1. IE 530 QUALITY ENGINEERING Prepared by Dr. Mohamed Abdel Fattah Sharaf King Saud university College of engineering Industrial engineering Department

2. IE 530 Quality Engineering 3 Catalog Data An understanding of the basic concepts of quality, An appreciation of the functions served by a quality management system; the ability to design quality into products so as to satisfy both internal and external customer The study of frequency distributions and probability models in quality control. Preparation and use various control charts. Design for Six Sigma: A roadmap for product development. Construction of different sampling plans. Methods to quality improvement and analysis of quality costs. Application of computer in the above area. LevelI.E. M. Sc program course TextbookDesign for Six Sigma, Kai Yang & Basem S. EI-Haik, McGraw-Hill, 2003. Reference  Introduction to Statistical quality control, 4th ed., D. C. Montgomery, John Wiley & Sons, Inc., 2001.  Certified Manager of Quality/Organizational Excellence”, 3 rd edition by Russell T. Westcott. ASQ Quality Press. Learning Objectives To introduce students to the use of statistical methods and other problem- solving techniques required in the area of quality control. The ability to control process performance using appropriate statistical tools. The ability to diagnose quality problems and develop sustainable improvement. To enable students to know how to measure the quality characteristics. In addition, to introduce students to apply the qulity improvement tools. In additional to road map to enterprise quality. Overview of quality management methodologies. Use of Six Sigma Fundamentals ( DMAIC)

3. Topics (classe s) 1.Introduction to quality control1 classes 1.Fundamentals of statistics for quality control 2.The basic concepts of quality 1 classes 1.Control charts for variables2 classes 1.Control charts for attributes2classes 1.Processes capability3 classes 1.Acceptance sampling 2.Design quality into products so as to satisfy both internal and external customers 3 classes 2 classes 1.Methods of quality improvement3classes 1.Quality costs 2.An appreciation of the functions served by a quality management system; 1 classes 1.Introduction to Total Quality Management (TQM), Six Sigma, Balance Score Card (BSC), ISO 9001, and Kazien. 2.Six Sigma ( Fundamentals of DMAIC, DFSS), Design of Six Sigma Deployment. 2 classes 8 classes Project work a-measuring some jobs in lab, and b- Collecting data from some factories. Then, use those data in computer programming to construct control charts. c- Six Sigma Project Comp uter Usage Minitab software package

4. Learning outcomes 1.Describe the history and importance of quality control. 2.Learn the statistical tools need to use in the quality control area. 3.Learn the main differences between variable and attribute control charts. 4.Learn how to construct the different types of control charts and how to interpret them. 5.Learn how to use contro charts to monitor the processes. 6.Learn how to determine the capability of the process and how to use the findings to analyze the control limits of the process. 7.Learn how to perform the qualification tests for the process. 8.Understand the Operating Characteristic Curve and prepare the acceptance sampling plan 9.Learn how to prepare the acceptance samples for control charts. 10.Diagnose quality problems and develop sustainable improvement. 11Describe the main principals of the Six Sigma, TQM, BSC, ISO9001 and Kaizen. 12Describe the main principals of Six Sigma, how to develop product based on fundamentals of Six Sigma. 13Learn and understand how to use Minitab software package in the quality area 14Work in teams and communicate effectively through class discussions, real case project from industrial, and presentation. Estimated Category Content Engineering Science : 2 credit hours or 67% Engineering Design: 1 credit hour or 33% Prepared byDr. Mohamed Abdel Fattah Sharaf Preparation Date March 2008

7. The Dialectic of Quality Product Standards Statistical Methods Quality Control Customer Focus Quality Assurance Human Factors Quality Engineering Process Analysis Quality Management Systems Engineering Six Sigma

8. Service Quality Gap Model Five ways service quality can fail...

9. Tools for Managers Statistical Process Control

10. Six Sigma 6 سيجما

11. بعض القياسات دائمة الاستخدام خلال تطبيق اسلوب 6 سيجما Sigma quality level= 0.8406 + بعض العلاقات الرياضية الخاصة بأسلوب 6 سيجما : Number of operation steps=m Defects=D Unit=U Opportunities for a defect= O Yield=Y Total opportunities: TOP=U*O Defects per unit: DPU=D/U Defects per unit opportunity: DPO=DPU/O=D/(U*O) Defects per million opportunity: DPMO=DPO*1000000

12. Process Capability قدره العمليات The Relationship between a Process and the Requirements of its Customer How Well Does the Process Meet Customer Needs?

13. l A Vision and Philosophical commitment to our consumers to offer the highest quality, lowest cost products l A Metric that demonstrates quality levels at 99.9997% performance for products and processes l A Benchmark of our product and process capability for comparison to ‘best in class’ l A practical application of statistical Tools and Methods to help us measure, analyze, improve, and control our process What is Six Sigma

14. A Six Sigma process –A Six Sigma  process is one that has at least six standard deviations between the process mean and the nearest specification limit when centred. +/- 6 sigma 99.9996% * Mean Value Lower Design SpecificationUpper Design Specification *Distribution shifted +/- 1.5  1.5 

15. DMAIC Process Metrics (Ys) linked to CTQs Define the Problem Project Objective Project Goal PROCESS X1X1 X2X2 X3X3 X4X4 Y1Y1 Y2Y2 Y3Y3 Establish Controls on the critical Xs so the improvements will be maintained Identify ways to improve the process and validate the solution Measure and Analyze data and process performance to determine the critical variables and root cause of the problem

16. DMAIC Process training Methodology

17. Six Sigma The Concept

18. Deployment

19. Actions Required to Institutionalize a Quality Process –TOP DOWN COMMITMENT AND INVOLVEMENT Set the example, be active in the audit process –MEASUREMENT SYSTEM TO TRACK PROGRESS At both macro and micro levels –TOUGH GOAL SETTING (REACH OUT!!) Benchmark Best-In-Class -- audit often –PROVIDE THE REQUIRED EDUCATION The “Why” and “How To” –SPREAD THE SUCCESS STORIES

20. Promoting Customer Satisfactions by Applying Six Sigma: An Example from the Automobile Industry

22. 5s Key to work place improvement

23. Putting 5s to Work Who does not like a -Clean -Orderly -Disciplined Environment ? At home & At work !!! 5s AIMS at achieving this state

24. 5-S Seiri - sort out Seiton -systematic arrangement Seiso - Scrub clean, Spic & Span Seiketsu – Standardize - State the rules Shitsuke - Self-discipline (Follow rules) KAIZEN  and GEMBAKAIZEN  are registered trade marks of KAIZEN INSTITUTE -JAPAN

25. 1 st Step of 5s SEIRI Sorting of all items Segregate Necessary from Unnecessary Take action on Unnecessary Step Zero - of 5s Identify strategic Spots & take Photos / Video – To Capture Current Status Red Tagging & Red Tag Areas (set Rules first) Heaps to Come out – 10 trucks (in a factory)

26. Red Tag To, Stock Facilities Locations / Space Documents Computer Files Machines Stationary Not People !! When In Doubt, Throw It Out !

27. Seiri Classify into: wanted, ? and unwanted Discard unwanted Create red tag area for ? items Move ? Items to red tag area Put red tag on unmovable ? items Wanted but not here Wanted but not in this Qty Wanted but not now Not Wanted at all KAIZEN  and GEMBAKAIZEN  are registered trade marks of KAIZEN INSTITUTE -JAPAN

28. Total Quality Management

29. Outline Meaning of Total Quality Management (TQM) TQM CONCEPTS TQM CONCEPTS TQM Beliefs. TQM Beliefs. Guru’s TQM Guru’s TQM. The Evolution of TQM. Principles. TQM Principles. TQM Constructs TQM Constructs. TQM Organization. TQM Organization. Benefits of TQM. TQM Tools. TQM Phases

30. BALANCED SCORECARD