Module Title Module Code

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Module Information Quality Management and Six Sigma EMM502

MODULE SUMMARY

Aims and Summary The module highlights the evolution of quality paradigm and thus enables the students to adopt quality as a strategy for continuous improvement in business performance. The students will be taught strategies for competitive quality, quality in design and manufacture and the customer supply chain to the concept of total quality. In addition, three driving forces of competitiveness such as customer focus, continuous improvement and total employee involvement that are shaping the industries globally will be discussed. The students will be exposed latest Quality Management Systems and problem solving tools. Module Size and Credits Module size CATS points ECTS credits Open / restricted Availability on/off campus Total student study hours Number of weeks Centre responsible Academic Year Single 12 N/A Restricted On Campus/Off campus 120 4 weeks Full-time or 8 weeks Part-time. Centre for Manufacturing/ Department of Mechanical and Automotive Engineering 2009

Entry Requirements (pre-requisites and co-requisites) Normally to be qualified for entry to the Postgraduate Engineering Programme Excluded Combinations None Composition of Module Mark (including weighting of components) Full-time / Part-time : 50% Written Examination and 50 % Assignment Pass Requirements A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment and overall 40% marks are required for a pass Special Features 80% attendance in theory and 80% attendance in laboratory are required. It is likely that considerable time will be spent in School facilities outside of normal timetabled class time. Courses for which this module is mandatory M.Sc. [Engg] in Engineering and Manufacturing Management

Courses for which this module is a core option None

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TEACHING, LEARNING AND ASSESSMENT On completion of this module the student should be able to: 1. 2. 3. 4. 5. Differentiate between Inspection, Quality Control, Quality Assurance and TQM programmes and critically review where and when these techniques are applicable Interpret customer focus and market forces as basis for all business activities Assess the maturity of an organisations Quality program including cultural and leadership aspects Plan and implement activities which will improve a quality program within an organisation and move it towards TQM Proficiently use Six Sigma Suite for analysis and solving industry problems

Intended Module Learning Outcomes

Indicative Content Class Room Lectures 1. The Philosophies and Principles of TQM, incorporating Customer Focus: Definition of quality, Evolution of quality, Principles of TQM and its powerful customer focus philosophy, Benefits of TQM Evolution of TQM through Phases of Inspection: QC & QA and their critical review, Evolution of quality concepts through different stages and times; Difference in approach to quality mgt between modern and traditional thinkers, Concept of Cost of Quality The Tools, Techniques, Systems and Management and Leadership styles Applicable to a TQM Environment: Definition of process management; Tools and Techniques used in the main processes of a company; Leadership styles most suitable for TQM; Building a quality culture in an organisation Cultural and Leadership Aspects and the Influence of Quality Gurus and their Contribution to TQM: Study of various persons and institutions who made an impact on the journey to TQM; Study and understanding of awards of excellence in quality. Concept of Variation and its Analysis: As an aid to Continuous Improvement, SPC and Process capability, Causes of variation in processes, Basic statistics; Concept of process capability; Understanding and practice in usage of quality control tools and Management Planning Tools ISO 9000, ISO 14000 and related Quality Management Systems: Introduction to ISO family of standards; Understanding the elements of the standard and the basis for these elements; Modern process view of ISO standards, Methodology of getting accredited ;Benefits of getting certified Understanding and Implementation of Six Sigma programs: DMAIC philosophy of Six Sigma; Supporting concepts of DFSS, FMEA Quality Costing as an Aid to Managing Quality and Motivating Continuous Improvement: Definition and importance of cost of Quality; Constituents and behaviour of the costs of quality, ABC method of costing, Implementing cost of quality. Benchmarking: BPR and EFQM as an aid to develop both strategic and tactical competitive advantage, Definition of Benchmarking and best practices; Different approaches to benchmarking, Steps in benchmarking, Details of BPR

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10. Designing Quality into Products and Processes including Quality Engineering: (Taguchi methods) Study of Taguchi methods; Loss function; Quality of Design, Tolerances Laboratory Practice 1) Visit a manufacturing industry to experience quality control practices 2) Visit to appropriate business organization to ascertain the benefits of implementing the QA practices

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3) Exercises using Quality Control Software (Six-Sigma Suite) Teaching and Learning Methods 1. Theoretical Knowledge [~30% of module time] a. Face to face lectures from a module leader - 30 hours b. Case study teaching and group discussion - 6 hours 36 hours 2. 3. Laboratory Practice (Skills) [~ 25% of module time] 30 hours Application Orientation and Problem Solving [45% of module time] a. Reading b. Research c. Written Examination d. Assignment Solving and Documentation 54 hours

Method of Assessment Part-A Written Examination [50% Weightage] At the end of the module, normally on the last day of the last week of the module, written examination is conducted to test students understanding of taught theoretical concepts. The question paper will comprise either or a combination of the following: 6 questions, out of which 5 questions need to be answered Practical laboratory work Presentations Field work Creation of a physical model

The marks scored by the student will be scale down to 50% weight. Part B Assignment [50% Weightage] Students are required to submit word processed assignment report on formally announced last day of the module. Assignment tests students problem solving skills based on taught concepts. The assignment is assessed for 100 marks but scored marks is scaled down to 50% Assessment Learning Outcomes Part A Part B 1 X X 2 X X X 3 4 X X 5 X X

Both written examination scripts and assignment reports will be double marked/valued Re-assessment

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A minimum of 40 % marks in the written examination and a minimum of 40% marks in the assignment are required for a pass in the module. A student failing in any one of the components or both is considered as FAIL in the module. A failed student is required to retake the module at the next opportunity. A maximum of 3 attempts including the original are allowed. Date of Last Amendment May -2009 3. MODULE RESOURCES

Essential Reading 1. Module Notes

Recommended Reading Books Sundara Raju, SM, Total Quality Management, Primer, McGraw Hill, 2001 John.S.Oakland, Total Quality Management, Butterqworth-Heinmann Publishers, 2003 Kume, Hitoshi, Quality Management in New Product Development, Productivity Press, 2004 James R.Evans, Total Quality Management, Organisation and Strategy, Thomson publication 2005 Dr. Gopalan, M R, Bicheno John, Management Guide to Quality and Productivity, Biztantra, 2005 Besterfield, Dale H, Total Quality Management, Pearson education Publication,2006 Basem El-Haik, Axiomatic Quality Integrating Axiomatic Design with Six Sigma, Reliability, Quality Engineering, Wiely, 2005 8. Bergma, Boklefjo, Bengt, Quality; From Customer needs to Customer satisfaction, Overseas press, 2006 9. Bhote, Kekir, The Ultimate Six Sigma; Beyond Quality Excellence to Total Business Excellence, Prentice Hall India, 2007 10. K.Sridhar Bhat, Total Quality Management, Himalaya Publishing house, 2007 Journals 1. International Journal of Quality and Reliability Management, Emerald Publishing group 1. 2. 3. 4. 5. 6. 7.

Internet Sites 1. Laboratory Hardware: PCs Software: Six Sigma Suite Software Manual: None www.asq.org

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MODULE ORGANISATION

Module Leader Name Room Telephone number E-mail Date and Time of Examination As per time table Prof.B.S.Ajit kumar G-02 080-2360 5539 ajit@msrsas.org

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Subject Quality and Approval Information Subject Quality Group / Subject Board Subject Assessment Board Shortened title Date of approval by MARP Mechanical and Automotive Engineering Postgraduate Engineering Programmes QM May 2009

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