1 Presented by: Dr. Husam Arman Quality management: Tools and Techniques

Outline 1. The 7 QC tools 2. Quality Function Deployment (QFD). 3. Concurrent Engineering (CE). 4. New quality tools

The Seven Management & Planning Tools The following are some of the most common TQM tools in use today. Each is used for, and identifies, specific information in a specific manner. It should be noted that tools should be used in conjunction with other tools to understand the full scope of the issue being analyzed or illustrated.

Quality Control Tools Pareto chart Histogram Process flow diagram Check sheet Scatter diagram Control chart Cause and effect diagram

Pareto Principle Vilfredo Pareto ( ) Italian economist 20% of the population has 80% of the wealth Juran used the term “vital few, trivial many”. He noted that 20% of the quality problems caused 80% of the dollar loss.

Pareto chart % Complaints

Histogram

Flowcharts Graphical description of how work is done. Used to describe processes that are to be improved.

Flow charts " Draw a flowchart for whatever you do. Until you do, you do not know what you are doing, you just have a job.” -- Dr. W. Edwards Deming.

Flowchart Flowcharts help problem solvers better understand the process so they can highlight quality problems.

Process Chart Symbols Operations Inspection Transportation Delay Storage

Process Chart

Check Sheet COMPONENTS REPLACED BY LAB TIME PERIOD: 22 Feb to 27 Feb 1998 REPAIR TECHNICIAN: Bob TV SET MODEL 1013 Integrated Circuits |||| Capacitors |||| |||| |||| |||| |||| || Resistors || Transformers |||| Commands CRT |

Fishbone Diagram Quality Problem MachinesMeasurementHuman ProcessEnvironmentMaterials Faulty testing equipment Incorrect specifications Improper methods Poor supervision Lack of concentration Inadequate training Out of adjustment Tooling problems Old / worn Defective from vendor Not to specifications Material- handling problems Deficiencies in product design Ineffective quality management Poor process design Inaccurate temperature control Dust and Dirt

Scatter Diagram.

Control Chart Sample number UCL = LCL = 1.99 c = 12.67

Check the book for examples A series of examples is used to demonstrate all the tools … 10/06/2009 Husam Arman 17

Quality Function Deployment (QFD) A system to translate customer requirements into appropriate company requirements at every stage, from research through design, manufacturing, distribution, marketing sales and services

The QFD Approach

The QFD Planning

House of Quality This matrix serves to describe the basic process underlying QFD: the transition (based on a strategy of input–output) from a list of customer requirements, the “what,” through to a list of considerations as to “how” the requirements will be met (product characteristics). The whats are the list of basic customer demands. These are generally rather vague requests, often expressed in imprecise terms requiring further detailed definitions. An example of a what could be the typical wish expressed by a coffee drinker: “to have a really good cup of coffee.”

HOQ

HOQ: Example

The QFD organizational Structure A teamwork must be established to develop an efficient QFD including the functions:  Marketing  Design  Quality  Technology  Production  Logistics  Suppliers

QFD tutorial Link to Summers file (Click here)Click here 10/06/2009 Husam Arman 25

Concurrent Engineering (CE) It is not a technology. It is a philosophy. It does not have to be an automated process. There may be computers involved …but Concurrent Engineering not just about shared data environments, communications etc. We’ll start by looking at the alternative: Sequential Engineering…

Basic Concept Sequential Engineering Design Process planning Manufacture time activities

Sequential Engineering Marketing Engineering / design ManufactureTest Full production Main information flow Errors, changes and corrections

Sequential Engineering No activity starts until the one before it has been completed If an error is detected the design goes back one or more steps for correction Process is slow, but design control and tracking are easy “Over the wall” syndrome

“The Wall”

Basic Concept Concurrent Engineering design the product design the manufacturing process set up manufacturing system and run it time activities Work harder in the early stages. Get the design right, and reduce the incidence of manufacturing problems. Overlaps show where people from different disciplines work together. Manufacturing starts sooner than with sequential engineering

A Definition of Concurrent Engineering Concurrent Engineering is a systematic approach to the integrated concurrent design of products and their related processes, manufacture and support... this approach intended to cause designers from the outset to consider all elements of the product life cycle from concept through to sales including quality, cost, schedule and user requirements.

“I will build a car for the great multitude… of the best materials by the best men… after the simplest designs that modern engineering can devise.” - Henry Ford Henry Ford

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