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Transcript of Quality english
H A S H M A N A G E M E N T S E R V I C E S L L P
C H E N N A I
P H : 9 1 7 6 6 1 3 9 6 5
The Essentials - Quality
Overview
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‘The Essentials’ series from Business Sense is an initiative to empower the students(freshers) and
professionals in performing more efficiently and effectively in the organization
This document is a part of the “Certified Manufacturing Professional” course offered by Business Sense
This course is aimed at bridging the gap between the institutions and the industry by providing the
fundamentals of manufacturing management which are not offered by any of our
institutions/curriculum
This course would immensely benefit students and professionals who are joining manufacturing
organizations
For more details, please visit www.businessense.in
At Business Sense, we help clients through consulting engagements focusing on improving their
Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools.
We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply
Chain Re-engineering.
You can subscribe to our bi-weekly newsletter here.
Follow us:
Contents
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Section 1 – Introduction to Quality Function
Section 2 – QMS and ISO 9001 Standard
Section 3 – NC, Corrective and Preventive Actions
Section 4 – 7 QC tools
Section 5 – MIS Reports and Analyses Points
What is Quality?
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“Quality is fitness for use” – Deming
In an organization, Quality function means the department which independently works
on attaining specified levels of product / process quality of the core business
Quality Department can either be a quality control department or a Quality Assurance
department
Quality Department is the final In-Charge of the quality at the customer’s end
Quality Control Quality Assurance
Focus on Product Focus on Processes
Analysis after Completion of work Prevention is better than cure
Operation specific Core value; Organisation-wide
Individual/department oriented Leads to team work
Organization Structure
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Head of Quality Assurance reports to the
CEO of the company
Normally there would be In-Charges for
the three focus areas of Quality:
Incoming Inspection
In-process or online inspection and
Final Inspection or Finished Goods Testing or Batch
Release Testing – previously done as QC
In Manufacturing Industries, Testing
Laboratories comes under the QA.
We have explained a typical functional hierarchy. It may
vary according to each organization
Head - Quality Assurance
In-Charge Incoming Inspection
In-charge
In-process Inspection
In-Charge
Final Inspection
CEO
Responsibilities of an Engineer in the Quality Function
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•Ensuring the Raw Materials used in production are as expected
and fit for use. Incoming Inspection
•Asserting the suppliers of their ability to supply consistently good quality and improve them Supplier Development
In-process Inspection
Final Inspection
•Identify the parameters of the machines and/or intermediates which are critical to quality of the Final Product and help production to avoid problems in those parameters
Customer Feedback
•Check the conformance of final products to the customers’ requirements and ensure that the customer who is going to receive them get satisfied with the products.
•Get the feeling of customers upon using our products and develop our internal product specifications
In-Charge Incoming Inspection
In-Charge Final
Inspection
In-Charge In-Process Inspection
Quality Plan
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All the five major aspects are covered in the Quality plan Document in
the following manner:
Specification for Raw Materials and Parameter to be checked upon receipts
Critical To Quality (CTQ) parameters of machine settings or intermediate products and
checking or verification points
Final product specifications and parameters to be tested for the conformance to customers’
requirements.
Sampling and Testing methods along with the action to be taken in case of any deviation for
all the above
In a nutshell, the quality plan describes how the quality of product /
process is managed in an organization.
Quality Plan - Example
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Let us assume the Customer requirement is metal sheets for fabrication which
measures 10 x 5 inch metal plate in Green color with two holes
Upon accepting the Purchase order from the customer, the company works on
defining the product requirements as per the internal understanding. This
becomes the product specification and the target output quality.
The customer requirement of 10 x 5 inch metal plate in Green color has
translated in to:
MS / SS / Aluminium sheet of
252 mm length,126 mm width and 0.4 mm thickness (not given in the product requirement and
developed internally based on factors such as strength, pricing, etc)
Powder coated with Green color of Standard Color (with code - abcd) with
Two holes of 2 mm diameter as per the drawing
Drawing based on the customer requirement
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252 +/- 2 mm
126 +
/- 2
mm
2 mm dia
10 mm
62 +
/- 1
mm
Color Code : Green (abcd)
Internal Specification
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This final requirement/drawing is worked backward - the internal requirements
needed are listed and those become our in-process specifications.
At Painting Section, Painting Color (abcd) and the coat thickness are internal
parameters.
At Cutting section, Size specifications are –
L : 256 +/- 2 mm
W : 130 +/- 2 mm (4 mm extension is made for bending)
The holes as per the drawing
For inward inspection, the sheet thickness, dimensions and paint color forms a
specification
Contents
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Section 1 – Introduction to Quality Function
Section 2 – QMS and ISO 9001 Standard
Section 3 – NC, Corrective and Preventive Actions
Section 4 – 7 QC tools
Section 5 – MIS Reports and Analyses Points
Quality Management System - QMS
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A quality management system is a set of co-ordinated
activities to direct and control an organisation ensuring
that the organisation is continually improving its
performance.
Quality Plan is an integrated component in the Quality Management System
A QMS enables an organisation to achieve the goals and objectives set out in
its policy and strategy.
It provides consistency and satisfaction in terms of methods, materials,
equipment, etc, and interacts with all activities of the organisation, beginning
with the identification of customer requirements and ending with their
satisfaction, at every transaction interface.
It can be envisaged as a “wedge” that both holds the gains achieved along the
quality journey, and prevents good practices from slipping
Quality Management System
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Benefits of QMS Improved business planning
Enhanced awareness on quality throughout the organisation
Improved Customer Satisfaction
Reduced cost of poor quality
Above all, an effective QMS provides the confidence to both the organisation and its customers that the organisation can provide good quality of product / service consistently.
If the Quality Management System of a company is inline with the set requirements of ISO 9001, the company may be certified as a quality assured company by a certification agency and the company will be declared an ISO 9001 certified company.
Quality Management System – ISO 9001
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What is ISO?
ISO (International Organization for Standardization) - a non-governmental organization
is the world's largest developer and publisher of International Standards.
ISO is a network of the national standards institutes of 162 countries, one member per
country, with a Central Secretariat in Geneva, Switzerland, that coordinates the system.
According to ISO, "ISO" is not an abbreviation. It is a word, derived from the Greek isos,
meaning "equal“.
Quality Management System – ISO 9001
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ISO 9001 is an international quality certification that defines
minimum requirements for a company's Quality Management
System (QMS)
Applies to the processes that create and control the products
and services an organisation supplies
Prescribes systematic control of activities to ensure that the
needs and expectations of customers are met
Is designed and intended to apply to virtually any product or
service, made by any process anywhere in the world.
Level 1
Quality Manual
Level 2
Processes
Level 3
Work Instructions
ISO 9001 – in a nutshell
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The requirements of a Quality Management System are
defined in the Standard (ISO 9001: 2008) in 8 clauses.
Clause 1 – Scope
1.1 General Requirements
1.2 Application
Clause 2 - Normative Reference
Clause 3 – Terms and Definitions
The clauses 1, 2 and 3 explain about the aim of this
standard, where this standard is applicable (Clause 1),
reference to the standard ISO 9000 : 2005, Quality
Management System – Fundamentals and Vocabulary
(Clause 2) and Terms and Definitions (Clause 3)
Plan
Do
Check
Act
ISO 9001 – in a nutshell
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ISO 9001:2008
Clause Clause Title Explanation
4.1 QMS (Quality Management
System) Define your working system as a series of processes and identify the criteria to measure the effectiveness of each process. (E.g. Timely delivery etc)
4.1 QMS (Quality Management
System) Proper controls like supervision, inspection, training, documentation etc. should be exercised on outsourced (Subcontracted) processes to ensure acceptable results.
4.2 Documentation Requirements Say what you do – in your documents. (E.g. methodology, Procedures, Drawings, Specifications)
4.2 Documentation requirements Document your working system as quality manual, procedures and work instructions.
4.2.3 Document Control
Only approved current documents should be made available for work. (E.g.. Drawings, Specification, Procedures etc.)This includes external standards also. The organisation will need to control other external origin documents necessary for planning and operation of QMS. This can even include excise regulations.
4.2.4 Control of records Prove that you are following the system by maintaining appropriate records.
Remaining clauses are covered in the “Certified Manufacturing Professional” course .To access login to www.businessense.in
Contents
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Section 1 – Introduction to Quality Function
Section 2 – QMS and ISO 9001 Standard
Section 3 – NC, Corrective and Preventive Actions
Section 4 – 7 QC tools
Section 5 – MIS Reports and Analyses Points
Defects and Non-conformance
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Defective
When an item fails to meet its specification and / or known to fail to meet its
intended use, the item is called a defective. E.g. A casting with a blowhole
Defect
The exact reason / cause for the problem is called the defect. i.e. the blowhole
Nonconformity
Any non fulfillment of requirement is called nonconformity. E.g. A casting with
out blowholes is required. But the process produced a casting with blowhole. This
is a non-conformity
Corrective and Preventive Actions
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Correction
An action to eliminate a detected nonconformity is called a correction.
A correction can be a rework, reprocess, repair, degrade, replacement or rejection.
Corrective Action (CA)
Actions to eliminate the cause of detected nonconformities are called corrective actions. (Actions to
eliminate the recurrence of nonconformity).
Timely Solution – Can be one-time solution – reactive – after the problem has occurred
Preventive Action (PA)
Actions to eliminate the causes of a potential nonconformities or other undesirable potential situations are
called preventive actions. (Actions to eliminate the occurrence of nonconformity).
Proactive solution – before the problem has occurred
Quality tools can be used (Pareto charts, Fish bone analysis, etc. / 5 Why analysis /
other tools) for taking CA&PA
Contents
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Section 1 – Introduction to Quality Function
Section 2 – QMS and ISO 9001 Standard
Section 3 – NC, Corrective and Preventive Actions
Section 4 – 7 QC tools
Section 5 – MIS Reports and Analyses Points
7 QC Tools
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Seven QC tools are fundamental instruments to improve the quality of
the product
Seven QC tools are utilized to organize the collected data in a way that
is easy to understand and analyze
They are used to analyze the production process, identify the major
problems, control fluctuations of product quality, and provide solutions
to avoid future defects
7 QC Tools – Check Sheet
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A check sheet is a pre-designed format for collection of data that encourages
organized collection and groups data into categories.
Categories are created in advance and may be added as needed. A check mark is
added for each example of a category. The marks are added to determine
subtotals.
When to use it? To keep track of the parameters of an on going process. It can
be used to track events by such factors as timeliness (on time, one day late, two
days late, etc.); reason for inspection failure (appearance, performance, etc.);
person accomplishing the task (sales calls per representative) etc...
7 QC Tools – Check Sheet
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Example: A company wants to check the
weight of bags of sugar that are supposed to
weigh 100 kg. The resulting checklist is
shown in the following Table. The checklist
indicates that the machine is not filling all the
bags within the specification.
Sugar Bag Weight Check Sheet -
(Specification : 100kg. ± 2 Kg.)
Weight (Kg.) Check Sheet Total
98 0
98.25 II 2
98.5 IIII 4
98.75 IIIII III 8
99 IIIII IIII 9
99.25 IIIII 5
99.5 IIIII III 8
99.75 IIIII IIIII IIIII II 17
100 IIIII IIIII IIIII IIIII III 23
100.25 IIIII IIII II 12
100.5 IIIII III 8
100.75 IIIII IIII 9
101 IIII 4
101.25 III 3
101.5 IIII 4
101.75 II 2
102 I 1
7 QC Tools – Graphs
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Graphs are used for the purpose of comparison of visual representation of data collected.
The most commonly used graphs are in the form of Bar charts, Line charts and Pie charts.
Bar charts can be used to compare revenue projections , growth in sales volume over a time period
Pie Charts can be used to represent the region-wise revenue share / category-wise contribution to the profits etc
Year-wise sales trend
Remaining quality tools are covered in the “Certified Manufacturing Professional” course. To access login to www.businessense.in
End of Free Content
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Please visit our website www.businessense.in to access the full course – “Certified Manufacturing
Professional”
Our website also contains list of ready-to-use templates and report formats containing Charts and
pivot tables.
Templates and report formats are available for Purchase, Stores, Production, Quality, Maintenance and
HR functions
These templates come in excel /word and can be downloaded and used right away
At Business Sense, we help clients through consulting engagements focusing on improving
their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and
other tools.
We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and
Supply Chain Re-engineering.
You can subscribe to our bi-weekly newsletter here.
Follow us: