Quality Concept and Quality Management

1. Quality India hub
Quality India Hub
Quality Concept And Quality
Management
Sunday, August 2, 2020 1
Quality Concept
And Quality Management
Date:- 02/08/2020
Prep. By- Dhiraj Singh

2. Quality India hub
Quality India Hub
1-Quality
What is Quality
Sunday, August 2, 2020 2
What is Quality
 Confirmation to Specification
 Fitness for Purpose
 Customer Satisfaction
 Right at first time
 Zero Defect
 Value of Money
 Reducing variation
 Customer delight

3. Quality India hub
Quality India Hub
2-Outflow Prevention
What is Quality
Sunday, August 2, 2020 3
Outflow Prevention Content
 Basic Rule and Std. Work
 Abnormality handling Rule
 Cabage Path
 Work Instruction Sheet
 Different condition of FIFO
 Rejection and Rework Part Handling
 Quality Inspector Skill enhancement
 Boundary Sample

4. Quality India hub
Quality India Hub
3-Basic Rule and Std. Work
What is Quality
Sunday, August 2, 2020 4
1) Inspection layout
Inspection
IN
OUT
Work
Instruction
Inspection
Std.
One Point
lesion
Daily Rejection
Record
Daily
Instrument
Check Sheet
Customer
Complaint
N.G
Part
Hold
Part
Quality Document

5. Quality India hub
Quality India Hub
3-Basic Rule and Std. Work
What is Quality
Sunday, August 2, 2020 5
2) Instrument check Sheet
Gauge and instrument
Name Should be
Clear in check sheet
Gauge and instrument
Range should be define
Check point
should be define
Checking Method
should be define
PIC Should be define
in check sheet

6. Quality India hub
Quality India Hub
3-Basic Rule and Std. Work
Sunday, August 2, 2020 6
3) Work Instruction
Work Instruction Should contain below content
 Process name and process no should be define
in WI
 Machine no should be define in WI
 Required no of operator should be define in WI
 Required Operator Skill Should be define in WI
 Working detail sequence wise and Sequence wise
photograph should be define
 Key point should be define
 Reason for Key point should be define

7. Quality India hub
Quality India Hub
4-Abnormality Handling
Management
Sunday, August 2, 2020 7
1) Abnormal Situation
A disturbance or series of disturbance in process that
cause plant operating to deviate from their Normal
/Operating Stage
2) Abnormality
During manufacturing process Quality Abnormality
occur due to defective material or wrong manufacturing
process such as mistake in operation, Skip in process
,Machine problem , wrong setting on machine
parameter , lack of process control and packing
problem.

8. Quality India hub
Quality India Hub
4-Abnormality Handling
Management
Sunday, August 2, 2020 8
3) Management of Abnormality
Floor Management
What to ManageHow to Manage
HR Management
Standard/Idea
Current Situation
Abnormality
Management
Shop Floor Subject
which cause abnormality
1- Physical / Environment
2- People/Process
3- 5’S Control
4- Stand Work

9. Quality India hub
Quality India Hub
4-Abnormality Handling
Management
Sunday, August 2, 2020 9
4) Sampling Inspection
Sampling inspection is a technique to determine whether a lot or
population should be rejected or accepted on the basis of the
number of defective parts found in a random sample drawn from
the lot.
5) Nokoshi Work (Retention of Quality Check Sample)
 It is practice approach of taking action to the problem at
earlier stage it self
 This system help to trace the part / batch in case of any
abnormality

10. Quality India hub
Quality India Hub
4-Abnormality Handling
Management
Sunday, August 2, 2020 10
6) Set Up Approval
It is the confirmation of first part production of part with respect
to Quality Parameter (Dimensional Appearance etc.)
7) Lot Approval System
Approval for lot after through inspection of the initial part
produced in the process as per set sampling plan
8) Cabage patch
 It is a system which is used communicated to all the defect
from the previous shift
 All the defect all displayed at the entrance so that each and
every member see and understand the defect

11. Quality India hub
Quality India Hub
Sunday, August 2, 2020 11
5-Inspector Skill enhancement
Step of Quality inspector Skill enhancement
Step-1→ Training
Key area of training
Standard Work (IIS/WIS)
Part awareness (Fitment/functional)
Identify defect and non defect condition
Defect monitoring system
Gauge handling and maintenance
Past defect history

12. Quality India hub
Quality India Hub
Sunday, August 2, 2020 12
5-Inspector Skill enhancement
Step of Quality inspector Skill enhancement
Step-2→ Skill Evaluation
 Skill Evaluation to confirm the member skill to perform assign
job
 To judge the member capability to work efficiency
Evaluation Method
 Sequence test
 Dummy test
 Q&A
 Audit

13. Quality India hub
Quality India Hub
Sunday, August 2, 2020 13
6-Boundary Sample & Feed
back System
Boundary Sample
Physical piece which are established when certain
characteristics of part which are difficult to define or
communicate by any other method
 Supplier shall maintained the master boundary sample in a
location where it is maintained without damage again etc.
Feed back System
It is a method of communication which is inform the stack holder
during any abnormality

14. Quality India hub
Quality India Hub
Sunday, August 2, 2020 14
7-Toyota production System
Toyota production system
Culture of
continuous
improvement
Operating Stability
Highest Quality,
lower cost ,Shortage lead
time by eliminating wasted time and activity
Just in Time (JIT)
• Kanban place
• Right time
• Right Qty.
• Tack time
• Std. in process stock
• Full stock
Jidoca
• Failure prevention
of equipment in
case of breakdown
or malfunction
• Process built in Quality
Heijunka Standard Work TPM Value Chain

15. Quality India hub
Quality India Hub
Sunday, August 2, 2020 15
7-Toyota production System
JUST-IN-TIME
 Produced according to What needed, when needed and how
much needed.
 Strategy to improve return on investment by reducing
inventory and associated cost
 The process is driven the Kanban Concept
JIDOKA
 Jidoca (meaning Autonomation) automation with human touch
 It is the Quality control system used in Toyota production
system which applies the following four principle
• Detect the abnormality
• Stop
• Fix or correct the immediate condition.
• Investigate the root cause and take countermeasure

16. Quality India hub
Quality India Hub
Sunday, August 2, 2020 16
7-Toyota production System
Kaizen
 Meaning- Continuous Improvement
 Kaizen refers to a workplace 'quality' strategy and related to
various quality-control systems.
 It aims to eliminate waste (defined as "activities that add cost
but do not add value").
 Kaizen is a daily activity whose purpose goes beyond
improvement. It is also a process that, when done correctly,
humanizes the workplace, eliminates overly hard work (both
mental and physical.
 It teaches people how to perform experiments using the
scientific method and how to learn to spot and eliminate waste
in business processes.

17. Quality India hub
Quality India Hub
Sunday, August 2, 2020 17
7-Toyota production System
Poke-Yoke
Poka - Mistake
Yokeru - proofing
It is methodology that used to strive toward zero defect by
1-Detection
2- Prevention
It is used to eliminate the product / process defect by preventing correcting
and drawing attention to human error as they occur
Level of Poke-Yoke
Level-1
• Detect defect before they move to next step
Level-2
• Detect error during processing
Level-3
Prevent error from occurring