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“Quality is never an accident; it is always the result of intelligent effort.” 

Developing a sustainable Quality Management Culture and Reducing Cost of Quality by Implementing Modern Techniques of Quality Management. “Quality is never an accident; it is always the result of intelligent effort.”  ………. William A. Foster. At a Glance. Quality Cost Of Quality

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“Quality is never an accident; it is always the result of intelligent effort.” 

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  1. Developing a sustainable Quality Management Culture and Reducing Cost of Quality by Implementing Modern Techniques of Quality Management

  2. “Quality is never an accident; it is always the result of intelligent effort.”  ………. William A. Foster

  3. At a Glance • Quality • Cost Of Quality • Seven Waste • Evaluation of Quality • TQM Approach & Seven Tools of Quality Control • Kaizen • PDCA Cycle • Practical Example for Implementation of Quality Tools • Quality Circle Activities

  4. Quality Quality is the ability of a product or service to meet a customer's expectations.

  5. Quality Control • Quality Control involves monitoring specific project results to determine if they comply with relevant quality standards, and identifying ways to eliminate causes of unsatisfactory results.

  6. Cost of Quality Preventive Costs COST OF CONFORMANCE Appraisal Costs Internal Failure Costs COST OF NON-CONFORMANCE External Failure Costs

  7. Cost of Quality Preventive Costs • Quality Planning & Re-engineering • New product review • Product process design • Process control • Training • Documentation • Inspection & testing • Calibration Appraisal Costs

  8. Cost of Quality Internal Failure Costs • Rework • Retest • Scrap • Downtime • Failure analysis • Compensation • Returned product/ material • Warranty changes • Liability costs • Reputation Loss External Failure Costs

  9. Seven Waste • Over Processing • Over Production • Rework • Waiting

  10. Seven Waste • Excess Motion • WIP • Excess Transportation

  11. “Quality is everyone Responsibility” .....W. Edwards Deming

  12. The Evaluation of Quality Inspection Based Quality Control Reactive Statistical Quality Control Reactive Quality Assurance Proactive Total Quality Management (TQM) Preventive

  13. TQM Approach • Continual Improvement • Customer Focus • Employee Empowerment • Team Approach • Competitive Benchmarking • Knowledge of Tools • Internal & External Customer Satisfaction • Long Term Relationship

  14. Poor Practice • Leaders not giving clear direction • Lack of Top Management involvement • Each department working only for itself • Do not adopt a new changes • Firefighter, reactive behavior • The “It’s not my problem” attitude

  15. The seven Tools of Quality Management Histogram Pareto Chart Check Sheet Control Chart Ishikawa Chart * * * * * * * * * Scatter Plot Flow Diagram

  16. Defects Record • Spot Qty • Reject Qty • Rework • Rectification Monday CHECK SHEET

  17. Methods Materials Cause Cause Cause Cause Cause Cause Cause Cause Cause Cause Cause Cause Effect Environment Man Machine/Equipment Cause-and-Effect Diagram

  18. HISTOGRAM

  19. Number of defects Spot Skip Stitch Missing label Other Pleat PARETO DIAGRAM 80% of the problems may be attributed to 20% of the causes.

  20. Out of control Upper control limit Process average Lower control limit 1 2 3 4 5 6 7 8 9 10 Sample number CONTROL CHART

  21. New Tools of Quality Control • Affinity Diagram • Relations Diagram • Tree Diagram • Matrix Diagram • Matrix Data Analysis • Arrow Diagram • Process Decision Program Charts

  22. Kaizen Kaizen = Change For Better

  23. The Basic Principles of Kaizen • Teamwork :A dozen heads are better than one. • Company Wide Activities • Small Improvement: A very Large number of small changes are effective than a few changes in large scale. • Thinking Attitude: Everyone in a company has to accept Change is Good and necessary for company survival. • Waste Elimination: Right the things first time • Failure Prevention

  24. “The Causes of inefficiency and poor Quality - is system” ....... W. Edwards Deming

  25. Basic steps in problem solving • Define the problem and set an improvement goal. • Data Collection. • Data Analysis. • Generate potential solutions. • Choose a solution. • Implement the solution. • Monitor the solution.

  26. PARETO CHART

  27. Benchmarking

  28. Methods Materials Lack of Training about maintenance No sufficient space for Maintenance Maintenance people unskilled Lack of proper Instruction about machine maintenance Idle machine is not covered Don’t follow daily M/C cleaning Routine Mechanic’s process Indiscipline Oil Spot Environment Man Machine/Equipment Cause-and-Effect Diagram Cleaning Tools are not sufficient Machine poor servicing Expired service life

  29. PDCA Cycle/Deming Cycle

  30. P (Plan) D (Do)

  31. C (Check) Time Line A (Act)

  32. Result

  33. “Quality is not an act, it is a habit”  …………….Aristotle

  34. A quality circle is a participatory management technique that enlists the help of employees in solving problems related to their own jobs. Quality Circle Activities

  35. Quality Circle

  36. “We are here to make another world” ………W. Edward Deming

  37. THANK YOU ALL

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