Guest lecture on

TQM tools

(Unit IV - GSS

103)

Presented by :Prof. M. Balaji., M.E., M.B.A., M.I.I.E.,M.I.S.M.,

Senior grade assistant professor,
Department of Mechanical Engineering,
Kumaraguru college of technology,
Coimbatore 641 049.

email to: balaji.m.mec@kct.ac.in

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1)Benchmarking
2)Quality Function Deployment (QFD)
3)Taguchi quality loss function
4)TPM Concepts, improvement needs
5)FMEA
6)Quality circles
7)Cost of Quality Performance measures

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Topics to be covered

 Benchmarking is a relatively expensive and time consuming

process in most industries against the critical Design
Measures.
Criticality is defined by how important a particular Measure is
to the success of the product and whether there are special
circumstances impacting a particular Measure.
Benchmarking is able to determine what the market likes and
dislikes.
When a manufacturer captures the customer's perceptions of
how well different products perform in the marketplace, they
can better understand what is driving the purchase decision.
Benchmarking is an attempt to correlate the actual
performance with the perceived performance of the product
attributes.
Benchmarking all of the competitive products may prove a
time consuming occupation, rather the best in trade.
ex: Maruthi 800 for hatch back sedan cars

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1) Benchmarking

 QFD is a rigorous method for translating

customer needs, wants, and wishes into
step by step procedures for delivering the
product or service tailored to customer
needs.
QFD cuts the normal development cycle by
50%, making faster moves into market.
QFD resembles a highway interchange
between the voice of the customer (VOC)
and the Voice of the Engineer(VOE).
Demand characteristics are represented in
rows and quality characteristics in columns.

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2) Quality Function Deployment

(QFD)

A sample
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QFD

translating
wants

what

the

customer

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Four steps to QFD

thinking
Product planning: ex- fuel efficient car
Part planning: ex- MPFI/CI/SI engine

translating product specifications

Process planning: ex-Pull/Push/Lean mftg.

translating part characteristics

Production planning: Loading/Sequencing

translating process characteristics

 Quality engineering should start with an

understanding of the cost of poor quality in
various situations much beyond the number of
items outside specification by the cost of rework
or scrap to a broader horizon as cost to society.
According to Taguchi, the products that do not
match the target, even if within specified limits
do not operate as intended and any deviation
from the target, be it within the specified limits
or not will generate financial loss to the
customers, the company and to society and the
loss is proportional to the deviation from the
target.

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3)Taguchi Loss function

 The loss function is the square of the

deviation multiplied by a constant k,
with k being the ratio of the cost of
defective product and the square of the
tolerance.
Loss function, L(y)= k (y-t) 2
were k = / m2
m = LSL t or t USL
LSL = Lower specification limit
USL = Upper specification limit

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contd

A machine manufacturer specifies the target

for the diameter of two rivets to be 6 inches
and the upper and lower limits of 5.98 and
6.02 inches respectively.
Two bolts measuring 5.99 inches
and 6
inches were inserted in its intended holes of
the machine and sold.
The machine breaks down within 4 months
as a result of loose parts. The cost of repair
associated with 5.99 inches bolt assembly
was estimated at $95, while the other still
kept functioning !

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Case study--- Taguchi loss

function

 TPM is considered as the medical science of

machines.
TPM is an innovative Japanese concept and
its origin can be traced back to 1951.
The goal of the TPM program is to markedly
increase production while, at the same
time, increasing employee morale and job
satisfaction.
Down time for maintenance is scheduled as
a part of the manufacturing day and, in
some cases, as an integral part of the
manufacturing process.

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4) Total Productive
Maintenance(TPM)

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Objectives of
Avoid wastage in a quickly changing
economic environment.
Producing goods without reducing
product quality.
Reduce cost.
Produce a low batch quantity at the
earliest possible time.
Goods send to the customers must be
non defective.

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TPM

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Pillars of
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TPM

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 5S:

Seiri (Sort), seiton (systemize), seiso (sweep),

(standardise) & shitsuke (self discipline).

contd
Autonomous maintenance:

seiketsu

Kaizen: Small improvements on a continual basis.

Planned Maintenance: trouble free machines

and equipment
producing defect free products for total customer satisfaction.

Quality Maintenance:

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operators to be able to take care

of small maintenance tasks, thus freeing up the skilled maintenance
people to spend time on more value added activity and technical repairs.

customer delight through highest quality

defect free manufacturing.

Training:

multi-skilled revitalized employees with high morale and

eager to perform all required functions effectively and independently.

Office TPM:

to improve productivity, efficiency in the administrative

functions and eliminate losses through automation.

Safety, Health and environment:

focus is on to create a safe

workplace and a surrounding area that is not damaged by our process or
procedures aiming Zero accident, Zero health damage and Zero fires.

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 It is a daily maintenance ( cleaning, inspection, oiling and retightening ), design to retain the healthy condition of
equipment and prevent failure through the prevention of
deterioration, periodic inspection or equipment condition
diagnosis.

Can be further subdivided into periodic and predictive

maintenance.

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Types of
1. Preventive Maintenance
Maintenance

2. Breakdown Maintenance
Waiting until equipment fails to repair it.

3. Corrective Maintenance
It improves equipment and its components (calibration) so
that preventive maintenance can be carried out reliably.

4. Maintenance Prevention
Studying the weakness of current machines ( on site
information leading to failure prevention, easier maintenance,
safety
and
ease
of
manufacturing
)
and
are
incorporated(DFM) before commissioning a new equipment.

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 FMEA (Failure Mode and Effects Analysis) is a

proactive tool, technique and quality method that
enables the identification and prevention of
process or product errors before they occur.
It is a systematic way to examine a process
prospectively for possible ways in which failure
can occur, and then to redesign the processes so
that the new model eliminates the possibility of
failure.
Types of FMEA
Process FMEA
System FMEA
Design FMEA

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5) FMEA

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 Captures the collective knowledge of a team

Improves the quality, reliability, and safety of the
process
Logical, structured process for identifying process
areas of concern
Reduces process development time, cost
Documents and tracks risk reduction activities
Helps to identify Critical-To-Quality characteristics
(CTQs)
Provides historical records; establishes baseline
Helps increase customer satisfaction and safety

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Benefits of FMEA

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It is possible to fail in
many ways...while to
succeed there is possibly
only one way. Aristotle

Thank you
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