Part III: Tools and Techniques for TQM

Dr. Ayham Jaaron Second Semester 2010/2011

TQM Tools and Techniques

These tools can be broadly divided into two categories: a) Tools for Quality Planning. b) Tools for Continuous Improvement.

Tools for Quality Planning.

1. Quality Function Deployment (QFD). 2. Concurrent Engineering (CE). 3. The New Seven Management & Planning Tools

1) Quality Function Deployment (QFD)

A system to translate customer requirements into appropriate company requirements at every stage, from research through design, manufacturing, distribution, marketing sales and services
The main features of QFD are a focus on meeting market needs by using actual customer statements (referred to as the "Voice of the Customer"), its effective application of multidisciplinary teamwork and the use of a comprehensive matrix (called the "House of Quality") for documenting information, perceptions and decisions.

The QFD Approach

The QFD Planning

House of Quality (HOQ)

Is a matrix which serves to describe the transition from a list of customer requirements, the what, to a list of considerations as to how the requirements will be met. The relationship between the what and the how is represented by symbols : Triangle for weak relationship Circle for medium relationship Two concentric circles for strong relationship

HOQ

HOQ: Example

The QFD organizational Structure

A teamwork must be established to develop an efficient QFD including the functions: Marketing Design Quality Technology Production Logistics Suppliers

The QFD organizational Structure

Every function participate in the work team, reporting to a Project Leader, nominated for each product or program. The work team for every function should not exceed the number of seven people, to respond quickly to the requirements to be met

The QFD organizational Structure

There are also disadvantages and risks applying the QFD method, compared with the traditional hierarchical approach: 1. Construction of long and complex tables of data difficult to handle 2. Confusion in defining customer requisites 3. Risk of misunderstanding the customer requirements 4. Incorrect data, given the difficulty to classify requirements 5. Difficult correlation between customer needs and technical characteristics of the product

The QFD Usage Benefits

The most renowned benefit of QFD usage is its ability to:
Generate and maintain involvement within the work team over the whole product development cycle

The QFD Usage Benefits ( Cont.)

The first benefit of QFD is the solution of 3 main problems:
1. The customers voice was held to be of no account 2. Loss of information during the cycle of product development 3. Different interpretation by the various departments on technical specifications

The QFD Usage Benefits...cont.

Reduced time to market Reduction in design changes Decreased design and manufacturing costs Improved quality Increased customer satisfaction Notable improvement in planning cycles Creation of a solid platform of basic knowledge thus creating a data bank storing important information for future products

Applying QFD
The principal phases necessary for the construction of the House of Quality are:
1. 2. 3. 4. 5. 6. Identifying customer requirements Identifying product and engineering design requirements Drawing up a relationship matrix Deploying expected quality (competitive benchmarking) Technical importance ranking Analyzing the correlations between various characteristics

Main Components of HOQ

Applying QFD
The raw data obtained from customers are called the voice of the customer ( VoC ) and represents the requirements of customers/users The QFD specialists rewrite the VoC into reworded data that become the technical specifications, to give the users greater satisfaction

Applying QFD
The ranking order of the requirements is also identified: a cluster is prepared according to teams members opinions An example of clustering requirements is given for a Portable Instrument for a Remote Control of a Model Aircraft

Applying QFD: Example

Techniques used to determine customer requirements:

1. Personal interviews :empirically it has been found that 20-30 persons interviewed are enough 2. Focus groups : 6 to 8 customers put together in a meeting lasting 2 hours 3. Qualitative techniques :the customers are requested to choose the products most similar and the ones most different 4. Product analysis techniques : customers are requested to say how they buy, use, and evaluate a single product

Applying QFD House of Quality Example.

2) Concurrent Engineering ( CE )
Is a systematic approach to the integrated design of products and their processes including manufacture and support OR The application of tools, techniques, methodologies, and behavioural initiatives used to minimise product development timescales by maximising the degree of overlap of design activities
The target of CE is to improve the design phase of a product , considering : the costs of production aesthetics Produce-ability, assemble-ability, maintainability and recyclability

Main Concept
The basic premise for concurrent engineering revolves around two concepts: 1. The first is the idea that all elements of a products lifecycle, from functionality, produce-ability, assembly, testability, maintenance issues, environmental impact and finally disposal and recycling, should be taken into careful consideration in the early design phases. 2. The second concept is that the preceding design activities should all be occurring at the same time, or concurrently. The overall goal being that the concurrent nature of these processes significantly increases productivity and product quality, aspects that are obviously important in today's fast-paced market

Main Concept...continued

Concurrent activities

Concurrent Activities

CE is not new!!

CE Activities ...continued..
DFM: design for manufacturing allows designers to be
able to access information that will help them improve design. They will be able to call-up computer programs that can analyze the current state, point out where the design is too complicated, and indicate possible areas of improvement.

DFA: Design for assembly aim to reduce the cost and time of
assembly by simplifying the assembly through means such as reducing number of part by combining them.

CE Design Facility

Benefits of CE
Advantages:

1.
2. 3.

A significant part of this new method is that the individual engineer is given much more say in the overall design process . Giving the designer ownership plays a large role in the productivity of the employee and quality of the product that is being produced. The ability to produce quickly and cheaply at the desired level of quality.
Issues such as the implementation of early design reviews, enabling communication between engineers, software compatibility and opening the design process up to allow for concurrency creates problems of its own. There must be a strong basis for teamwork since the overall success of the method relies on the ability of engineers to effectively work together. Often this can be a difficult obstacle. software is playing a huge role in the engineering design process. the ability to quickly and easily modify digital models to predict future design problems is hugely important no matter what design process you are using.

Difficulties in CE systems:

Tools for Design Quality /CE

Tools are divided in four Macro areas: 1. Market Studies for an estimation of actual and potential market dimensions 2. Design activities focused toward: Function analysis Costs-benefit analysis Planning & scheduling ( Project Management) Creative group methods ( brainstorming) Problem solving

Tools for Design Quality/CE

3. Detail design activities tools: CAD ( Computer aided design ) CAE ( Computer aided engineering ) CAM ( Computer aided manufacturing ) CAT ( Computer aided testing )

Tools for Design Quality/CE

4. Process design verification : Includes: Rapid prototyping ( CAD 3D system ) Variety reduction Change management Documentation management Design review

3) The Seven Management & Planning Tools

The following are some of the most common TQM tools in use today. Each is used for, and identifies, specific information in a specific manner. It should be noted that tools should be used in conjunction with other tools to understand the full scope of the issue being analyzed or illustrated.

Pie Charts and Bar Graphs

Used to identify and compare data units as they relate to one issue or the whole, such as budgets etc. Histograms To illustrate and examine various data element in order to make decisions regarding them. Effective when comparing statistical, survey, or questionnaire results.

Histograms

Pareto Charts / Analysis (designed by Vilfredo Pareto)

Rates issues according to importance and frequency by prioritizing specific problems or causes in a manner that facilitates problem solving. Identify groupings of qualitative data, such as most frequent complaint, most commonly purchased preservation aid, etc. in order to measure which have priority Can be scheduled over select periods of time to track changes. They can also be created in retrospect, as a before and after analysis of a process change.

Pareto Charts

Cause and Effect, Ishikawa or Fishbone Diagrams

Illustrates multiple levels of potential causes (inputs), and ultimate effects (outputs), of problems or issues that may arise in the course of business. May be confusing if too many inputs and outputs are identified. An alternative would be a tree diagram, which is much easier to follow.

Fishbone Diagrams

Flowcharts and Modelling Diagrams

Assist in the definition and analysis of each step in a process by illustrating it in a clear and comprehensive manner. Identify areas where workflow may be blocked, or diverted, and where workflow is fluid. Identify where steps need to be added or removed to improve efficiency and creates standardized workflow.

Flowcharts and Modelling Diagrams

Relations Diagram
To understand the relationships between various factors, issues, events, etc. so as to understand their importance in the overall organizational view.

Scatter Diagram
To discover cause and effect relationships, as well as bonds and correlations, between two variables To illustrate and validate hunches To chart the positive and negative direction of relationships