Unit 6
Unit 6
Quality Management
and
Japanese Operations
Managements
2
– Quality Management
– Philosophical Elements of Quality
Management
– Quality specification and Quality Costs
– Statistical Quality Control
– Process Control
– Features of Japanese Operations
Managements
– Stabilizing Schedule
– Elimination of Waste
– Acceptance Sampling ISO 9000
3
Introduction and Background
Quality is a key business driver. While quality and
quality management have been around for a long
time, it is only since the rise of Japanese
Companies such as Toyota, Honda, Sony and
others in consumer markets that people have
begun to realize the importance of quality in the
production and delivery of goods and services. In
Newzealand, after the economic deregulation of
1984, leading companies started putting emphasis
on improving the quality of their goods and
services as the basis of ensuring their survival.
Similarly In Australia, during the 1980s and
subsequently, managers in most industries have
been attempting to improve the quality of all their
process and their goods and services. This has also
been the experience in many other countries.
4
Quality management
As we know the field of operations management is
replete with acronyms. The field of quality management
has also contributed its share of acronyms. In its early
days people used the term “Quality Control”(QC).
This term reflected the fact that the approach to quality
at that time was all to do with control and typically
companies employed a group of people called quality
inspectors who came along as the product was about
to go to the customer, and they decided whether or not
the product met the customer’s specification. The term
“QC” also reflected the origins of quality management
in a manufacturing environment. It included a lot of
inspection and rework as needed, and also some good
works on building quality into the organization’s
operational processes, in order to reduce errors.
5
Contd…..
When people realized the importance of services in the
economies of the developed countries, quality
assurance (QA) was developed to describe all the
processes and procedures that organizations used
to ensure that their products and services did meet
customers’ specifications or provided consumers
with goods and services of appropriate quality. Since
the 1970s the term total quality management(TQM)
has been adopted. Fundamentally, TQM implies that
of quality is not solely a control or technical issue but
quality must be addressed from the perspective of
strategic management and the top levels in the
organization. In leading companies, it has been a
company-wide approach and initiative.
6
Defining Quality
Different Views
User-based – better performance, more
features
Manufacturing-based – conformance to
standards, making it right the first time
Product-based – specific and
measurable attributes of the product
8
implications of Quality
1. Company reputation
Perception of new products
Employment practices
Supplier relations
2. Product liability
Reduce risk
3. Global implications
Improved ability to compete
9
Total Quality Management (TQM)
A holistic approach to long-term
success that views continuous
improvement in all aspects of an
organization as a process and not
as a short-term goal. It aims to
radically transform the
organization through progressive
changes in the attitudes, practices,
structures, and systems.
10
Cost of Quality
Cost of quality refer to the cost expended by
organization in managing current level of quality
(or lack of quality) and in seeking to improve that
level of quality. Cost of quality are those cost
incurred by an organization in preventing non-
conforming product and services, in evaluating
processes, product and services; and cost
associated with failure to confirm with
requirement. As per ISO 8402, Quality related
costs are those costs incurred in ensuring and
assuring satisfactory quality, as well as the
losses incurred when satisfactory quality is not
achieved.
17
Contd….
Up to late 60s quality costs are analyzed under
the head of overheads. However in the
present circumstances, quality related costs
are much larger, approximately 20-30% of
total sales revenue. Hence, it is considered
separately. Quality losses are the inherent
aspects of the most products and services,
most industry offer. Any reduction in quality
cost is a direct profit. There is a huge potential
to increase profit, so for the productivity by
monitoring, evaluating and controlling quality
related costs.
18
Cost of Preventive
Cost of any activity which is needed to be carried out
of preventing faults in the product/services is called
prevention cost. It is the money part that is spent to
ensure whether the things are performed correctly at
the first time. Do the things right first time is an
essential slogan to keep the failure at minimum
level. Prevention cost includes:
Pre production quality control
Vendor quality control
Inspection and test planning
Design and development of inspection and test
equipment
Quality control
Quality system audit
20
Cost of Appraisal
Appraisal activities determine conformance of a product or
service. Those include such activity as tests, inspections,
verifications and checks to identify failure or errors. Appraisal
activities do not include rework and re-inspection activities
following failure.
Appraisal costs may include the following costs:
Cost of incoming inspection and tests to evaluate the quality
of purchased part/subassemblies/raw materials
Cost of in process inspection and tests to carry out evaluation
of conformance to requirement(during manufacturing)
Cost of final inspection and test to evaluate conformance to
requirement for product acceptance
Cost of audit performed on process of finished goods
Cost of inspection of test material and services
Cost of evaluation of stocks includes cost of storing the
tested items in the field
21
Cost of Internal Failure
Failure activities are those activities related to
correcting, reworking or disposing of errors.
Errors prior to sale /delivery to a customer
are internal failure. They are as follows
Scrape, rework
Trouble shooting
Analysis of deflects and failures
Re inspection and re test
Loss of production due to defective supplied
material
Modification permits in process sheets and also
in design
22
Cost of Internal Failure
Failure activities are those activities related to
correcting, reworking or disposing of errors.
Errors after sale /delivery to a customer are
external failure. They are as follows
Management complaints
Product or customer service
Product returns
Product liability product recalls and product
replacement
Marketing errors
23
International Quality Standards
Quality is so important globally that the world is uniting
around a single quality standard, ISO 9000. ISO 9000
is the only quality standard with international
recognition. In 1987, 91 member nation (including the
U.S.) published a series of quality assurance
standards, known collectively as ISO 9000. The U.S.,
through the American National Standards Institute,
has adopted the ISO series as the ANSI/ASQ Q9000
series. The focus of the standards is to establish
quality management procedures, through leadership,
detailed documentation, work instruction, and
recordkeeping. These procedures, we should note,
say nothing about the actual quality of the product-
they deal entirely with standards to be followed.
24
History
SQC was pioneered by Walter A. Shewhart
at Bell Laboratories in the early 1920s.
Shewhart developed the control chart in 1924 and
the concept of a state of statistical control.
Shewhart consulted with Colonel Leslie E. Simon in
the application of control charts to weapons
manufacture at the Army's Picatinney weapon store
in 1934.
History
28
CHARACTERISTICS OF S.Q.C.-:
Designed to control quality standard of goods produced
for marketing.
Value
This point is out of the control limits
UCL
3
Center
3
Line
LCL
Time
AAprocess
processisisconsidered
consideredininstatistical
statisticalcontrol
controlififitithas
hasno
noassignable
assignablecauses,
causes,only
only
naturalvariation.
natural variation.
36
PURPOSE & USES OF CONTROL CHARTS
1. Helps in determining the quality standard of
the products.
2. Helps in detecting the chance & assignable
variations in the quality standards by setting
two control limits.
3. Reveals variations in the quality standards
of the products from the desired level.
4. Indicates whether the production process is
in control or not.
5. Ensures less inspection cost & time in the
process control.
37
Types-:
Types of
Control
Charts
Control
Control
Charts
Charts for
for Attributes
Variables
np-
Chart R-Chart σ-Chart p-Chart C-Chart
Chart
38
CONTROL CHATS FOR VARIABLES
CHART/ MEAN CHART-: This
chart is constructed for controlling
the variations in the average quality
standard of the products in a
production process.
EXAMPLE-:
Solution-:
Sample Weights (X) Total Range
no. Weights =(ΣX/5) R=(L-
(ΣX) S)
1 20 15 10 11 14 70 14 10
2 21 18 10 8 22 70 14 14
3 21 19 17 10 13 80 16 11
4 22 12 19 14 20 80 16 8
5 20 19 26 12 23 100 20 14
Grand Chart
Grand = 16 (Central line)
Control limits-:
UCL = Grand + A2
= 16 + 0.577 x 11.4
= 22.577
LCL = Grand - A2
= 16 – 0.577 x 11.4
= 9.423
42
Control limits-:
UCL = D4.
= 2.115 x 11.4
= 24.09
LCL = D3.
= 0 x 11.4
=0
σ Chart-: This chart is constructed to get a 43
Example-:
Sample No. Size of sample No. of Fraction
(n) defectives (d) defectives
(d/n)
1 100 5 0.05
2 100 3 0.03
3 100 3 0.03
4 100 6 0.06
5 100 5 0.05
6 100 6 0.06
7 100 8 0.08
8 100 10 0.1
9 100 10 0.1
10 100 4 0.04
K = 10 Σd = 60
46
UCL = + 3√ . q̅/n
= 0.06 + 3√0.06x0.94/100
= 0.1311
LCL = - 3 √ . q̅/n
= 0.06 - 3 √ 0.06x0.94/100
= -0.0111 = 0
47
48
Example-:
An inspection of 10 samples of size 400 each from 10 lots
reveal the following number of defectives:
17, 15, 14, 26, 9, 4, 19, 12, 9, 15
Calculate control limits for the no. of defective units.
n = Σd/k = 140/10 = 14
n = 14 (central line)
UCL= n + 3√ n q̅ LCL= n - 3√ n q
̅ = 14 + 3√400x0.035x0.965 = 14 -
3√400x0.035x0.965
= 25.025 = 2.975
49
50
ACCEPTANCE SAMPLING
Meaning-:
Another major area of S.Q.C. is “Product
Control” or “Acceptance Sampling”. It
is concerned with the inspection of
manufactured products. The items are
inspected to know whether to accept a
lot of items conforming to standards of
quality or reject a lot as non-
conforming.
53
DEFINATION-:
“ Acceptance Sampling is concerned with the decision
to accept a mass of manufactured items as
conforming to standards of quality or to reject the
mass as non-conforming to quality. The decision is
reached through sampling.”
By-:
SIMPSON AND KAFKA
54
Risks in Acceptance sampling
1. Producer’s risk-: Sometimes in spite of
good quality, the sample taken may show
defective units as such the lot will be
rejected, such type of risk is known as
producer’s risk.
Is ‘d’ ≤ ‘c’
If yes, than accept the lot If no, then reject the lot
57
Double Sampling Plan-:
Under this sampling plan, a sample of ‘n 1’ items is
first chosen at random from the lot of size ‘N’. If
the sample contains, say, ‘c1’ or few defectives,
the lot is accepted; if it contains more than ‘c 2’
defectives, the lot is rejected. If however, the
number of defectives in the sample exceeds ‘c 1’,
but is not more than ‘c2’, a second sample of ‘n2’
items is take from the same lot. If now, the total
no. of defectives in the two samples together
does not exceed ‘c2’, the lot is accepted;
otherwise it is rejected. (‘c1’ is known as
acceptance no. for the first sample & ‘c 2’ is the
acceptance no. of both the samples taken
together)
58
Double Sampling Plan-:
Count the no. of defectives,
d1in the first sample of size
n1
Is d1 ≤ c1 ?
Is d1 + d2 ≤ c2
ADVANTAGES OF S.Q.C.-:
Helpful in controlling quality of a product
Eliminate Assignable causes of variation
LIMITATIONS-:
Does not serve as a ‘PANACEA’ for all
quality evils.
It cannot be used to all production process.
Contd….
Japanese Management practices specially focuses on two
area.
People-oriented
Work-oriented
People oriented
Work oriented