Research

1.  SHEHARYAR
 ABDUL WAJID

2.  Introduction
 TQM Basics
 Tools for quality
improvement
 5S Theory
 QA/QC
CONTENTS:

3. The essence of Total Quality Management is
a common sense dedication to understanding
what the customer wants and then using
people and science to set up systems to
deliver products and services that delight the
customer.
What is TQM??What is TQM??

4.  Customer Focus
 Continuous Process Improvement
 Employee Empowerment – Everyone is responsible for
quality
 Quality is free - focus on defect prevention rather than
defect detection for it is always cheaper to do it right the
first time
 Benchmarking – Legally stealing other people’s ideas
 Customer-Supplier Partnerships
 Management by fact..by numbers..by data –
Balanced scoreboard (financial, customer, process,
learning)
BASIC CONCEPTS OF TQMBASIC CONCEPTS OF TQM

5. Quality ImprovementQuality Improvement
Traditional
Continuous Improvement
Time
Quality

6. Continuous improvement philosophy
1. Kaizen: Japanese term for continuous improvement.
A step-by-step improvement of business processes.
2. PDCA: Plan-do-check-act as defined by Deming.
3. Benchmarking : what do top performers do?

7. “Creating the Best Vehicle/Systems with All the People All
the Suppliers All the Time”
7
SOR
YOU meet the
requirements! Let’s create
the best
Vehicle and
Systems
together.
Partnership - Collaborative relationship

8. Tools Used For Continuous Improvements:
1.1. Process (Manufacturing)Process (Manufacturing)
2.2. Run diagramRun diagram
3.3. Control chartsControl charts
4.4. FishboneFishbone
5.5. Check sheetCheck sheet
6.6. HistogramHistogram
7.7. Pareto analysisPareto analysis

9. 1. Process ( Manufacturing)
Process: Plot data to identify the working procedure.

10. 2. Run Chart
Run Charts: Plot data as a function of time

11. 3. Control Charts
Time
Performance Metric
Control Charts: are statistical tools used to determine if the
variation in results is caused by common or special events

12. Makes
custome
r wait
Absent receiving
party
Working system of
operators
Customer Operator
Absent
Out of office
Not at desk
Lunchtime
Too many phone calls
Absent
Not giving receiving
party’s coordinates
Complaining
Leaving a
message
Lengthy talk
Does not know
organization well
Takes too much time to
explain
Does not
understand
customer
4. Cause and effect diagram (fishbone)
Cause and effects Charts: fishbone diagrams are used to identify
the root causes of a problem

13. 5. Check sheet
Item A B C D E F G
-------
-------
-------
√ √ √
√ √
√ √
√
√
√ √
√ √ √
√
√
√
√
√ √
Check Sheets: Easy way to count frequency of occurrence by
front line workers

14. 6. Histogram
Frequency
Histograms: Categorize data is cells and plot (see if any
patterns emerge)

15. 7. Pareto Analysis
A B C D E F
Frequency
Percentage
50%
100%
0%
75%
25%
10
20
30
40
50
60
Pareto Charts: Organize data on a histogram based on
frequency from most prevalent to least. Help identify major
causes or occurrences (80:20 rule)

16. SEIRI – Organisation/Sort out
SEITON – Orderliness/Systemize
SEISO – The Cleaning/Shining
SEIKETSU – STANDARDIZE
SHITSUKE - Sustain/Discipline

17. Decide what you need
Remove unnecessary clutter
All tools, gauges, materials,
classified and then stored
Remove items which are
broken, unusable or only
occasionally used

18. Once you have eliminated unneeded
items
Now turn to left over items.
Organise layout of tools and
equipment
 Designated locations
 Use tapes and labels
 Ensure everything is available as it is needed and at the
“point of use”

19. Create a spotless workplace
Identify and eliminate causes of dirt
Sweep, dust, polish and paint
Divide areas into zones
Focus on removing the need to clean

20. Generate a maintenance system for the
first three
Develop procedures, schedules, practices
Regularly audit using checklists and
measures of housekeeping
Real challenge is to keep it
 clean

21. Means immunize courtesy & good habits
Driving force behind all 5S
Make it a way of life
Involve the whole workforce*
Develop and keep good habits

23. Time saving.
Quick retrieval.
Accidents & mistakes minimized.
Health and Safety is ensured
Machine maintenance
Quality, Productivity
Lean Manufacturing
Company image improves

24. Quality Assurance:
It is a process based approach which allows to
prevent defects in first place and to satisfy
requirements of quality
Quality Control:
It is a product based approach which allows us to
detect defect in product making and to prevent
them in deliverables.

25. Shipping Quality Audit
1.Audit of whole shipment
2.Sampling
Customer Quality Engineering
Quality Planning
1.Monthly Audit
QA SUB DEPARTMENTS

26. Quality Engineering:
1.LAB
2.Mass Production
3.Project
Customer Satisfaction Inspection Line
Vehicle Performance Inspection
Final Confirmation
Quality Inspection Group
QC SUB DEPARTMENTS