Assignment 5

This Assignment is completed by me, Sneha Purohit, individually.

Contents:
1.
2.
3.
4.
5.
6.

Introduction and Objectives of the Project

A brief description of the methodologies applied
The Main Body of the project
Summary
References
Social Networking

1. INTRODUCTION AND OBJECTIVES OF THE PROJECT

The objective of this Assignment is to show what we have learned by now from TQM
course. The Main Body of the project has 4 parts. The idea of the Part 0 is to rework
prior assignments. Part 1 is devoted to RFID technology, since it is very important to be
aware and understand the huge potentials RFID technology can offer when combined
with the methods and toolsets we learn in this class. Part 2 will address some of the
Quality Audit issues. Finally, Part 3 depicts the Video Conferencing I had with my
colleague over Skype during which we had discussed each others design.
2. A BRIEF DESCRIPTION OF THE METHODOLOGIES APPLIED
Additionally to CIMprg models, CORA and PFRA that were explained in the previous
assignments, we will use RFID and Quality Audits in this assignment.
RFID, Radio-frequency identification, is the use of a wireless non-contact system that
uses radio-frequency electromagnetic fields to transfer data from a tag attached to an
object, for the purposes of automatic identification and tracking. The tag contains
electronically stored information which can be read from up to several metres away.
Unlike a bar code, the tag does not need to be within line of sight of the reader and may
be embedded in the tracked object. The tag can be read if passed near a reader, even if it
is covered by the object or not visible. The tag can be read inside a case, carton, box or
other container, and unlike barcodes RFID tags can be read hundreds at a time. Bar
codes can only be read one at a time.
Quality Audit is a systematic and independent examination to determine whether
quality activities and related results comply with planned processes and arrangements,

and whether or not these arrangements are implemented effectively, and are suitable to
achieve management objectives. Hence, audits help to implement and enforce the
continual improvement principle for the organization.
As a minimum result, a well conducted, effective audit yields the following information
for management:

A measure of how does the current quality system conform to specified

requirements
A basis and incentive for corrective actions on any non-conformances observed
The verification that effective corrective action was performed successfully,
meaning in a timely and efficient manner

There are also several different types of audit, including the following:
1. Internal Audit (or First-Party Audit). It is conducted by, or on behalf of the
organization itself on its own systems for management review and other internal
purposes. Independence can be demonstrated by deploying internal auditors who are
not directly responsible for the activity being audited.
2. External Audit (Second and Third Party Audit):

Second party audits are conducted by parties having an interest in the

organization, such as a customer, or by other persons on their behalf.
Third party audits are conducted by external independent auditing organizations
such as those providing registration / certification of conformity to the
requirements of ISO9001, or ISO14001.

3. Combined Audit. When a quality management system and an environmental

management system are audited together.
4. Joint Audit. When two or more auditing organizations co-operate to audit a single
auditee.
3. THE MAIN BODY OF THE PROJECT
PART O: Reworked Assignments
First, I would like to say that I have changed the structure of my entire web page. Before,
my all assignments were in a sequence in one page. Now each assignment has its own
page.

In Assignment 0, I have changed the Social Networking part. Initially, I just did
copy/paste from the Moodle. Now there is a summary for each discussion topic and
beneath is the link to the full discussion on Moodle. I followed this arrangement for all
assignments, except for the Assignment 0, so I wanted to correct that.
In Assignment 1, I have added RFID technology as a resource to the parent CIMpgr
model diagram, as well as to its child diagram (more details about this you can find in
Part 1: RFID).
In Assignment 2, I have updated our CORA spreadsheet. I have added RFID as an
engineering solution to the customer requirement Vehicle tracking (more details
about this you can find in Part 1: RFID).
In Assignment 4, I have updated our PFRA spreadsheet (more details about this you can
find in Part 1: RFID) , and I have also added Social Networking to the Content, since I
was missing social networking for the related week.
PART 1: RFID
Clip 1: The clip is explaining the basis of the RFID and it is pointing out why someone
should use RFID instead of bar code.
With the RFID you are getting information about the product(s), such as shipping
weight, temperature, unit price and quantity, etc. If you have, for an example, 10 units in
one palette, by scanning the palette, you will have the information on number of units
on it, and thus you dont have to scan one by one unit. Also, bar code is limited in space,
where with the RFID you can track the movement of the product(s), just like a GPS
does, so you can even use it for tracking the stolen product(s).
Clip 2: The clip shows how RFID is applied on material flow.
The company in the clip has deployed RFID system in manufacturing to track and
control the movement f raw materials. RFID enables them to capture real time, zero
error information, such as assembly specifications. That information is then sent up to
that Quality Assurance Department in order to assure that the assembly process is
within accepted quality guidelines. And, with the RFID system, object oriented
approach is applied. Now everything goes together. The product has its own unique
serial identifier that goes along with the tag. So, now there is now space for human error
in a missed scan or a loss tag, or a tag that you can not read. Now the antenna captures

the information that is on the RFID tag, and thus with the RFID system scanning is
automated process there is no need for a human to do the scanning.
RFID at my company:
An RFID have a wide application in automobile industry, and since Kalaba Inc. is
automobile manufacturer, we are going to use RFID system in a variety of applications:
Managing the inventories: We will use the RFID system for receiving the parts of
vehicle and other inventory, and also for tracking them. Therefore, we can have total
visibility and full control of all items. We can know the location of every single part of
vehicle, which can help improving the efficiency and reliability of overall manufacturing
process.
Vehicle information: Each EV OK G12 will have its own unique serial identifier,
which will benefit us during the manufacturing process and our customers in the postsale period:
1. Manufacturing process: Tag attached to an automobile during production
can be used to track its progress through the assembly line; and
2. Post-sale period:

In case of theft, vehicle can be easily located thanks to the RFID tag that is
unique to each vehicle, and thus can help detect and retrieve stolen cars;
In case of recall, our company will be able to allocate all vehicles produced
during particular series that resulted in unsatisfactory quality level, which will
improve efficiency and reliability of the recall process.

According to these applications, I have corrected the tools I used in my prior

assignments. In the CIMpgr, RFID is added as a resource to parent model, and also to
some processes of its child model, which you can see below. RFID is colored in red.
Furthermore, one of the requirements of our customers is Vehicle tracking, and this
requirement is accomplished trhough the use of RFID technology, which can be seen
from our revised CORA table below. As stated above, in case of theft, vehicle can be
easily located thanks to the RFID tag that is unique to each vehicle, and thus can help
detect and retrieve stolen cars.
CORA with RFID
Finally, RFID system can be used to reduce the risk related to relevant processes.
During the final inspection of our OK G12, last process step is to check if the RFID

vehicle tracking system functions adequately. For more details, take a look at our PFRA
spreadsheet below.
PFRA with RFID
PART 2: Quality Audit
First, we are going to go through each assignment in order to recap the learned methods
and tools in this course, and to point out how could we apply them to improve our own
company.
Assignment 0 Review: In this assignment, I have learned about the Dimensions of
Quality and ISO TQM Standard Principles. Most importantly, I have applied them on
my invented 5th company sgp Inc., the vehicle manufacturer, and on my new green,
high quality, sustainable product EV OK G12.
Having established the dimensions of quality for my new green product, I was able to
address its quality issues. I had to think about its brand name quality, distinct features,
performance, reliability, durability, serviceability, aesthetics, excitement quality, safety
quality and conformance to standards. This helped me to build strong and high quality
product with distinct features. Also, in the future I will review these dimensions,
compare them to the competitors, and look for the possibilities for product
improvement.
ISO TQM Standard Principles are like a foundation of my company. These principles
will permeate through every aspect of our business. What ever we do, we always have to
keep in mind good customers and supplier relationship, leadership, involvement of
people, factual approach o the decision making, both process and system approach, and
continual improvement. Hence, we will always keep in mind the needs and
requirements of our customers, we will always seek for the possibilities of building and
maintenance the mutually beneficial relationship with our suppliers, we will encourage
people involvement, and assure that everybody involved in our processes understand
their own responsibilities and the relations among processes and different entities, as
well as to keep in mind that quality is not a target point at the end of the road, but the
journey itself that needs to be continually improved.
Assignment 1 Review: In this assignment I have learned how to develop objectoriented TQM system model that will graphically and visually show us the way through
which our green idea can become reality.

A complete CIMpgr model is a set of diagrams which systematically illustrate the objectto-object relationships between the objects, their functions and entities, which enables
the user to have a whole system picture in mind and how everything is related within the
system. It also enables the user to document the processes for purpose of improving
them and educating the others. CIMpgr is describing material and/or information flow
and relations in a simple graphical format. It defines key process input(s), output(s),
control(s) and resource(s).
We used this method to map the processes needed for manufacturing our new green,
high quality and sustainable product. However, we are planning to apply these models
to all processes in our company. We will start form the parent process, then we will
decompose it to its child processes, furthermore we will decompose these processes to
their own child processes, etc. until we reach the activities level. This way we will
actually apply TQM Standard Principles that refer to the process approach and system
approach. Also, each employee within our company will have better understanding of
not only his/her responsibilities within the relevant process, but also of process itself in
which he/she is involved, of the relationship of that process with other processes, and of
the overall picture from the birds-eye view.
Assignment 2 Review: In this assignment I have learned how to use Component
Oriented Requirements Analysis (CORA).
CORA is a matrix-based method developed for the user requirement need
analysis. CORA code is integrated in four modules: User requirements, Engineering
solutions, Parameter calculations and Benchmarking. We used CORA in this assignment
to identify the customer needs related to our new green, high quality and sustainable
product EV OK G12.
We are going to continue applying this developed CORA for TQM/TQC and other
purposes and updated it on a regular basis to document changes in requirements and/or
best practice engineering and management solutions related to our new product. Also,
we are going to use CORA for each product in our portfolio in order to minimize
dissatisfaction and financial loss due to inadequate requirements specification and poor
communication between customers and us as a manufacturer. We will use Crossfunctional team for CORA creation that will consist of not only the representatives of the
design functional unit, but also of the production, marketing and
aftersales/maintenance representatives, and also of our collaborative companies, and
customers.
Assignment 3 Review: In this assignment I have learned how to use Process Control
Charts.

The control chart is a graphical display of quality characteristic that has been measured
and computed. Control chart represents one of the most useful tools for studying
variation. It therefore can be interpreted as an on-line monitoring tool used for assuring
that the process does not go out of control, since process out-of-control is not
sustainable, and for securing the elimination of variability in the process, in order to
maintain smooth production.
We used control chart for variable for controlling the carbon footprint of a new EV OK
G12, because even though OK G12 has zero emissions during its usage, we still have to
consider the greenhouse gases emitted during its manufacture. Furthermore, we used
control charts for attributes, p-chart and c-chart, for controlling the shape of floor
rubber mats and for completeness of Telematics Systems, respectively. Moreover, we are
going to continue applying this on-line monitoring tool on other critical processes
within our company sgp. In other words, we are going to analyze our critical processes
statistically in order to control them. Control charts can help us to maintain smooth
production.
Assignment 4 Review: In this assignment I have learned how to apply Processrelated Failure Risk Analysis Method (PFRA) on a risky process within our company
sgp, Inc.
PFRA represents a systematic, rule-based, quantitative, and open-source computational
model developed to identify and minimize potential failure risks, and/or failures of
processes in general. In other words, PFRA addresses negative quality and is concerned
with potential events that can make any process fail. Within our plant facilities, we also
have car show and selling facility. Before we sell the EV to our customer, we have to do
the final inspection of the vehicle. We applied PFRA analysis on this process.
Moreover, we are planning to apply PFRA on all risky processes within our company in
order to manage the risk, or in other words to prevent the risk. We will use it in order to
minimize dissatisfaction, and financial loss for process related failure risks. We are
going to apply PFRA during the planning stages of a process, and then updated it on a
regular basis to document the changes. It is important to distinct PFRA and Control
Charts explained in the previous assignment. We will also use control charts for risky
processes, but during the execution phase for statistical control of process behavior,
where PFRA is going to be used during the planning phase with the goal of preventing
the risk.
Also, what is common to all assignments is that I have learned how to think the TQM
way. Everything is related within our company sneha Inc., and also our company is a
part of broader external environment. By looking outside the walls of our company, we

have found the ways to work with our collaborative companies in order to make
improvements and become more sustainable.
PLANNING FOR AUDIT:
1. WHO should be audited?
Each activity, process, and each department within sgp. should be audited in order to
support Quality/Environment Management System audits. We should keep in mind that
the system audit is an attempt to evaluate the effectiveness of a quality system, not the
quality of a product.
2. WHY should be audited?
In the case of internal audit, the reason can be management review and other internal
purposes. It also may form the basis for our self declaration of conformity.
In the case of external audit, the reason is to confirm compliance with the requirements
of relevant ISO Standards.
3. WHAT type of audit should be conducted?
sgp. should conduct at least internal and external audit.
4. WHAT should be the depth and scope of these audits?
It depends on the type of the quality audit and the purpose of the audit.
5. WHEN should the audit take place?
Internal audit should take place at least once in a year.
Second party audit will take place according to our customer needs and requirements,
while Third party audits will take place on a six monthly or annual basis.
6. WHO will perform the audit?
In this case of internal audit, independence will be demonstrated by deploying internal
auditors who are not directly responsible for the activity being audited.
In the case of external audit, Second party audits will be conducted by customer, or by
other persons on their behalf, where Third party audits will be conducted by external
independent auditing organizations

7. IS the audit schedule prepared?

It will be.
STAGES OF AN AUDIT:
Stages of and audit will be explained in terms of Internal Audit within our company s
First of all, our company has established a procedure to define how internal audits
should be planned, performed, reported, and recorded. This procedure is support
by CIMpgr audit process model, and these are the stages of our internal audit:
1. Audit Initiation: At this stage, communication channels will be established with the
representative of the department, process or an activity that will be audited. Also, in this
stage we will appoint the audit team leader, define audit objectives, scope and criteria,
and select the audit team.
2. Document Review: Auditees documentation will be reviewed in order to
determine the conformity of the system (as documented) with the audit criteria. The
documents under review may include management system documents, records, and
previous audit reports.
3. Preparing for an on-site audit: Each audit team leader will have to:

Prepare the Audit Plan

Assign Work to the Audit Team
Prepare Work Documents (Checklists and audit sampling plans)

The CIMpgr audit process model will be very helpful here, since it can clearly identify
roles and responsibilities of the audit team and audit team leader as well. Also,
allocation of appropriate resources to critical areas of the audit will be represented in
this model.
4. Conducting an on-site audit: At this stage, the audit plan and the communication
channels will be confirmed, and short summary of how the audit activities will be
undertaken is going to be provided.
During the audit, information relevant to the audit objectives scope and criteria,
including the information relating to interfaces between processes, will be collected by
appropriate sampling. The information will also be verified, and only verifiable
information may be treated as audit evidence during internal audit sgp. Also, audit

evidence should be formally recorded. Such evidence can be recorded as text, but also as
images, and even as video clips.
Furthermore, audit evidence will be evaluated against the audit criteria to generate the
audit findings, indicating conformity, or non-conformity with the audit criteria, set
during the planning stage.
Finally, the closing meeting will take place and it will be chaired by the audit team
leader and attended by the auditors, and the auditees of our company sgpThe purpose is
to present the audit finding and the conclusions, so that they are clearly understood and
acknowledged by the auditee.
5. Preparing, approving and distributing the audit report: The audit team
leader is responsible for the preparation and contents of the audit report. The audit
report should provide a complete, accurate, concise, and clear record of the internal
audit conducted at our company sgp.
6. Audit Completion: An audit is formally completed only when all activities
described in the audit plan have been carried out and all approved audit reports have
been distributed to relevant people within our company sgp .
7. Audit Follow-up: The conclusion of the audit may indicate the need for corrective
preventive or improvement action. Such actions are usually decided and undertaken by
the auditee within an agreed timeframe and are not considered to be part of the
audit. The completion and effectiveness of corrective action has to be verified, and this
verification will be part of a subsequent internal audit, or even before.
PART 3: VC session
What was the purpose of the video-conferencing session?
The purpose of this VC session was to discuss each others TQM assignments with my
classmate Syed.
What software did you use for VC and how?
We used Skype for our VC session. Below are the screen shots of our conversion.

What did you discuss and achieve during the VC session?

We discussed our 5th companies and also our collaborative companies in overall, and
we went briefly through each assignment. sri assured me that I chose right process for
the Assignment 4, because I had certain doubts about PFRA (not in terms of the tool
itself, but whether I chose the right process for applying this tool). I explained Sri how to
use Visio for his Assignment 1 and I also helped him to create separate page for each
assignment, because he had the same problem as I did all assignments were under the
same link lined in a sequence, one after the other.
How do you like this video-conferencing approach for collaborative
problem solving?
I like it because it is convenient for me, since I am living in NY and Sri is living in NJ, so
I would have had to travel for 2 hours in one direction in order to have this discussion
face-to-face. Hence, with Skype I had no need to physically go anywhere. However, I
dont think this approach is always applicable. Sometimes having face-to-face discussion
is much more effective.
What were the main challenges?
We had no technical difficulties in the sound or camera. However, sometimes we were
wasting our time on the issues that would have been avoided if we were having face-toface discussion. For example, when Sri was reviewing my Assignment 0 and I wanted to
ask him for opinion about some particular paragraph that I wrote, I had to count the
paragraphs and tell him Go on that and that paragraph, the one under my picture,
etc.. But, if we were having discussion face-to-face, I would have simply shown to him
the relevant paragraph. Also, the challenge was to get into the Sris TQM world in a short
time, where he spent the all semester on it.
What worked well, and what did not, and why?
Syed and me had a good conversation. We didnt interrupt each other and we put an
effort to understand each others 5th company and collaborative companies, and to give
each other constructive advice about our assignments. What didnt work well, I
explained under the previous question.

In comparison to a face-to-face visit, versus VC, what is the estimated

carbon footprint saving to the environment? How did you calculate this
result?
The estimated carbon footprint saving to environment is directly proportional to savings
made in gas that we would have spent if we had to meet face-to-face. Light and
electricity are the same for both visits and thus are excluded from the calculation, since
even if had met in person, we would have been using our laptops and we would have
needed the light.
The distance between NY and NJ, Newark, is 8 miles. For 8 miles trips, 0.26 gallons of
gasoline is needed, which is equivalent to emissions of 5.1 pounds of carbon dioxide.
Hence, estimated carbon footprint saving to the environment due to our VC session is
5.1 pounds of carbon dioxide.
I used this site for calculation: http://www.epa.gov/cleanenergy/energyresources/calculator.html#results
PANORAMA NAVIGATION MAP
Panorama navigation map is technology that enables 360 Degree view of the scene with
embedded panoramas, images, videos and others, which makes it an excellent learning
tool. In our E-book we had opportunity to explore a small USA town and I felt as I was
watching a documentary 3D movie.
Panorama navigation map has multiple use and a user just has to be a little bit creative
to see its various opportunities. For example, in my company sgpI would use Panorama
navigation map as an evidence of conformity to the relevant standard requirements
during the quality audits. As we explained in previous assignments, Panorama
Navigation Map can be used as an instruction tool. By taking the pictures of products
and the parts they consist of and also by recording the steps of relevant processes, my
employees and other interested parties, such as audit team, would have a much better
understanding of the subject matter and of the system as whole how parts, activities
and processes are interrelated. By exploring these dependences, one can also notice the
opportunities for making improvements and reducing the risk related to some process
steps. Hence, Panorama Navigation Map can be used as an evidence of having work
instructions at the work cells, and also as a tool for identification of possibilities for
improvements and reducing the risk.

4. SUMMARY
In this assignment, I looked back at all previous assignments to see the big picture
again, as part of a TQM audit. I was answering the following question: How could I
apply the learned methods and tools in this course to improve my own company Kalaba
Inc.?. I also incorporated RFID technology that is of tremendous importance in
nowadays, especially for the automobile industry, in which my company Kalaba Inc.
operates. This assignment was like a crown of all previous work.
5. REFERENCES

Answers, How much gas does it take to drive 8

miles?, http://wiki.answers.com/Q/How_much_gas_does_it_take_to_drive_8
_miles
Clean Energy, Greenhouse Gas Equivalencies
Calculator, http://www.epa.gov/cleanenergy/energyresources/calculator.html#results
Distance from New York to
Newark, http://www.timeanddate.com/worldclock/distanceresult.html?p1=179
&p2=861
IE376 TQM eLearning Pack, ID: IE673-Spring2012-95-48
PRLOG, RFID Vehicle Tracking System with high identification
accuracy, http://www.prlog.org/10217239-rfid-vehicle-tracking-system-withhigh-identification-accuracy.html
RFID VEHICLE
TRACKING, http://www.alientechnology.com/docs/CS_STS.pdf
Wikipedia, Radio-frequency identification, http://en.wikipedia.org/wiki/Radiofrequency_identification

6. SOCIAL NETWORKING

Report: Third Of Large Manufacturers Considering Reshoring

Although the prediction of manufacturing jobs returning to the USA from China is
starting to become a reality, there are still doubts about it in many peoples minds based
on what they have seen over the years. However, this article definitely gives us another
hope that the jobs will return to the states soon (by Riddhiben Naik). Hopefully, Made
in the USA is coming back.

Here is the link to the full conversation:

http://njit.mrooms.net/mod/forum/discuss.php?d=130166#p401987

Animated Engines

Naik made really good point about this one Anyone who did not checkout the link for
the animated engines, please do! It is really a great and innovative idea for the
user/maintenance manuals. I wish I thought of this for my midterm assignment.
Here is the link to the full conversation:
http://njit.mrooms.net/mod/forum/discuss.php?d=130206#p401988
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Olga Kalaba

Author
Collaborative Companies
1. InnovMetric Software Inc.
2. Lenze
3. Akro-Mils
4. Datex