2. Chapter Objectives
Understanding of the different approaches to Quality
The Statistical approach to quality control
New approaches to quality
Modern Quality Concepts
3.
4. Quality Management
The act of overseeing all activities and tasks needed to
maintain a desired level of excellence.
This includes creating and implementing quality
planning and assurance, as well as quality control and
quality improvement.
It is also referred to as total quality
management (TQM).
5.
6.
7. Quality
It is totality of features and characteristics of a product
or service that bear on its ability to satisfy stated or
implied needs
It is in terms of fitness for purpose and safety in use.
It is a crucial issue at the interface between marketing
and production.
Quality is not only central to profitability but crucial to
business survival.
8. Aspects of Quality
Quality of Design:-suitable for the purpose to which
they will be put and meet the requirement or
perception of the customers.
Quality of Conformance:-Extent to which goods are
produced conform to the specifications and cosistancy
to meet the standards.
9. How to ensure quality
Type of Process Task Resposibility for Quality
Jobbing task & quality integrated.Depends on the skill persons performing task
of the people doing & supervising the work and supervision
Batch and Line work has been de-skilled separate QC and inspection
Continuous Process Quality determined by the process built into the process.
quality reintegrated into the task Monitoring becomes the res-
-ponsibility of those perform-
-ing other aspects of task
10. Proactive or Reactive control
Preventive Or Feed forward Control:-focused on
inputs like human resource, machinery and material.
Concurrent Control:- focus on ongoing activities to
ensure quality
Feedback or post –action control:-focus on output
11. Statistical Quality control
Is based on the assumption that perfect quality is
unattainable and / or too expensive.
Is a trade-off between the costs associated with the
maintenance of quality and the cost of failure due to
lack of quality
12. Statistical Quality control
Cost of lack of quality Cost of quality
Scrape
Reworking
Downgrading/seconds
Inspection
Waste material
Warranty claims
Complaints
Lost sales opportunities
Loss of customer goodwill
Legal claims
Product liability
Verification costs
Inspection costs
Quality audit
Appraisal equipment
Prevention cost
Additional maintenance
Training
Special investigation
Quality planning
13. Statistical Quality control
It can be divided into acceptance sampling and process control.
Acceptance Sampling:-testing a random sample of existing goods
and deciding whether or not to accept an entire lot.
Statistical process control:-testing a random sample of output
from a process to determine whether or not to accept the process.
Acceptable Quality Level (AQL):- the maximum number of
defective goods per 100.
Lot Tolerance Percentage Defective (LTPD):-if the percentage of
defective goods is greater than a specified amount.
Consumers’ Risk:-probability of accepting low quality lot.
Producers’ Risk:-probability of rejecting of satisfactory goods.
14. Stages of Quality Control
The average no. of defectives expected in each batch.
Standard deviation of the distribution
Probability of different numbers of defective goods
Fix the risk levels-AQL-LTPD, producers’ risk and
consumers’ risk
Set the control limits
Implement
15. Control By Variables
Take a succession of random samples
Calculate means value of samples-normal distribution
Standard deviation of error
Determine level of risk
Draw up a control chart
17. Quality Control
Old Philosophy New Philosophy
Second to profit
higher cost
Minimize defects
Only quality controller
Result of poor workmanship
Should be caught n remedied
Ensure profit
Lower cost
Zero defects
Everyone control quality
Poor management
Should be eliminated
18. Total Quality Control (TQM)
Mission statement
Top to bottom learn new philosophy
Inspection for improvement
Suppliers selected for quality
Continuous improvement in production process
Adequate training
Participatory leadership
Trust climate
Cross the board approach
Improve customer satisfaction
No target in production only methods of improvement
Pride in each worker’s own work
Education and self improvement
Climate of quality improvement
19. Juran’s Ten Steps to Quality Improvement
• Build awareness of the need and opportunity for improvement
• Set goals for improvement
• Organize to reach the goals
• Provide training
• Carry out projects to solve problems
• Report progress
• Give recognition
• Communicate results
• Keep score
• Maintain momentum by making annual improvement part of
the regular systems and processes of the company
20. Crosby's 4 Steps to Quality Improvement
• Management is committed to quality – and this is clear to
all
• Create quality improvement teams – with (senior)
representatives from all departments.
• Measure processes to determine current and potential
quality issues.
• Calculate the cost of (poor) quality
21. Total Quality Control (TQM)
The Benefits of TQM Requirements for Success
Improved quality
Increased productivity
Increased market share
Competitive advantage
A release of employee
potential
A motivated workforce
Increased profits
Reduced waste as a result of
zero defects
Leadership from the top
Patience to carry through a
long-term strategy
Communication skills
A change in culture
A recognition of quality in all
aspects of management
Recognition and reward
22. A Cultural Change in Organization
The customer is the driver of change
Continuous improvement
Employee participation
Partnership with employees
Commitment from the top management
Trust in workers’ abilities
Flexibility
Training for the workforce
Acceptance of responsibility
Willingness to contribute