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Procon Engineering Private Limited


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Statistical Quality Review

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Procon Engineering Private Limited

  1. 1. procon Engineering private limited____________<br />A Statistical Quality Management Review<br />The Statistical quality review was conducted by SaadSarfraz<br />
  2. 2. Company Profile<br />Master Group of Industries <br />Establishment<br />Manufacturing Facility<br />Standards <br />ISO 9002 Certification<br />QS 9000 Series Certification <br />
  3. 3. Company Profile (contd.)<br /><ul><li>Automobile seats
  4. 4. Sports car seats for export
  5. 5. Reclining mechanism
  6. 6. Automotive fabric
  7. 7. Roof headlining
  8. 8. Door trim
  9. 9. Steering wheels
  10. 10. Rear package tray
  11. 11. Sun visors
  12. 12. Fender liner
  13. 13. Engine under coversheet
  14. 14. Armrest
  15. 15. Cargo deck
  16. 16. Chassis frame
  17. 17. Suzuki
  18. 18. Toyota
  19. 19. Honda
  20. 20. Nissan
  21. 21. Hyundai
  22. 22. Kia Motors
  23. 23. Daihatsu
  24. 24. Hino
  25. 25. Nissan Diesel
  26. 26. Volvo
  27. 27. Yamaha Motorcycle
  28. 28. Millat Tractor
  29. 29. Al-Ghazi Tractor</li></ul>Products<br />Clients <br />
  30. 30. Statistical Quality Control Systems<br />Categories<br />Descriptive Statistics<br />Statistical Process Control (SPC)<br />Acceptance Sampling <br />PROCON SQCS<br />Failure Mode and Effect Analysis (FMEA)<br />Checks Sheets <br />Control Plans <br />Process Flow Charts <br />Process Quality Control Tables <br />Cause and Effect Diagram <br />Pareto Charts <br />Kaizen<br />
  31. 31. Application of Management Strategies <br />Total Quality Management (TQM)<br />Problem History Charts <br />Scrap and Rework Log <br />Quality vs. Price<br />HACPL Quarterly Presentations<br />Operational Manuals Diagrams <br />Team Work Encouraged vs. Fear of Management <br />Kaizen<br />Target Monitoring<br />Ergonomics <br />
  32. 32. Eight Dimensions of Quality <br /><ul><li>Performance  Inspection right off assembly
  33. 33. Features  Seat recliners and comforters
  34. 34. Reliability  Performance tests (pressure/temperature)
  35. 35. Conformance  Design diagram during production
  36. 36. Durability  Process capability
  37. 37. Serviceability  Rework Redesign
  38. 38. Aesthetics  Style, color, shape, tactile characteristics
  39. 39. Perceived Quality  100% inspection on outgoing products</li></li></ul><li>Descriptive Statistics <br />Objective <br />Summarize data to be used for inference <br />Pattern and Distribution<br />Discrete  Binomial Distribution <br />Variable  Normal Distribution <br />Visual Representation <br />Examples <br />
  40. 40. Stem and Leaf Display<br />
  41. 41. Histogram<br />
  42. 42. Box and Whisker Plot <br />
  43. 43. Magnificent Seven (Statistical Process Control)<br /> Major Tools <br />Histogram or stem-and-leaf diagram<br />Check sheet--<br />Pareto chart<br />Cause-and-effect diagram<br />Defect concentration diagram<br />Scatter diagram<br />Control chart<br />
  44. 44.
  45. 45. Chance and Assignable Causes of Variation <br />Definition<br />Impact/Implication on Quality <br />Identification <br />Failure Modes and Effects Analysis (FMEA)<br />
  46. 46. Control Charts for Variables <br /> Definition<br /> Purpose and Usefulness <br /> X-Bar Chart and R-Chart <br />
  47. 47.
  48. 48. Control Chart for Attributes<br />Definition<br /> Purpose and Usefulness <br /> P- Chart and C- Chart<br />
  49. 49.
  50. 50. Process and Measurement System Capability Analysis<br />Process capability involves evaluating process variability relative to preset product specifications in order to determine whether the process is capable of producing an acceptable product<br />To produce an acceptable product, the process must be capable and in control before production begins<br />
  51. 51. Process and Measurement System Capability Analysis<br />The Indices of Process Capability<br />The processes and measurement systems considered<br />Evaluation Criteria<br />Results<br />
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  56. 56. Acceptance Sampling for Attributes and Variables<br />Acceptance sampling refers to the process of randomly inspecting a certain number of items from a lot or batch in order to decide whether to accept or reject the entire batch<br />A sampling plan is required for acceptance sampling that precisely specifies the parameters of the sampling process and the acceptance/rejection criteria<br />
  57. 57. Acceptance Sampling for Attributes and Variables<br />Sampling plan for attributes<br />Lot size (N) = 100,000<br />Inspection level = Normal<br />Acceptance quality level (AQL) = 2%<br />Sample size code letter = N<br />Sample size (n) = 500<br />Acceptance number (c) = 18<br />
  58. 58. Acceptance Sampling for Attributes and Variables<br />Sampling plan for variables<br />Lot size (N) = 100,000<br />Inspection level = Normal<br />Acceptance quality level (AQL) = 2%<br />Sample size code letter = O<br />Sample size (n) = 100<br />Acceptance number (k) = 1.765<br />
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  62. 62. ISO Standardization<br />ISO develops international standards of quality for all industrial standards<br />ISO has gained popularity and recognition because of the facts that it controls quality, it saves money, customers expect it and competitors use it<br />ISO 9000 and ISO 14000<br />
  63. 63. ISO Standardization<br />PROCON strictly follows the ISO standards of quality and its QMS is based entirely on the ISO 9000 family<br />The compatible standard that applies to PROCON is ISO T/S 16949 quality specification for automotive industry supplier<br />
  64. 64. Application of Six Sigma Approach<br />Six Sigma Quality is defined as a high level of quality associated with approximately 3.4 defective parts per million<br />Six Sigma simply means a measure of quality that strives for near perfection<br />A Six Sigma defect is defined as anything outside of customer specifications<br />
  65. 65. Application of Six Sigma Approach<br />There are two aspects to implementing the Six Sigma concept: DMAIC and DMADV<br />The first is the use of technical tools to identify and eliminate causes of quality problems<br />The second aspect of Six Sigma implementation is people involvement<br />
  66. 66. Critique of the Quality Control System<br />The objective is to study, evaluate and critically analyze the quality control system of the company<br />The quality control measures for the most part conform to the standard operating procedure<br />One drawback of the quality control system of PROCON is its cost<br />Overall, the quality control system is highly efficient and effective at establishing and maintaining quality<br />