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Q1 Explain various Principles of Total Quality Management
Solution: Top management involvement; The successful implementation of TQM can be
ensured with the support and active involvement of the top management of an
organisation. The top management not only sets the visions and goals of the organisation,
assigning jobs to employees, and changing work processes in TQM implementation.
Customer-oriented approach: The central idea of TQM is to bring organisation-wide
improvement to create customer orientation at all levels of the oranisation. This is to meet
customer expectations and generate maximum satisfaction. Methods, such as surveys,
external benchmarking, and market reports, can help in identifying the needs of the
customer. By listening to customers, the organisation can identify the direction in business
and improvements to be set. After assessing customer requirements, the organisation can
set the road map and continuously update the assessments about quality.
Employee empowerment; TQM
ement; One of the most important aspects of TQM is that it is not a one-time process.
TQM focuses on the practice of continuous improvement wherein an organisation should
continually strive to make improvements in quality through learning and problem solving.
For example, the quality improvement process in Toyota does not end after Toyota cars
achieve a certain level of quality in terms of various parameters, such as performance of
comfort. The employees of the company continuously strive to find out the features in cars
that can be further improved to create more customer satisfaction or beat competitors.
Supplier relationships; TQM extends the concept of quality to an organisations suppliers.
TQM makes it necessary for organizations to procure materials from the suppliers who can
meet their pre-defined standards of quality. If suppliers meet the pre-defined quality
standards, organisations need not inspect materials on arrival. For this, many
organistions have their representatives at the suppliers facility. This collaboration
involves both the supplier and the organisation, at every stage of quality improvement.
Performance measures; Measurement plays an important role in quality improvement. In
the absence of effective measurement tools and techniques, an organisation cannot measure
the performance of its TQM efforts. TQM measures and standreds of quality performance
should be based on certain criteria such as level of customer satisfaction, market image,
and total return. For doing so, oranisations should go for regular assessment of its
processes, products, and services.
Certification of ISO 9001;2008
The ISO is not responsible for providing any certifications to organizations. Its work is
limited to the development and publishing of standards. The 9001; 2008 certifications can
be achieved through various independent certification bodies. These bodies are authorized
to issue the certification if the requesting organisation fulfills the set criteria. Generally, an
organisation refers itself as ISO 9000 certified, but the actual standard for which it is
certified is 9001;2008. There are many accredited bodies in various countries that empower
independent certification bodies to issue the certification. To make the certification
acceptable in all countries, various accredited certification bodies follow a mutual
agreement. The standard under which certification bodies and accreditation bodies
function is ISO/IEC 17021 and ISO/IEC 17011, respectively.
ISO 9004; 2009
ISO 9004;2009 was created as the latest revision to replace ISO 9004;2008 and was released
on November 1, 2009.
In todays dynamic environment, sustained success is imperative. ISO 9004;2009 is
developed to provide a base to organizations for sustained development by providing a
modal based on the quality management approach. The standard has been divised to
support an organisation in achieving its long-term goals and objectives in terms of
economy, quality, satisfaction of customers and stake holders ect. The latest ISO 9004
standard guides an organisation in using the systematic approach based on the quality
management system, which consequently leads to the achievement of sustained success.
ISO 90003;2004;Software Quality Management
ISO 90003: 2004 is a standard that is developed with the aim of improving the quality of
software-related products in terms of supply, development,maintenance and support services. It
is not meant for making any amendments to the requirements of ISO 9001;2000 neither it is to be
used for
this way, they can avoid wrong selections that can lead to complications and raise the costs and
time consumption in manufacturing.
At the beginning of the DFM process, designing occurs within prevailing manufacturing
capabilities. With time, the interactions between designers and manufacturing people result in the
formation of a relation; this in turn leads to the expansion of manufacturing capabilities.
Implementing DFM can lead to quality improvement, as all the potential problems are addressed
at the designing stage itself. This consequently results in saving a lot of time.
Design for assembly
Design for Assembly (DFA)can be defined as the process of designing products by keeping in
mind the ease of assembly. DFA works on two principles, which are as follows;
Fewer parts take less time to be assembled.
Parts that are easier to move, grip and fit also take less time to be assembled.
In other words, by using DFA keeping the number of parts to minimum leads to reductions in
assembly time and costs.
Design to cost
Design to cost (DTC) is a methodology that is used by designers to monitor the level of costs at
the time of designing. As manufacturing costs are inclusive of the costs of components, assembly
and overhead, it is essential for DTC to take into consideration all these factors too at the time of
designing the product. To reduce the costs of assembly and components, various strategies and
rules used for easing the assembly can be used. To reduce overhead costs, DTC must perform
activity- based costing for getting an accurate idea about the overheads created by the production
of a single unit of products so that adequate measures can be devised at the time of designing.
Design for usability
Effective designing of a product is not restricted to designing a good architecture, DFM ,DFA
and DTC. It also calls for attention towards usability that is essential for producing a successful
product. Design for Usability (DFU) is an approach used for designing while keeping users
needs at a high priority. DFU emphasises on creating an ease of handling for the user while using
the product.
DFU used two sources to emphasise on usability. These forces are as follows;
Industrial engineers- Usability is their primary charter. Some of the questions that industrial
engineers keep in mind to focus on users are as follows;
What degree of ease of use is required?
Keeping track on the warranty periods of machines and equipment and preparing maintenance
schedules.
Establishing standards for inspection and quality checks of machines and equipment.
Conformance to machine specifications determines how efficiently a machine or equipment is
designed to meet the quality standard specified by an organisation. For example, the dimensions
of a machine part may be specified as 3+0.05 inches. This means that the standard dimension is 3
inches but may very between 2.95 to 3.05 inches, which is acceptable to maintain quality.
However if the specification of a light bulb is 60 watts but it generates 50 watts, it clearly
indicates the non-conformance to quality. Therefore, conformance to specifications is essential to
maintain the quality of not only the machines and equipment used in an organisation but also the
products or services delivered by the organisation.
Frequency of machine failures
In simple words, machine failure can be defined as any event in a machine or any of its part or
component that interrupts the normal functioning of the machine. Machine failures are also
referred to as the loss of usefulness of a machine or equipment. For example, if a pump at an oil
station is installed to drive 100 gallons of oil per minute but is able to pump only 50 gallons per
minute, it is the loss of usefulness of the pump. The most common reasons for the failure of
machines and equipment are faulty designs, material defects, and discrepancies in manufacturing
and processing.
Meaning of Condition Monitoring Steps Involved in Condition Monitoring Program
A process of monitoring the condition of machines and equipment with the aim to identify any
potential failures is called condition monitoring. Condition monitoring involves measuring the
different parameters of machines and equipment, such as temperature, vibration, oil pressure and
debris, and running performance.
1. Establishing the type of condition monitoring; In this step, the type of condition
monitoring is selected viz. online monitoring or offline monitoring. An organisation
selects the type on the basis of its requirements.
2. Listing machines to be monitored; In the second step, a list of all the machines existing in
the plant must be prepared. As there are numerous machines exist in a plant of an
oraganisation, the selection should be made based on their importance in production.
3. Specifying the characteristics of machines; After making the selection of machines, the
specifications of machines that are required for conducting vibration analysis should be
defined. These specifying are given as follows;
Rotational speed of shafts; number of teeth in hears; number of blades and vanes in
pumps and fans; etc.
Vibration forces that include misalignment, mass imbalance, and mass resciprocation.
Vibration responses that occur due to changes in temperature, pressure, heat, etc.
Fault responses that are related to particular types of machines, such as fans, motors, and
pumps.
Modifications in operating conditions.
4. Selecting the suitable vibration measurement parameter; There are three parameters for
measuring vibrations, namely acceleration, velocity, and displacement. The most suitable
parameter may follow the rule of providing the flat spectrum, which only applies to
measure the frequency range of interest. Thus, the selection of a parameter depends on
the type of machine and faults considered.
5. Selecting the appropriate vibration pickup; In this step, an appropriate vibration pickup
must be selected. There are three types of pickups, namely displacement transducers,
accelerometers, and velocity pickups. In displacement transducers, a mechanical
displacement input is converted into electrical output that is proportionate to the input
displacement. Displacement transducers are vital for machines having journal bearings
(type of plan bearings that are designed to decrease friction between surfaces.)
Accelerometers and velocity pickup are useful in detection breakdowns occurring at high
frequencies, for instance, above 1500 HZ. By measuring accelerations of bearing,
vibration can help in detecting failures in a machine at an early stage by providing
warning signs.
6. Selecting the locations to measure; In this step, locations where parameters are to be
monitored must be selected depending on the type of condition monitoring chosen. For
example, in offline condition monitoring, a limited number of points is selected for
measurements so that the time taken for measurement is minimised. In case of online
condition monitoring, the number of locations set for measurements is minimised due to
economic reasons. Another way to locate measurement points is to study the vibration
spectra. By doing so, points having expected faults may be easily measured by
determining vibration leaves.
7. Selecting time intervals between measurements; The time interval between measurements
can be selected only after acquiring the knowledge of a particular machine. This is
because faults occur in various machines at different times. Therefore, at the initial
stages, measurements should be taken frequently to prevent faults from occurring.
However, whenever a change is detected, the interval of measurement must be shortened
to eliminate the risk of further breakdown prior to the next measurement.
8. Determining an optimum arrangement of data collection; In order to collect data in
condition monitoring, the arrangement of data must be planned. Data arrangement can be
planned based on plant layout, type of data requirement, and component sequence in a
machine.
Zero based budgeting; It is a method of budgeting in which all expenditures are justified
each time budget is prepared for a new period. Zero based budgeting begins with a zero
base. Each function within the organisation is evaluated in terms of cost and
requirements for the coming fiscal year. Budgets are later prepared on the basis of the
evaluation regardless of whether the budget is higher or lower than the previous period.
In simple terms, the zero based budgeting approach does not depend on historical data
and justifies all expenditures on the basis of the requirement and availability of resources.
Let us understand this with the help of an example. Assume that the marketing
department of Company XYZ spent 80,00,000 on its operations the last year. For the
current year, if the department is again provided with 80,00,000 as annual budget, it may
not reflect the changes in the marketing programs in the current year such as hiring of
more marketing personnel due to additional sales, new project, etc. The main advantages
of zero based budgeting are improved information for allocation decisions owing to
yearly reviews of resources, and better understanding of organizational objectives.
However, the issues with this approach are that it is time consuming and requires a lot of
paperwork.
Remote maintenance audit; In this type of maintenance audit, t auditor need not visit the
plant and can perform an audit through computerised databases. The data is plotted,
represented graphically, and analysed to reveal valuable information about the existing
maintenance function. Remote maintenance audit is generally conducted when there is no
time for on-site auditing. For example, an auditor may simply ask for maintenance
records of the organisation to check for any pending or failed maintenance tasks.
A single machine or equipment may require several spare parts for restoration at the time
of failure. It is often cumbersome and time consuming for maintenance personnel to
identify the required spare parts from the entire stock. Apart from this, at the time of
purchasing new spare parts, an organisation should have clear specifications of the spare
parts. Therefore, it is essential to allot code numbers to each spare part in order to
simplify the identification process. This process of specifying codes to each spare part for
its unique identification is called the codification of spare parts. These code numbers help
maintenance personnel and spare part vendors to gain the following information about
spare parts;
The machine or equipment type, make and model in which the parts are used
The type or class of spare parts
The size or material (metal, plastic, etc,) specification
The main objective of codification is to organise the total spare parts inventory so that the
spare parts are easily located and available when required. Moreover, codifying spare
parts minimises the duplication of spare parts.; thereby reducing inventory and aiding the
accounting process. The codification of spare parts is done using digits depending on the
range of equipment used in the organisation and the types and number of spare parts
required to be maintained in the inventory. The codification system differs across
organizations; however, organisations generally use 9 to 16 digit codes for their spare
parts.