Some info on unit test 2 Answers from ppt 2.

Answers from ppt 2.5
How can performance be appraised?
What is Marshlow's heirarchy of needs?
Explain Herzberg's two factor theory.
What is empowerment?
Name the type of teams.
Explain the stages of team development.
What are the barriers to teamwork?
Differentiate between reward and
recognition.
Mention the different types of appraisal
systems.
16 mark questions
What are the steps to achieve a motivated
workforce?
What are the characteristics of successful
teams?
Answers from ppt 3.1 & pdf file 7 qc tools
2 marks will be like What is cause and effect diagram? (Can ask all the seven tools)
16 marks will be Explain the Seven QC Tools with examples.
What are the type of process problems?
Explain the PDSA cycle
Mention any two process improvement
approaches.
Mention the strategies used for
improvement.
Write short notes on 5S
What is meant by Kaizen?
Write short notes on Supplier Partnership.
16 mark questions
What is meant by a Process? Explain with
a model.
Describe a continuous process
improvement cycle.

Answers from ppt 3.2 & pdf file new 7 tools

2 marks will be like What is arrow diagram? (Can ask all the seven new tools)
16 marks will be Explain the New Seven Management Tools with examples.
• History
• The House of Quality
• The Voice of the Customer (VOC)
• Deploying the VOC
• Personal Use
 What is QFD?
Quality Function Deployment is a design
planning process driven by customer
requirements.

1. QFD deploys “The Voice of the Customer” throughout the

organization.
2. QFD uses planning matrices -- each called “The House of Quality”.
 Voice of the Designer

Voice of the Customer

x = Design Trade-offs
Benchmarking
Reverse Engineering
 Deploying the VOC
Technical
Requirements
Requirement
Customer

Product
Requirements
Requirement
Technical

Process
Requirements
Requirement
Product

Control
Requirements
Requirement
Process

s
 Taguchi Loss Function Definition

Taguchi defines Quality as “the loss imparted by

the product to society from the time the product is
shipped.”

LOSS = Cost to operate, Failure to function,
maintenance and repair cost, customer
satisfaction, poor design.

Product to be produced “being within
specification”
 5 important points of Taguchi
 Continual quality improvements and cost
reduction
 The total loss that is generated by a product
to the society should be taken as the
measure of quality of the product
 Pre production experimental procedure from
varying 1factor at a time vary
 5 important points of Taguchi
 Customer loss due to poor quality----square of the
deviation of the performance characteristics from its
target (nominal value)
achieving conformance to specifications-------
achieving the target and mini the variability
 By analysing the non linear effects of factors.
 CONCEPT

Design quality into the product from the start and
not by inspection and screening

Reduce the deviation from the target 2 achieve
quality .don’t blinding aim at confirming to
specifications

Quality is not 2 b based on the products
performance , features r characteristics
 CONCEPT

Cost of quality is measured as a function of
product performance variations and the
losses measured system wide
Taguchi’s Quadratic Quality Loss Function
• Quality Loss Occurs when a product’s deviates
from target or nominal value.
• Deviation Grows, then Loss increases.

• Taguchi’s U-shaped loss Function Curve.

Taguchi’s U-shaped loss Function Curve.

Taguchi loss Fn

Scrap or Rework Cost.

Loss

Measured
characteristic

LTL Nominal UTL

Total Productive Maintenance (TPM) is a maintenance
program concept.Philosophically,TPM resembles
Total Quality Management (TQM) in several aspects, such as

(1)total commitment to the program by upper level

management is required,

(2) employees must be empowered to initiate

corrective action, and

3) a long range outlook must be accepted as TPM

may take a year or more to implement and is an on-going

process.
Changes in employee mind-set toward their
job responsibilities must take place as well. 17
 What For TPM?
•TPM brings maintenance into focus as a necessary
and vitally important part of the business.

•It is no longer regarded as a non-profit activity.

• Down time for maintenance is scheduled as a part

of the manufacturing day and, in some cases, as an
integral part of the manufacturing process.

•It is no longer simply squeezed in

whenever there is a break in material flow.

•The goal is to hold emergency and

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unscheduled maintenance to a minimum.
 What is TPM?

T Total • Overall efficiency.

• Total production system.
• Participation of all employees.

P Productive • Zero defect.

• No trouble in operation.
• Safety.

M Maintenance • Longer life cycle of production

system.

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 TPM Results in…
• Results in building up corporate culture that thoroughly pursues
production

• System efficiency improvement OEE (Overall Equipment efficiency-)

• Constructs a system to prevent every kind of loss, for example “Zero
accidents, Zero defects and Zero failures” based Gemba (Work Place)
and Genbutsu (actual thing) over the entire life cycle of a production
system.
• Covers all departments including production, Quality Control, Purchase,
marketing, Administration, Design & development, Maintenance &
Engineering.
• Requires all and full involvement from top management to frontline
employees. It builds up an overlapping multidiscipline process based
management teams to achieve excellence

20
 What is OEE?

Overall Equipment Efficiency

OEE = A x P x Q

A= Availability
P= Performance
Q= Quality
21
 7 Types of Waste

1. Over Production waste

2. Inventory waste

3. Conveyance waste

4. Defect production waste

5. Idle time waste

6. Process related waste

7. Operation related waste

22
 5S

JH

PM

QM

E&T

DM

SHE

OTPM
23
 Basics of TQM
Document what is done-becomes a guideline for others to follow- ISO
Look at everything as a process-Process Mapping
Measure a process-Metric development
Analysing a process-root cause identification-7 QC tools
Continuous Improvement-Six Sigma, Kaizen
Aligning individual's activity to the company's goal-Policy Deployment
Involving everyone-SGA, CFT, Quality Circle, Suggestion Scheme.
Checking whether everything is improving-Audits-Internal / external.
Special documentation-expert-tacit and explicit knowledge-Knowledge management
ISO the original document
Just like section 420 of the Indian Penal Code refers to cheating, the
section heading number of the ISO document is referred to as Clause.
Any documentation defect is referred to as non conformance as per
Clause 4.2 etc....
Sections 1 to 3 are definitions and
descriptions
about the ISO document. Hence user
reference
starts ONLY after section 4

Clause 4.2
 6.Resource
5.Mgmt 7.Product
4.QMsystem Manageme 8.MAP
responsibility Realization
nt
 4.QM System

5.Management Responsibility

6.Resource 7.Product
Management Realization

8.Measure, Analyse, Improve

6.Resource
5.Mgmt 7.Product
4.QMsystem Manageme 8.MAP
responsibility Realization
nt
1.Document 2.Clause and 3.Revision
type sub heading status

4.Purpose What for this procedure is written

5.Scope Who all have to follow this

 6.Tasks and Who does what
responsibilities

7.Communication media How this message will be passed on to others

8.Verify / Validate Approval by higher ups on the correctness of info

9.Records What kind of proof will be available as evidence

 Audits

Audit- checking whether a process is done as per written procedure

Any deviation is called Non conformance
The auditor provides this deviation as a report called NCR (Non
conformance report).

The owner of the process has to Close the non conformance within a
stipulated time period.

Such changes are called Amendments. The corresponding process

specification is amended.
In order to track such amendments, each spec has a number and a
version number.

The numbering system enables sorting out in various classifications.

 Corrective and Preventive actions

CAPA- corrective action / preventive action

This is the most important aspect of ISO audits.

When we move towards improvement, it is important
that we do not allow mistakes.
So, any mistakes-rejections or complaints- need to be
dealt with correctly.

Corrective action refers to how that individual customer

was satisfied after his complaint.

Preventive action refers to how we set up new check

points and modifications in our process to avoid getting a
similar complaint in future.