Operation Planning and Control

Quality Control

NAME :- SATYAJIT .N. SINGH

MAHESH .S. GHUGE
CLASS :- MBA I (B)
ROLL NO :- 97 ,96
UNDER THE GUIDANCE :-MRS
SHILPA MA’AM
 Operation Planning and Control
Outline:
 What is Supply Chain?
 Production and Operation Analysis
 Warehousing and Logistics
 Human Factors
What Is Supply Chain?
Supply Chain is …

Supply Chain Management is …

Supply Chain Entities are …

 Operation Planning Control
Demand Forecasting
Operations Planning
Inventory Planning & Control
Operation Scheduling
Dispatching and Progress Control
Dispatching, Data Acquisition, Corrective
Action, Measure of Effectiveness
 Just-In-Time (JIT)
“Stockless Production”
Method to reduce inventory level

Requirements:
Smooth Material Flow
Reduced Setup Time
Reduced Supplier Lead Time
Zero-Defect Components
Disciplined Shop Floor Control
 Material Handling,
Distribution, and Routing
 Material Handling
Equipment Concepts
Conveyors, industrial trucks, cranes and hoists, containers
and racks, elevators and lifts, Automatic Storage and Retrieval
System (ASRS), and Automatic Guided Vehicles (AGV)
Principles of Material Handling
Planning, systems, material flow, simplification, gravity,
space utilization, unit size, mechanization and automation,
equipment selection process, standardization, adaptability, dead
weight, utilization, maintenance, control, obsolescence, capacity,
performance, and safety principles.
Quantitative Techniques
Transportation programming, Assignment technique, and
Hungarian Method
 AGV Picture
ASRS Picture
 Distribution
Warehouse Location
 Analytical technique: tedious
 Easier: simulation

Operations Management
 Routing
 Logistic Systems (adequate inventories of FG,
supplying WH, and customers in an efficient and
effective way)
 Extra Information for Material
Handling
BUCKET BRIGADE
A way of organizing workers on a flow line so that the line
balances itself
(Prof. Bartholdi, Georgia Institute of Technology)
Benefits:
 A reduced need for planning and management
(“Self Balancing”)
 Production becomes more flexible and agile
(“Self Tuning”)
 Throughput is increased

(“Spontaneously optimal division of work”)

 Reduced 2ndary labor and improved quality (“Min WIP”)
 Training and coordination are simplified because it is easy for
workers to know what to do next .
 Role-Play Time!!
Question:
Our class is opening a Virtual Factory currently
employed 4 workers.
 Pick up the rubber band using a pin, pencil-
chopstick, ruler, and hand
 Put check mark on the items you have picked

We have a stack of orders. Each order requires

different amount for different items. How can
we improve the system?
 Bucket Brigade
Position: Slowest  Fastest
Whenever the fastest finishes a product:
Push off the order
Walk back to take over the work of his predecessor
Predecessor walks back and so on, until the first
worker walks back to start a new product
Work is "pulled" into the system by the last, fastest
worker
 What Did We Learn?

Beginning: out of balance

Afterward: quickly gravitate to the optimum

partition of work
 Quality
Management
 Outline
Quality Management Definition
Quality Control Concepts
Quality Dimension and Cost
The Seven Tools of Quality Control Methods
Quality Improvement
 Quality Management Definition
Definition
Quality management is a method for ensuring that all the activities
necessary to design, develop and implement a product or service are
effective and efficient with respect to the system and its performance.

Quality Management can Be considered to have three main components:

 Quality Control
 Quality Assurance
 Quality Improvement

Focus: product / service quality, System / Process

 The Differences…
Quality Control: is the ongoing effort to maintain the
integrity of a process to maintain the reliability of
achieving an outcome.

Quality Assurance: is the planned or systematic actions

necessary to provide enough confidence that a product or
service will satisfy the given requirements for quality.

Quality Improvement: is the purposeful change of a

process to improve the reliability of achieving an
outcome.
 Quality Concepts
W. Edward Deming
85% of quality problems within an organization or
a company is a management responsibility. This is
well known as the “common causes”.
Introduced 14 points of management obligations in
order to produce successfully.
Suppliers must be evaluated based on both price
and quality.
The use of customer input to derive quality
requirements.
Mass inspection should only be used for critical
operations.
 Quality Concepts
Joseph M. Juran
Introduced the concept of Quality as “fitness for use”
including quality of design, conformance, and
performance, all parameters of fitness for use.
Introduced Quality Cost Model and emphasize the
importance of maintaining good vendor relations.
Companies must understand the needs of their
customers. Company waste must be reduced.
Companies need to do things right the first time.
 Quality Concepts
Philip B. Crosby

Definition of Quality: Conformance to requirements. Every

individual produce product / service and has customers.
The individual is a customer of someone else.

Quality achievement is a rational approach through

preventing the occurrence of defects or errors.

Standard performance: zero defects (no errors allowed)

Measuring Parameter: quality cost, the sum of all costs a

company invests into the release of quality product or
 Quality Dimension in
Manufacturing
 Performance: the conformance of product to its primary
function.
 Feature: the specific attribute of a product
 Reliability: the ability of a product to perform and maintain its
function in routine circumstances.
 Conformance: the ability of a product to meet certain
requirements or standard that has been determined
 Durability: product’s ability to endure its usable life over a long
period of time.
 Serviceability: the ease to repair a product and the ease of
obtaining replacement of broken or damaged components.
 Aesthetic: the philosophical notion of the beauty of a product.
 Perception: product’s image that has to do with customer’s
fanatism and loyalty that will trigger repeat orders / buyers.
 Quality Cost
Expenditure in manufacturing or service that is in
excess of that which would have been incurred if
the product had been built exactly right the first
time.
Including: quality planning, production design,
processing, training, information on quality
parameters, inspection, and testing equipment.
Also included in quality cost: scrap, rework,
process failure, process delay, discounted selling
Price, customer’s complain, product claim,
warranty claim, legal claim and (market loss).
 The Seven Tools of Quality
• Cause and Effect (Fishbone Diagram)
 The Seven Tools of Quality

Histogram
Control Chart
The Seven Tools of Quality

Pareto Chart

Scatter Diagram
 The Seven Tools of Quality
• Stratification: A technique that separates data
gathered from a variety of sources so that patterns
can be seen (some lists replace "stratification"
with "flowchart" or "run chart“).
Quality Improvement Methods
ISO 9001
Quality Función Deployment (QFD)
Kaizen (continual improvement)
Six Sigma (based on SPC)
PDCA (plan-do-check-act)
Quality Circle
Taguchi Method
Toyota Production System (adapted to become
Lean Manufacturing)
Total Quality Management (TQM)
BPR – Business process reengineering
 Total Quality Management
TQM is a management approach for an organization,
centered on quality, based on the participation of all its
members and aiming at long-term success through customer
satisfaction, and benefits to all members of the organization
and to society.
TQM is a management strategy aimed at embedding
awareness of quality in all organizational processes. TQM
has been widely used in manufacturing, education, call
centers, government, and service industries, as well as NASA
space and science programs.
It is aimed to reduce variation from every process so that
greater consistency of effort is obtained.
 TQM Roles in Company
Image
Saving
Increase Market Share
Product accountability
Export Opportunity
Quality Management Planning
Design and Build: including structure, process dan
its implementation by top management.
Deployment: Processes are broken down into
documented sub-processes, supported by
institution of training related to each particular
sub-process.
Control.
Measurement.
Review.
Improvement.
THANK YOU