Assignments-Mba Sem-Iii: Subject Code: QM0004

ASSIGNMENTS- MBA Sem-III
QM0004 Quality Management Tools Capability
ASSIGNMENTS- MBA SEM-III Subject code: QM0004 Subject Name: QUALITY MANAGEMENT TOOLS Set 1& Set 2
Submitted By: Mr. Mithesh Kumar Reg. No. 520930668 948-000-9987 Kumar.mithesh@gmail.com
Mr. Mithesh Kumar
Reg. No. 520930668
Page 1
SET 1
Q1.
What are the objectives and features of Quality Function Deployment
(QFD)?
Customer expectations for a product or services are vivid and certain time it is vague too. Understanding exactly the total customer requirements and translating this into detailed technical specification in a product or services is very difficult. The Japanese developed a concept called Quality deployment function, through which they addressed the issue by capturing the voice of the customer and ensure through QFD that the customer is the focus of all design activities and he can only dictates the design tradeoffs.
Therefore QFD is a customer driven planning process which guides through the design, manufacture and marketing of a product or services. Objectives
Quality Function Deployment [QFD] is a team based management tool in which customer expectations are used to implement the product development process.
It is a methodology of translating customer requirements into the appropriate and most suitable technical requirements into actual reality of manufacture.
QFD is a planning tool used to fulfill customer expectations. It is a disciplined approach to product design, engineering and production and provides in-depth evaluation of a product.
It is a very useful tool when customer requirements (both needs and product specifications) must be transferred into either an organizational design or a technical product design.
Its limitations being that the exact needs must be identified in complete detail. However, despite this difficulty, this is an excellent tool for reducing off the shelf designs that are made before understanding requirements.
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Special Features & Overview of Quality Function Deployment
QFD focuses on customer expectations or requirements, often referred as the voice of the customer. It is process to translate customer expectations, in terms of specific requirements, into directions and actions in engineering or technical characteristics that can be deployed through major production activities of:

Product planning Part development Process Planning Production Planning Service industries
QFD enables the design phase to concentrate on the customer requirements, thereby spending less time on redesign and modification using traditional means, thus saving development cost
QFD helps identify new quality technology and job functions to carry out operations. This tool provides previous reference to enhance future technology and prevent design errors. QFD is primarily a set of graphically oriented planning Matrices that are used as the basis for decisions affecting the product development cycle. Results of a QFD are measured based on the number of design and engineering changes, time to market, cost and quality. It is considered as a perfect blueprint for quality by design.
QFD-most developed proactive process and is a planning tool that defines a process for developing products or services The competitive analysis provides a place to start looking for ways to gain a competitive advantage. The relationships between customer needs and engineering attributes need to be specified. These will improve the performance measures of the company.
QFD approach provides a way to set targets. While Engineers use the data to focus on product design features. Marketing uses for determining marketing strategies and Operations to identify the processes that are crucial to improving product quality etc. Therefore QFD encourages inter-functional communication for improving the quality of products and services.
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An organization that correctly implement QFD can improve engineering knowledge, productivity and quality and reduce costs, product development time and engineering changes,
Q2.
Explain the concept of FMEA.
Definition and context of FMEA:
FTA and FMEA are means of identifying or investigating potential failure modes and related causes. They can be Applied in the early concept selection and design phase and then progressively refined and updated as the design evolves. Helpful in identification of all possible causes, including root causes in some cases and also helpful in establishing relationships between causes. Used as a tool in the improvement of the design of any given product or process.
FMEA is used to identify potential failure modes, determine their effect on the operation of the product, and identify actions to mitigate the failures. A crucial step is anticipating what might go wrong with a product. While anticipating every failure mode is not possible, the development team should formulate as extensive a list of potential failure modes as possible.
To illustrate this feature of FMEA in the design stage, we could consider the use of a particular raw material based on the thoughts and knowledge we have on the strength and its characteristics. The part is designed, manufactured and assembled. At a later date, the part has lived its life and needs to be replaced. In the process of disassembling, replacing the part and reassembling, there could be chances of losing the alignment with the other parts of the assembly or may warrant the replacement of parts that are in working condition. It would be prudent to avoid such an incidence by choosing a material that could give a longer life. Alternatively, since the assembly is only as strong as its weakest element, all the parts of the assembly could be made
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equally strong to enable replacement of the assembly after a defined run and avoid replacements part by part. There are two levels of input data in this model. Typical examples of primary inputs include: Field and test failures Problem Solving Records and Case Studies Customer Surveys Rebuilder/Remanufacturer input
Typical examples of Secondary input include: Service Replacement parts Competitive product data Service Information Quality Function Deployment Studies
Field Data from these various sources are incorporated into the database and establish historical system performance levels, including failure information on various components. This historical information is one source of the information used as baseline data for the FMEA. FMEA Failure Mode and Effects Analysis is:
A simple and powerful tool to use and look ahead, anticipate and eliminate probable failures
that helps you to spot and recognize areas of weaknesses and take precautionary measures to prevent and correct them
in the primary conceptual and creative stage of all products and processes A structured approach that is easy to put into operation and a valuable instrument for everyone.
FMEA Types: There are three types of FMEA: 1. System Level FMEA: The System level FMEA is the highest level FMEA that can be performed. It is used to identify and prevent failures that are
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related to systems or sub systems in the early design concept stages. The system level FMEA is performed to validate that the system level specifications minimize the risks of functional failure during operation.
2. Design Level FMEA: The Design level FMEA is used as a tool to help identify and prevent product failures that are related to the product design. This FMEA can be performed upon a system level, sub-system level or a component level design proposal and is intended to validate the design parameters selected for a given functional performance requirement.
3. Process Level FMEA: The Process level FMEA is used to identify and prevent failures that are related to the manufacturing or assembly or for a family of components or assemblies.
The overall purpose of the FMEA is to prevent a new design or process system from failing to meet any of its requirements. The logical approach and thoroughness of the FMEA help the Product Development teams to ensure that a new product or process has been thoroughly analyzed, validated and tested prior to release. In 1994, Ford, General Motors and Chrysler, under the auspices of the USCAR, ( United States Council for Automotive Research), created and adopted Society of Automotive Engineers Standard SAE JE 731 for both their industry and their supply base.
The specific advantage that FMEA provides when used at the design stage is the minimizing or avoiding failures and errors in the product. The resultant benefit for the production engineer is the production of a safe and reliable product that would satisfy the customers. FMEAs scrutinize past data and capture historical information for designing and developing improved products in the future.
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Figure: FMEA Continuous Improvement Model
Q3.
Describe Cause and Effect Diagram with example.
Cause & Effect Analysis /Fish Bone / Ishikawa Diagram
A fish bone diagram often called as Ishikawa diagram, shows relationships between events and is a useful analysis in generating ideas and in identifying the root cause of problem. Because it somewhat resembles the skeleton of a fish as causes provides graphic display of the relationship with main bone in the center. These diagrams are used to analyze the characteristics of a process or situation and the factors that contribute to them. The dispersion or the deviations in raw material, equipment, work method etc are affecting the quality in the product.
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Hence the causes are factors and the effect is the characteristics and when these two are charted together will give us the Cause and Effect Diagram. This is a tool employed in diagnostic exercises in quality improvement. In a composite form the break-up of causes are known to affect the end result (usually a defect) in an inter-related diagram. In other words the Effect= Quality characteristic, and Cause=Factors.
The cause and effect diagram is useful in helping in sorting out the causes of dispersion and organize the mutual relationships. EX: Fish Bone Diagram for solving problem of Wobbling in a Machine tool: In the example given below, all the causes that may contribute to the Wobbling of a machine element, which is rotating, are listed in the Fish bone diagram. As can be seen for the single effect of severe wobbling of a machine element has have as many types of causes as around twenty and if allowed to deteriorate in the quality of these causes may eventually lead the total failure of the entire machine from operating.
Fig: Fish Bone Diagram
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Benefits of using Fish bone diagram or cause and effect diagram: 1. Used for solving quality control problems 2. Making this diagram is educational in itself 3. It is a guide for discussion 4. Causes are sought activity and the results are written in on the diagram 5. Shows the level of technology 6. Can easily identify bad practices which are causing problems. 7. It becomes a guide to concrete action 8. It is a prime step for promoting QC activities 9. Helps identify root cause 10. Helps generate ideas 11. Is an orderly arrangement of theories 12. Is helpful in guiding further inquiry
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SET 2
Q1.
What is reliability? Explain the methods of achieving reliability.
Reliability is the probability of a device (system, vehicle, machine or product) performing its purpose (its intended function) adequately for a specified period of time under specified operating conditions encountered. Reliability may be defined in several ways:

The idea that something is fit for purpose with respect to time; The capacity of a device or system to perform as designed; The resistance to failure of a device or system; The ability of a device or system to perform a required function under stated conditions for a specified period of time;
The probability that a functional unit will perform its required function for a specified interval under stated conditions.
The ability of something to "fail well" (fail without catastrophic consequences)
Reliability engineers rely heavily on statistics, probability theory, and reliability theory. Many engineering techniques are used in reliability engineering, such as reliability prediction, Weibull analysis, thermal management, reliability testing and accelerated life testing. Because of the large number of reliability techniques, their expense, and the varying degrees of reliability required for different situations, most projects develop a reliability program plan to specify the reliability tasks that will be performed for that specific system. Methods of achieving Reliability: 1. Through mature design and design margins after considering all factors of material, safety, environmental requirements, ease of production aesthetics etc. 2. through design margins relating to product strength variability that can be gained. 3. through method of reliability prediction 4. By considering the redundancy factor.
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Improving Reliability: Modern programs for improving reliability of existing product involve:
Collection and analysis of reliability data from studies such as laboratory tests or design experiments of materials, devices and components.
Tests of early prototype units Careful monitoring of early production units in the field Analysis of warranty data Systematic longer term tracking of product in the field.
General provisions of reliability specifications: An effective reliability specification should provide means for measurement, evaluation, improvement and prediction. Each specification in turn should define the general purpose, place, methods, instruments, personnel, circumstances and procedures involved. The following elements are the major provisions of reliability specifications;

Defining a device Information concerning system age, production stage and modification status. Criteria of adequate performance Basis for computing time. Description of operating conditions Description of maintenance conditions Description of mal function
Some major goals in obtaining reliability data includes:
Obtaining early identification of failure modes and understanding and removing their root cause to improve reliability.
Obtaining field failure information to help improve product design. Determining how long each unit run prior to shipment to avoid premature failure at field.
Quantifying reliability to determine whether or not a product is ready for release after meeting specified level of reliability.
Predicting warranty costs
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Deciding on the need for recall of a product in the field (Ex. Chrysler recall of cars)
Q2.
What are the uses of Quality Information System?
Quality Information System: A quality information system is both a quality system and an information system. A well designed information system allows information generated at one level or in one part of the organization to be used for many different purposes. Uses of Quality Information Systems Information systems may be used to: Initiate action (for example, generating a shop order from a customers order) Control a process (for example, controlling the operation of a laser cutting machine within given specification limits) Monitor a process (for example, real-time production machine interface with control charting) Record critical data (for example, measurement tool calibration) Create and deploy operating procedures (for example, an ISO 9001based quality management system) Manage a knowledge base (for example, capturing, storing, and retrieving needed knowledge) Schedule resource usage (for example, personnel assignments) Archive data (for example, customer order fulfillment)
The importance of information systems becomes apparent when looking at their impact on various aspects of quality management. Both process management and problem solving require accurate and timely information. One information system might be designed for manufacturing and testing equipment, with monitors displaying real-time information complete with alarms and action signals; it could have options for graphic display of statistical and trend analysis for quick intervention.
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Another system in the same plant could connect executives, project teams, and off-site employees together through an intranet; organizational objectives and milestones appropriate for each level and function could be displayed as both text and graphics, along with actual performance and gaps. These two QISs are quite different. Good information systems are critical to cross-functional collaboration, since distributed information access is required in order for groups and employees to make quicker and better decisions. For example, some projects can be carried out largely through computerized discussions and transmission of documents. Often this enables highly skilled team members to participate regardless of their physical location and can also reduce the amount of time required for the project.
Q3.
Write short notes on the following:
a. Control charts A control chart is a statistical tool used to distinguish between variation in a process resulting from common causes and variation resulting from special causes. It presents a graphic display of process stability or instability over time . Every process has variation. Some variation may be the result of causes which are not normally present in the process. This could be special cause variation. Some variation is simply the result of numerous, ever-present differences in the process.
This is common cause variation. Control Charts differentiate between these two types of variation. One goal of using a Control Chart is to achieve and maintain process stability. Process stability is defined as a state in which a process has
displayed a certain degree of consistency in the past and is expected to continue to do so in the future. This consistency is characterized by a stream of data falling within control limits based on plus or minus 3 standard deviations (3 sigma) of the centreline. Types of Control Charts There are two main categories of Control Charts, those that display attribute data, and those that display variables data.
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Attribute Data: occurrences.
This category of Control Chart displays data that result from
counting the number of occurrences or items in a single category of similar items or These count data may be expressed as pass/fail, yes/no, or
presence/absence of a defect.
Variables Data: This category of Control Chart displays values resulting from the measurement of a continuous variable. Examples of variables data are elapsed time, temperature, and radiation dose.
While these two categories encompass a number of different types of Control Charts. There are three types that will work for the majority of the data analysis cases you will encounter. In this module, we will study the construction and application in these three types of Control Charts: X-Bar and R Chart Individual X and Moving Range Chart for Variables Data Individual X and Moving Range Chart for Attribute Data
Control charts have three basic applications: Establishing a state of statistical control Monitoring a process to identify assignable causes Determining the process capability.
b. The seven new SQC tools
While the above said seven quality tools are used extensively, it may warrant certain times when we want to structure unstructured ideas to make certain decisions, the new seven tools listed and explained in brief will help analysts. These new tools are part of the Operation Research methodology and serve the needs of management in planning and implementation of quality improvement projects.
These tools are also useful in promoting team work and active involvement of individuals in quality decisions.
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1. Relations Diagram: This diagram clarifies the interrelations in a complex situation involving many interrelated factors and serves to clarify the cause and effect relationships among other factors.
2. Affinity Diagram: This is essentially a brain-storming method. It is based on group work in which every participant writes down his ideas and ideas are then grouped and realigned by subject matter.
3. Tree Diagram: This is extension of the value engineering concepts of functional analysis. It is applied to show the interrelations among goals and measures.
4. Matrix Diagram: This format is used to clarify the relations between two different factors. The matrix diagram is often used in deploying quality requirements into counterpart (Engineering) characteristics and then into production
requirements. Ex: house of quality.
5. Matrix-Data-Analysis Diagram This diagram is used when the matrix chart does not provide sufficient detailed information. This is only method within the new seven tools that is based on data analysis and gives numerical results
6. PDPC (Process Decision Program Chart) This is an application of the process decision program chart used in operations research. Because implementation programs to achieve specific goals do not always go according to plan, and because unexpected developments are likely to have serious consequence, PDPC has been developed not only to arrive at the conclusion but also to avoid surprises.
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7. Arrow Diagram: This is often used in PERT (Program Evaluation and Review Technique) and CPM (Critical Path Method). It uses a network representation to show the steps necessary to implement a plan. The above seven new QC Tools could be widely used in the following applications: Research and Development activities New Product development Quality Deployment Production Scheduling Productivity improvement studies Cost reduction and energy saving Competitive analysis QA-System improvement Supplier management Policy deployment
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ASSIGNMENTS- MBA Sem-III

QM0004 Quality Management Tools Capability

Mr. Mithesh Kumar

Reg. No. 520930668