Electronic Magazine from

Sri Padhmam Consultancy & Training

What a persons mind can conceive & believe, it can achieve

November 2012
A V Manivannan Principal Consultant & Trainer E-mail : avm@sripadhmam.com Website : www.sripadhmam.com
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INSIDE..
1. Best performers.. a) Eicher Bhopal b) Preethi Chennai c) Wheels India (TVS ) Chennai d) Sundaram Fasteners ( TVS ) Chennai & e) Maxwell Chennai

A V Manivannan
Principal Consultant & Trainer

2. Article on Process Approach 3. Interesting Q & A 4. Management Thought 5. Opinion survey results 6. Common mistakes in SPC Control charts
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Sri Padhmam Consultancy & Training

Chennai & Pondicherry Website : www.sripadhmam.com Cell : 094428 92185

PERFORMERS BEST
Mr. Shravan Kumar Mr. Naresh Gupta Mr. Vijendra Kumar Mr. Jamiluddin Ansari Mr. Arpit Jain Mr. Pradeep Sharma

Process FMEA workshop Eicher Tractors

Bhopal Madhya Pradesh

Facilitated by Mr. Parthasarathy Basu

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PERFORMERS BEST
Mr. C Socratees Mr. S Rudramoorthy Mr. G Dhanasekaran

S P C Workshop

Facilitated by Mr. P K Sitaraman

Preethi Home Appliances

Chennai
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PERFORMERS BEST
Mr. R Sashikumar Mr. M Dineshkumar Mr. S V Praveenkumar Mr. R Rangarajan

3 day EMS Internal Auditor program Wheels India ( TVS ),

Chennai plants & Bangalore plant
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Facilitated by Mr. R Sashikumar

PERFORMERS
Mr. G R Guru Prasad Mr. R Marimuthu Mr. S Mahalingam Mr. M Baskaran Ms. C Ramya & Ms. Fernando Catherine Asir

BEST
2 day Process FMEA workshop

Facilitated by Mr.John Paul

Sundaram Fasteners ( TVS )

SEZ, Mahindra City, Chennai
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PERFORMERS BEST
Mr. V T Krishnamurthi of OM Sakthi Inds Mr. M Kalicharan of J K Tyre Mr. J Senthilkannan of EL Forge Mr. N Gokulnath of Brakes India

2 day Measurement Systems Analysis workshop Maxwell, Chennai Public program

Facilitated by Mr. V K Gurumoorthy

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Interesting article on Process Approach THE Base for the Quality Management System

8 Management Principles of ISO 9001 : 2008

1. 2. 3. Customer focus Leadership Involvement of people

4.
5. 6. 7. 8.

Process approach
System approach Continual improvement Factual approach to decision making Mutually beneficial Supplier relationship Share & Care - November 2012
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Process approach : What & Why ?

A desired result is achieved more efficiently when related resources and activities are managed as a process.
All work is a process because it uses resources to perform actions that produce results. In the organizational sense, such processes add value to the input. Processes are therefore dynamic, i.e. they cause things to happen. An effective process would be one where the results were those that were required to fulfill the purpose of the organization. Every job involves people or machines equipped with resources performing a series of tasks to produce an output. No matter how simple the task, there is always an objective or a reason for doing it, the consumption of resources and expenditure of energy, a number of constraints that influence the way the work will be performed, a sequence of actions, decisions concerning their correctness, a judgment of completeness and an output which should be that which was expected.
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Process approach : What & Why Continued

The organization exists to create and satisfy customers and other stakeholders therefore the organizations processes must serve the needs of these stakeholders.

The impact
Procedural approach to Process approach A process is as capable of producing rubbish as a procedure is capable of wasting resources therefore processes need to be managed effectively for the required results to be produced. The process approach to management is therefore not simply converting inputs into outputs that meet requirements but about managing processes effectively. An organization applying the process approach principle would be one in which people are: Establishing what it is they want to do what objectives they want to achieve or what outputs they want to deliver. Establishing measures of success the factors that will indicate whether the objectives have been achieved or the outputs meet requirements.
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Process approach : What & Why Continued

Defining the activities that are critical to achieving these objectives and delivering these outputs. Identifying the interfaces between the process and the functions of the organization the external customers, suppliers and other stakeholders. Establishing clear responsibility, authority, and accountability for managing the process. Defining the resources, information and competences required to deliver the required outputs. Identifying and measuring the inputs and outputs of the process. Identifying the risks and putting in place measures that eliminate, reduce or control these risks Taking action to eliminate the cause of nonconforming inputs or outputs. Taking action to prevent use or delivery of nonconforming inputs or outputs until remedial action has been effected.
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Process approach : What & Why Continued

Determining how performance will be measured against the objectives and reducing variation. Finding better ways of achieving the process objectives and improving process efficiency. Establishing whether the processes objectives remain relevant to the needs of the stakeholders and if necessary changing them.

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Interesting
&

Question & Answer

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Mr. Saravanakumar of CRI Pumps, Coimbatore When, by process design itself, one process incompletion or deficiencies is corrected and managed in the subsequent process, should it be analyzed in both the stages ?

A well thought out question. Appreciations !

Process FMEA

The straight forward answer is YES. In each stage, the process requirements ( say size, shape or finish ) to be determined and they have to be standardized. This standardization can not be managed by the Product designers in all the cases. I mean to say that the product drawings may not cover all these intermittent specifications. Process drawings shall be developed by the Process planning and these drawings must cover all such dimensions, including the finish related requirements, if any. These have to be analyzed in the respective stages on Process FMEA. This is because the previous stages EXCESS deficiencies may cause Failure modes in the Subsequent stages too. Also lets remember, that 4th edition of FMEA suggests to analyze the incoming stages of variations also, when there is a historical data supports it.
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Mr. S Tamilselvan of Leyland Deeree, Chennai What would be the advantage of a Box plot analysis, compared to other Methods of data analysis ? Can we analyze 2 different characteristics in one Box plot ?

Box plot analysis

Nice one ! The greatest advantage of a Box plot analysis would be, the ease of comparison. When a particular characteristic ( say MTBF factor of 4 different plants ) is plotted, the Comparison becomes very easy. This would be the biggest advantage of Box plots over other methods. Also we need few data Points to plot. Even with 5 points, it becomes possible to plot a graph. The purpose of Normality analysis is also the same, however, comparison becomes very difficult in this method. Answering to the next question, we should NOT try to analyze different characteristics in One graph at all.

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Mr. Diwakar of Krysalis, Chennai Which type of processes may give a good Cp may not be a good Cpk ?

Process Capability

Most of the Press tool parts ! The tool for its extended life will be designed to the minimum size ( in case of External Diameters ) or the Maximum size ( in case of Internal Diameters ). This is intentional and this will result in poor Cpk value in the beginning and end of the tool life ! Generally pressing is considered to be a very consistent process and hence the Cp will be good. Whereas because of the tool design the Cpk will be less than the Cp. It may happen in Sintering process too. When I was auditing a Bangalore based company doing sintering process, I witnessed this. When I enquired further, the organization representative was insisting me to satisfy with good Cp ( 2.4 I remember ). It was on part weight. They wanted to save material on part weight which made them to design the cavity at the lower side of the tolerance ! As a result of this, the Cpk was poor. Later with the help of the Customer organization I corrected this ( of course after lot of debates and curses on me by the Supplier organization !! )
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Without a set of principles, achieving a common understanding in the field of Quality management would be impossible.

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The Prime reason behind the recent Economic reforms by the Central Government would be . A B C
To divert the peoples attention from the Mega level Corruptions ! To build the Partys image in the country & for International popularity ! A very genuine attempt to bring back economic growth of India !

Your feed-back for the opinion survey is in the next page !

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Results of Opinion Survey.

The Prime reason behind the recent Economic reforms by the Central Government would be .
To divert from Mega corruptions

A genuine attempt

12 %

23 %

65 %

For Popularity

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Thanks for your appreciations for previous months SPC related articles. There was one Question from many patrons :

FREE DOWNLOAD
A detailed report is available in our website For Free download please visit www.sripadhmam.com
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