olei nSPC Under standt heval ueofSPC I mpl ement ingSPC Tr ainI mpl ement ati ont eams Pi lot I ndi vidualus eSPCast ool stoi mpr oveout putqual it y Mi ssi onar iess preadt he“wor d”t oot herar eas TheOut putofSPCi snotcont rolchar tbut … Qual i ty/ product ivi tyi mpr ovement Cos tReduct ion Cus tomerSat isf act ion Whati srequi redofmanagement ? Pr ovi def ulls uppor tont hepr oject Under standgener alSPCt obeus ed Expectact iont obet aken Expectqual it ytoi mpr ove Whati srequi redofcer tif icat iont eam? Techni caldi rect ion/ Leader shi p Des ignPr oces sCapabi li ty Knowhowt odes ign,mai ntai n,anal yseSPCcont rol Under standhowt oper for m pr oces sexper iment s  PROCESSCONTROLANDCAPABI LITYI MPROVEMENT PDCACYCLE TOOLS PLAN Pri ori ti zeandchoos ean - ParetoChart ar eaf ori mpr ovement - ProcessFl owChart - Costofquali tyr eport CHECK Es t abli s hbas eli nef ora controls t udypr oces s - Fi shboneDi agr am potentialstudy( Short - Scat terDiagram t er m).Es ti mat eexpect ed - ControlChart vari at i on. ACT Oncet heprocessis - Cont rolChar ts determi nedtobe potent i all ycapableof meetings pecif icati ons, determi newet herthe proces sisstabl e, predi ct ableandcapabl e onl ongt erm basi s. PDCACYCLE TOOLS PLAN Cont r olChar t - Cont rolchar ts Createt hechar t - Meas ur ement Preli mi nar ysteps - Checkli st Gatherdat a Calculat e DO CHECK -Runt hechar t - Pat ter nanal ysi s,f ishbonedi agr am -Interpret t he pr ocess ACT cont r ol - Scat terDi agr am ,( Oper ati onact ion) -t akeact i ont oes t abli sh cont r ol i denti fy and removes pecialcauses Whati srequi redofoper ati ons ? Monitorprocesswith X-R contr olchartsi denti fy unnat uralpat ter nsast hey occurdet ermi necausesoffunnat uralpat ternseli minat ecauses. 1.PROCESS PROCESSCONTRI LSYSTEM Mat eri als Met hod Manpower Process f l ow char t cause/ef fect Di agram OUTPUT Machi ne Meas ur Pa emenreto Envi roD niagr me ams ProcessControlchar t l 3.Act ionon 2.Infor mati on 3.Act ionof theproces s aboutthe theoutput per f ormance Val ueofpr oces ssi mpl if icat ion - Si mplepr ocessareeasi lyunderst ood - Unders toodpr ocessesareeasi lycontr oll ed - Contr olledprocessesareeasi lyimproved. PRCESSI MPROVEMENTMODEL Anal yze Cont rol I mpr ove Pr oces sConr tolChar t Takeact ion: Var iabl es( x-Pchar t) El imi nat eUnnat uralcaus es At tri but es( P/NPchar t) ChangePr oces s  Pr ocessDesi gn– Hast her espons i bil it yf ordevel opingprocessesandproceduresthat wil lproduceaquali typroductors ervice.Thisresponsi bil it yisachievedbys peci fi cact i vit ies , i ncludi ngproces ssel ecti onanddevelopment ,product ionplanni ngands uppor tacti vit ies. Pr oducti on – hasthe r espons ibi li tyto pr oduce aquali typroductors ervice qual it y cannotbeins pectedi ntoaproductors ervi ce,i tmus tbebui lti ntotheproductorservice. I nspect ion and Tes t– Hasr espons ibi li tyt o appr ais ethe qual it y ofpur chas ed and pr oduceit emsandt oreportt her esul ts. Packagi ngandSt or age– hast her espons ibi li tyt opr eser veandpr otectt hequal it yof t hepr oductorser vice. Servi ce – Hast he responsi bil it yt o provide the cost umerwi t ht he meansf orf ul ly r eali zi ngthei ntendedfunct i onoft hepr oductors erviceduri ngitsexpectedli fe.Itincl udes, s alesanddis tributi on,i nstal lati on,techni calassi stance,mai nt enanceanddispos alafteruse. Quali tyAs s urance– Doesnothavedir ectres ponsibi li tyf orquali ty.Buti tdoeshavet he di rectr esponsi bil it ytoconti nual lyeval uatet heef f ecti venessofthequal itysyst em. QC– Anal yze QA-Sur e