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Quality english Quality english Presentation Transcript

  • The Essentials - Quality HASH MANAGEMENT SERVICES LLP CHENNAI PH: 91766 13965
  • Overview ‘The Essentials’ series from Business Sense is an initiative to empower the students(freshers) and professionals in performing more efficiently and effectively in the organization This document is a part of the “Certified Manufacturing Professional” course offered by Business Sense This course is aimed at bridging the gap between the institutions and the industry by providing the fundamentals of manufacturing management which are not offered by any of our institutions/curriculum This course would immensely benefit students and professionals who are joining manufacturing organizations For more details, please visit www.businessense.in At Business Sense, we help clients through consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools. We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply Chain Re-engineering. You can subscribe to our bi-weekly newsletter here. Follow us:Copyright of Hash Management Services LLP www.businessense.in
  • Contents Section 1 – Introduction to Quality Function Section 2 – QMS and ISO 9001 Standard Section 3 – NC, Corrective and Preventive Actions Section 4 – 7 QC tools Section 5 – MIS Reports and Analyses PointsCopyright of Hash Management Services LLP www.businessense.in
  • What is Quality? “Quality is fitness for use” – Deming In an organization, Quality function means the department which independently works on attaining specified levels of product / process quality of the core business Quality Department can either be a quality control department or a Quality Assurance department Quality Department is the final In-Charge of the quality at the customer’s end Quality Control Quality Assurance Focus on Product Focus on Processes Analysis after Completion of work Prevention is better than cure Operation specific Core value; Organisation-wide Individual/department oriented Leads to team workCopyright of Hash Management Services LLP www.businessense.in
  • Organization Structure Head of Quality Assurance reports to the CEO of the company Normally there would be In-Charges for CEO the three focus areas of Quality:  Incoming Inspection  In-process or online inspection and Head - Quality Assurance  Final Inspection or Finished Goods Testing or Batch Release Testing – previously done as QC In-Charge In-charge In Manufacturing Industries, Testing In-Charge Incoming In-process Inspection Final Inspection Inspection Laboratories comes under the QA.  We have explained a typical functional hierarchy. It may vary according to each organizationCopyright of Hash Management Services LLP www.businessense.in
  • Responsibilities of an Engineer in the Quality Function •Ensuring the Raw Materials used in production are as expected Incoming Inspection In-Charge and fit for use. Incoming Inspection •Asserting the suppliers of their ability to supply consistently Supplier Development good quality and improve them In-Charge •Identify the parameters of the machines and/or intermediates In-Process In-process Inspection which are critical to quality of the Final Product and help production to avoid problems in those parameters Inspection •Check the conformance of final products to the customers’ Final Inspection requirements and ensure that the customer who is going to In-Charge receive them get satisfied with the products. Final Inspection Customer Feedback •Get the feeling of customers upon using our products and develop our internal product specificationsCopyright of Hash Management Services LLP www.businessense.in
  • Quality Plan All the five major aspects are covered in the Quality plan Document in the following manner:  Specification for Raw Materials and Parameter to be checked upon receipts  Critical To Quality (CTQ) parameters of machine settings or intermediate products and checking or verification points  Final product specifications and parameters to be tested for the conformance to customers’ requirements.  Sampling and Testing methods along with the action to be taken in case of any deviation for all the above In a nutshell, the quality plan describes how the quality of product / process is managed in an organization.Copyright of Hash Management Services LLP www.businessense.in
  • Quality Plan - Example Let us assume the Customer requirement is metal sheets for fabrication which measures 10 x 5 inch metal plate in Green color with two holes Upon accepting the Purchase order from the customer, the company works on defining the product requirements as per the internal understanding. This becomes the product specification and the target output quality. The customer requirement of 10 x 5 inch metal plate in Green color has translated in to:  MS / SS / Aluminium sheet of  252 mm length,126 mm width and 0.4 mm thickness (not given in the product requirement and developed internally based on factors such as strength, pricing, etc)  Powder coated with Green color of Standard Color (with code - abcd) with  Two holes of 2 mm diameter as per the drawingCopyright of Hash Management Services LLP www.businessense.in
  • Drawing based on the customer requirement 252 +/- 2 mm 62 +/- 1 mm 126 +/- 2 mm 2 mm dia 10 mm Color Code : Green (abcd)Copyright of Hash Management Services LLP www.businessense.in
  • Internal Specification This final requirement/drawing is worked backward - the internal requirements needed are listed and those become our in-process specifications. At Painting Section, Painting Color (abcd) and the coat thickness are internal parameters. At Cutting section, Size specifications are – L : 256 +/- 2 mm W : 130 +/- 2 mm (4 mm extension is made for bending) The holes as per the drawing For inward inspection, the sheet thickness, dimensions and paint color forms a specificationCopyright of Hash Management Services LLP www.businessense.in
  • Contents Section 1 – Introduction to Quality Function Section 2 – QMS and ISO 9001 Standard Section 3 – NC, Corrective and Preventive Actions Section 4 – 7 QC tools Section 5 – MIS Reports and Analyses PointsCopyright of Hash Management Services LLP www.businessense.in
  • Quality Management System - QMSA quality management system is a set of co-ordinatedactivities to direct and control an organisation ensuringthat the organisation is continually improving itsperformance. Quality Plan is an integrated component in the Quality Management System A QMS enables an organisation to achieve the goals and objectives set out in its policy and strategy. It provides consistency and satisfaction in terms of methods, materials, equipment, etc, and interacts with all activities of the organisation, beginning with the identification of customer requirements and ending with their satisfaction, at every transaction interface. It can be envisaged as a “wedge” that both holds the gains achieved along the quality journey, and prevents good practices from slippingCopyright of Hash Management Services LLP www.businessense.in
  • Quality Management System Benefits of QMS  Improved business planning  Enhanced awareness on quality throughout the organisation  Improved Customer Satisfaction  Reduced cost of poor quality Above all, an effective QMS provides the confidence to both the organisation and its customers that the organisation can provide good quality of product / service consistently. If the Quality Management System of a company is inline with the set requirements of ISO 9001, the company may be certified as a quality assured company by a certification agency and the company will be declared an ISO 9001 certified company.Copyright of Hash Management Services LLP www.businessense.in
  • Quality Management System – ISO 9001What is ISO? ISO (International Organization for Standardization) - a non-governmental organization is the worlds largest developer and publisher of International Standards. ISO is a network of the national standards institutes of 162 countries, one member per country, with a Central Secretariat in Geneva, Switzerland, that coordinates the system. According to ISO, "ISO" is not an abbreviation. It is a word, derived from the Greek isos, meaning "equal“.Copyright of Hash Management Services LLP www.businessense.in
  • Quality Management System – ISO 9001 ISO 9001 is an international quality certification that defines minimum requirements for a companys Quality Management System (QMS) Level 1 Quality Applies to the processes that create and control the products Manual and services an organisation supplies Level 2 Prescribes systematic control of activities to ensure that the Processes needs and expectations of customers are met Level 3 Is designed and intended to apply to virtually any product or Work Instructions service, made by any process anywhere in the world.Copyright of Hash Management Services LLP www.businessense.in
  • ISO 9001 – in a nutshell The requirements of a Quality Management System are defined in the Standard (ISO 9001: 2008) in 8 clauses. Clause 1 – Scope  1.1 General Requirements Plan  1.2 Application Clause 2 - Normative Reference Clause 3 – Terms and Definitions Act Do The clauses 1, 2 and 3 explain about the aim of this standard, where this standard is applicable (Clause 1), Check reference to the standard ISO 9000 : 2005, Quality Management System – Fundamentals and Vocabulary (Clause 2) and Terms and Definitions (Clause 3)Copyright of Hash Management Services LLP www.businessense.in
  • ISO 9001 – in a nutshell ISO 9001:2008 Clause Title Explanation Clause QMS (Quality Management Define your working system as a series of processes and identify the criteria to 4.1 System) measure the effectiveness of each process. (E.g. Timely delivery etc) QMS (Quality Management Proper controls like supervision, inspection, training, documentation etc. should be 4.1 System) exercised on outsourced (Subcontracted) processes to ensure acceptable results. Say what you do – in your documents. (E.g. methodology, Procedures, Drawings, 4.2 Documentation Requirements Specifications) 4.2 Documentation requirements Document your working system as quality manual, procedures and work instructions. Only approved current documents should be made available for work. (E.g.. Drawings, Specification, Procedures etc.)This includes external standards also. The 4.2.3 Document Control organisation will need to control other external origin documents necessary for planning and operation of QMS. This can even include excise regulations. 4.2.4 Control of records Prove that you are following the system by maintaining appropriate records. Remaining clauses are covered in the “Certified Manufacturing Professional” course .To access login to www.businessense.inCopyright of Hash Management Services LLP www.businessense.in
  • Contents Section 1 – Introduction to Quality Function Section 2 – QMS and ISO 9001 Standard Section 3 – NC, Corrective and Preventive Actions Section 4 – 7 QC tools Section 5 – MIS Reports and Analyses PointsCopyright of Hash Management Services LLP www.businessense.in
  • Defects and Non-conformance Defective  When an item fails to meet its specification and / or known to fail to meet its intended use, the item is called a defective. E.g. A casting with a blowhole Defect  The exact reason / cause for the problem is called the defect. i.e. the blowhole Nonconformity  Any non fulfillment of requirement is called nonconformity. E.g. A casting with out blowholes is required. But the process produced a casting with blowhole. This is a non-conformityCopyright of Hash Management Services LLP www.businessense.in
  • Corrective and Preventive Actions Correction  An action to eliminate a detected nonconformity is called a correction.  A correction can be a rework, reprocess, repair, degrade, replacement or rejection. Corrective Action (CA)  Actions to eliminate the cause of detected nonconformities are called corrective actions. (Actions to eliminate the recurrence of nonconformity).  Timely Solution – Can be one-time solution – reactive – after the problem has occurred Preventive Action (PA)  Actions to eliminate the causes of a potential nonconformities or other undesirable potential situations are called preventive actions. (Actions to eliminate the occurrence of nonconformity).  Proactive solution – before the problem has occurred Quality tools can be used (Pareto charts, Fish bone analysis, etc. / 5 Why analysis / other tools) for taking CA&PACopyright of Hash Management Services LLP www.businessense.in
  • Contents Section 1 – Introduction to Quality Function Section 2 – QMS and ISO 9001 Standard Section 3 – NC, Corrective and Preventive Actions Section 4 – 7 QC tools Section 5 – MIS Reports and Analyses PointsCopyright of Hash Management Services LLP www.businessense.in
  • 7 QC Tools Seven QC tools are fundamental instruments to improve the quality of the product Seven QC tools are utilized to organize the collected data in a way that is easy to understand and analyze They are used to analyze the production process, identify the major problems, control fluctuations of product quality, and provide solutions to avoid future defectsCopyright of Hash Management Services LLP www.businessense.in
  • 7 QC Tools – Check Sheet A check sheet is a pre-designed format for collection of data that encourages organized collection and groups data into categories. Categories are created in advance and may be added as needed. A check mark is added for each example of a category. The marks are added to determine subtotals. When to use it? To keep track of the parameters of an on going process. It can be used to track events by such factors as timeliness (on time, one day late, two days late, etc.); reason for inspection failure (appearance, performance, etc.); person accomplishing the task (sales calls per representative) etc...Copyright of Hash Management Services LLP www.businessense.in
  • 7 QC Tools – Check Sheet Weight (Kg.) Check Sheet Total Example: A company wants to check the 98 0 98.25 II 2 weight of bags of sugar that are supposed to 98.5 IIII 4 98.75 IIIII III 8 weigh 100 kg. The resulting checklist is 99 IIIII IIII 9 99.25 IIIII 5 99.5 IIIII III 8 shown in the following Table. The checklist 99.75 IIIII IIIII IIIII II 17 100 IIIII IIIII IIIII IIIII III 23 indicates that the machine is not filling all the 100.25 IIIII IIII II 12 100.5 IIIII III 8 bags within the specification. 100.75 IIIII IIII 9 101 IIII 4 101.25 III 3 Sugar Bag Weight Check Sheet - 101.5 IIII 4 101.75 II 2 (Specification : 100kg. ± 2 Kg.) 102 I 1Copyright of Hash Management Services LLP www.businessense.in
  • 7 QC Tools – Graphs Graphs are used for the purpose of comparison of visual representation of data collected. The most commonly used graphs are in the form of Bar charts, Line charts and Pie charts.  Bar charts can be used to compare revenue projections , growth in sales volume over a time period  Pie Charts can be used to represent the region-wise revenue share / category-wise contribution to the profits etc Year-wise sales trend Remaining quality tools are covered in the “Certified Manufacturing Professional” course. To access login to www.businessense.inCopyright of Hash Management Services LLP www.businessense.in
  • End of Free Content Please visit our website www.businessense.in to access the full course – “Certified Manufacturing Professional” Our website also contains list of ready-to-use templates and report formats containing Charts and pivot tables. Templates and report formats are available for Purchase, Stores, Production, Quality, Maintenance and HR functions These templates come in excel /word and can be downloaded and used right away At Business Sense, we help clients through consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools. We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply Chain Re-engineering. You can subscribe to our bi-weekly newsletter here. Follow us:Copyright of Hash Management Services LLP www.businessense.in