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Concept of Quality

Module1 QualityControl

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Learning Outcomes Aftercompletingthismodule,youwillbeableto:

Understandthedefinitionofquality

Understandtheimportanceofqualityforcompetitiveness

Understandthebasicconceptofqualitymanagement

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2Module1:ConceptofQuality

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IntroductionTMA@2008

Module1:ConceptofQuality 3

KEMET Awarded Certificates of Registration to the Aerospace Quality StandardAS9100

GREENVILLE, S.C., Oct. 1 -- KEMET Corporation (NYSE: KEM) today announced that their Tantalum andCeramics manufacturing operations have been awarded Certificates of Registration to the AerospaceQuality Standard AS9100. Registration is rapidly becoming a prerequisite for aerospace customers andthe certificate will reduce the need for numerous customer audits.

"KEMET is diligently focused on both product quality and customerservice," stated Don Aldworth, KEMET's Vice President of Quality. "These certificationsclearly demonstrate that we are putting our resources into areas of ouroperation that are important to our customers and will make doing business withKEMET even easier for all customers serving the Aerospace industry," continued Aldworth.AS9100 is a set of requirements for quality management systems that include all ISO 9001:2000requirements expanded to address international aerospace requirements approved by major aerospacecompanies around the world. Registration is reserved for companies committed to providing excellent

customer service, continual improvement, and outstanding product quality.KEMET Corporation (KEM) applies world-class service and quality to deliver industry-leading, high-performance capacitance solutions to its customers around the world. KEMET offers the world's mostcomplete line of surface-mount and through-hole capacitor technologies across tantalum, ceramic, film,aluminum, electrolytic, and paper dielectrics. KEMET's common stock is listed on The New York StockExchange under the symbol KEM.

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Qualityproduct!

Qualityproducttoo?

Poorqualityproduct?

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Definitions of QualityTMA@2008


Merriam-Webster:degreeofexcellence;superiorityinkind Juran:

Qualityisfitnessforuse

Crosby:Qualityisconformance

torequirement

ISO9000:Qualityisthetotalityoffeaturesandcharacteristicsofaproductorservicethatbearonitsabilitytosatisfy

statedorimpliedneeds

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Dimensions of QualityTMA@2008


Willproductdotheintendedjob?Performance

Howoftendoestheproductfail?Reliability

Howlongdoestheproductlast?Durability

Howeasyisittorepairtheproduct?Serviceability

Whatdoestheproductlooklike?Aesthetics

Whatdoestheproductdo?Features

Whatisthereputationoftheproductorcompany?

PerceivedQuality

Istheproductmadeexactlyasthedesignermade?

Conformancetostandard

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Definition of Quality: revisitedTMA@2008


Qualitymeansfitnessforuse

Qualityofdesign

Qualityofconformance

Howwelldoestheproductconformtothe

specificationsrequiredbythedesign?:-Choiceofmanufacturingprocesses-Trainingoftheworkers-Supervisionoftheworkers-Motivationoftheworkers-Quality-assuranceproceduresthatwereused

Automobiledifferences:-Materialsusedinconstruction-Specificationsofthecomponents-Reliabilityofdrivetraincomponents

-Reliabilityofaccessories

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Qualityisinverselyproportionalto

variability

Ifthevariabilityintheimportantcharacteristicsoftheproduct

decreases,thentheproductqualityincreases

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Quality Improvement Qualityimprovementisthereductionofvariabilityinprocessesandproducts.

Alternatively,qualityimprovementisalsoseenaswastereduction.

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Quality EngineeringTerminology(1) Qualityengineeringisthesetofoperational,managerial,andengineering

activitiesthatacompanyusestoensure

thatthequalitycharacteristicsofaproductareatthenominalorrequired

levels.

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Quality EngineeringTerminology(2) QualityCharacteristics:

Physical - length,weight,voltage,viscosity

Sensory - taste,appearance,color

TimeOrientation- reliability,durability,serviceability

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Listthequalitycharacteristicsofthegear:1

2..3..4...

Whyyounamedthat?

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Listthequalitycharacteristicsofthemug:1

2..3..4...

Whyyounamedthat?

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Quality EngineeringTerminology(3) Specifications:Qualitycharacteristicsbeingmeasuredareoftencomparedto

standardsorspecifications. Desiredmeasureforthequalitycharacteristic

Example:Shaftandbearing

Tooloosetheassemblywillwobblecausingwear

Tootight,andtheassemblycannotbemade,noclearance

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SPECIFICATION

Nominalortargetvalue:Desiredvalueforaqualitycharacteristic

UpperSpecificationLimit(USL)LowerSpecificationLimit(LSL)

Largestandsmallestallowablevalues

UpperSpecificationLimit(USL)LowerSpecificationLimit(LSL)

One-sidedThecompressionstrengthofa

CokebottlemustbegreaterthanagivenpsivalueTwo-sided

Theweightofpotatochipsinthebagcanbebetween7.8and8.3ounces

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Quality EngineeringTerminology(4) Whenacomponentorproductdoesnotmeetspecifications,itisconsideredtobe

nonconforming. Anonconformingproductisconsidered

defectiveifithasoneormorenonconformitiesthatmayseriouslyaffectthesafeoreffective

useoftheproduct.

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Abubbleinthepaintonthedoorisnoticed

Nonconformity yesDefectivecar- no

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History of Quality Control andImprovement

Inspection

QualityControl

QualityAssuranceSystem

Total Quality

Management

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Sorting&Classification;Correction

Basicquality

planning;processperformancedata;statisticalmethod

Advancedqualityplanning;

statisticalprocesscontrol;costofquality;involvementofnon-productionunit

Qualitypolicy,involvementofallorganizationunit,supplier,customer;

teamwork;performancemeasurement

1920

1940

1970

1970

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Statistical Methods for QualityControl and ImprovementTMA@2008


StatisticalMethod

AcceptanceSampling

DesignofExperiment

StatisticalProcessControl

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Statistical Process ControlTMA@2008


Process

MeasurementEvaluationMonitoringandControl

Input:rawmaterial,components,

sub-assemblies

UncontrollableInputs

Z1

Z2

Z3

X1 X2

ControllableInputs

Y=qualitycharacteristics

Outputs Products

1. Variationsduetoassignablecause(tool

wear) outofcontrolprocess

2. Chancevariation:randomvariation incontrolprocess

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Design of Experiment Anapproachtosystematicallyvaryingthecontrollableinputfactorsintheprocessanddeterminingtheeffectthesefactorshaveon

theoutputproductparameter

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Acceptance Sampling Acceptancesampling istheinspectionandclassificationofasampleoftheproductselectedatrandomfromalargerbatchorlotandtheultimatedecisionaboutdispositionof

thelot. Twotypes:

1.Outgoinginspection- followsproduction

2.Incominginspection- beforeuseinproduction

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QualityPlanning

QualityAssurance

QualityControlandImprovement

Identifyingcustomers;Identifyingneeds;Developingproduct

andservicesDevelopingprocess

Documentingpolicies,procedures,workinstructions;Maintaining

document

Processcontrol;Quality

improvementprojects

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Quality Philosophy andManagement Strategies Threeimportantleaders

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Emphasisonstatisticalmethodsinqualityimprovement

IntroduceDemings14pointsformanagingqualityEdwardDeming

Emphasisonmanagerialroleinqualityimplementation

JuransTrilogy:planning-control-improvementJosephJuran

Emphasisonorganizational

structure

TotalQualityControl:qualityleadership-qualitytechnology-organizationcommitment

A.Fiegenbaum

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Otherqualityphilosophyandmanagementstrategies:

TMA@2008


TQM isamanagerialframeworktoaccomplishqualityimprovement.

Thepracticesinclude:-Participationinqualitygroups-Workculture-Customerfocus-Supplierqualityimprovement-Cross-functionalteamsconcerned

withquality

ISO9000isastandardforqualitysystem.Thequalitysystemisdocumented,implementedandregisteredforcertification.

Saywhatyoudo,dowhatyousay

SixSigmadevelopedbyMotorola.Thefocusisreducingvariabilityinkeyproductqualitycharacteristicstothelevelatwhich

failureordefectsareextremelyunlikely

Specificationlimitsaresixstandarddeviationsfromthemean

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The Link Between Qualityand Productivity Effectivequalityimprovementcanbeinstrumentalinincreasingproductivityandreducingcost.

Improvedquality

Lowerreject;lowerproductioncost

Competitiveprice;increasedprofit Higheroutput;reducedinput;increasing

productivity

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Quality, Market Share, Returnon InvestmentMA@2008


Features Lower deficiencies

Profit

Price Share

Income

Cycle Time Warranty Waste

Cost

ROI

QualityIm

provement

CostReduction

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Quality Costs MA@2008


QualityCosts

Prevention

Costs

AppraisalCosts

Failure

Costs

InternalFailureCosts

ExternalFailureCosts

Costsassociatedwitheffortsindesignand

manufacturingthataredirectedtowardthepreventionofnon-conformance

Costsassociatedwithmeasuring,evaluating,orauditingproducts,componentsandpurchasedmaterialstoensureconformancetothestandard

Coststhatareincurredwhenproducts,components,materialsorservicesfailtomeetqualityrequirements,andfoundbeforeshipmenttocustomer

Costsoccurwhentheproductdoesnotperformsatisfactorilyafteritissuppliedtothecustomer

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MA@2008


Prevention Costs

Quality planningand engineering

New productreview

Product/processdesign

Process control Burn-in Training Quality data

acquisitionanalysis

Appraisal Costs

Inspection andtest of incomingmaterial

Productinspection andtest

Maintainingaccuracy of testequipment

External Failure

Costs Scrap Rework Retest Failure analysis Down time

Downgrading

Internal Failure

Costs Complaint

adjustment Returner

product ormaterial

Warranty

charges Liability costs Indirect costs

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QualityCostsModel

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Implementing QualityImprovement StrategicManagementofQuality

Almostallsuccessfuleffortshavebeen

management-driven. Toomuchemphasisonregistrationand

certificationprograms(ISO,QS)

Insufficientfocusonqualityplanninganddesign,qualityimprovement,overemphasisonqualityassurance

Pooruseofavailableresources

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THANK YOU

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APPENDICES

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Demings 14 Points1. Createconstancyofpurposeforimprovementofproductandservice2. Adoptthenewphilosophy

3. Ceasedependenceonmassinspection

4. Endthepracticeofawardingbusinessonpricetagalone

5. Improveconstantlyandforeverthesystemofproductionandservice

6. Institutetraining

7. Instituteleadership

8. Driveoutfear

9. Breakdownbarriersbetweenstaffareas

10. Eliminateslogans,exhortations,andtargetsfortheworkforce

11. Eliminatenumericalquotas

12. Removebarrierstoprideofworkmanship

13. Instituteavigorousprogramofeducationandretraining

14. Takeactiontoaccomplishthetransformation

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QC Module1

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