Quality points #Problem-Anything that limits a system from achieving higher performance versus its goal #Solving Process=Objective

Finding -Fact Finding -Problem Redefinition -Idea finding- Solution Finding -Acceptance Finding- Implement chosen ideas - Action plan #Plan(indentify the problem)-do(analyze)-check(develop solns)-act(implement the soln)-sheck the results-standardaize the soln

#7 QC tools-a) Check Sheet,Pareto Diagram,Stratification,Cause and Effect Diagram,Histogram,Scatter Diagram,Control Charts

#Stratification is the process of separation of data into categories. Done for identifying the categories contributing to the problem tackled. #Control charts-It was developed in the 1920s by Dr. Walter A. Shewhart of the Bell Telephone Labs; it is a graph showing the characteristics of a process after statistical calculations have been made from data collected; #Control charts for Attributes. p chart ,c chart ,u chart # Control charts for Variables. X bar chart ,R chart #Too many points clustered around the centre lineIndicate sub-grouping is not rational(in control charts) If points are spread out & occupy full range of control limits, it indicates rational subgrouping #FMEA is a tool for preventing problems Most effective low risk techniques for identifying potential problems and preventing them #FMEA is a procedure for developing and implementing new or revised designs, processes and services A structured approach for prioritizing, evaluating, tracking and updating design and process development #FMEA was developed in mid 60s in USA, by NASA, for Apollo project #Three Distinct types-Design FMEA,Process FMEA,Service FMEA #Recent applications in Preventive Maintenance have given excellent result.=Equipment FMEA

#The main deference in the above three (or four) applications is the OBJECTIVE. DPMO = DPU 106 Defects per Million Opportunities It simply indicates how many errors would show up if an activity is to be repeated million times 1sig=68.27,2=95.45,3=99.73,4=99.47,5=99.999943,6=99.9999998 DPMO-1=317300,2=45400,3=2700,4=63,5=.57,6=.002 A shift of 1.5 is widely agreeable Sigma level 1 2 3 4 5 6 % within specification limit 30.23 69.15 93.23 99.379 99.9767 99.99966 Defective PPM 697700 308500 66810 6210 233 3.4

Six sigma is driven by close understanding the needs of customer, disciplined use of factual data, and statistical analysis while paying diligent attention to managing, improving, and reinventing business processes

Define-Measure-Analyse-Improve-Control

Quality Function Deployment is method prioritizing and translating customer inputs in design and specification for product, service and / or process. #Network of the national standards institutes of 156 countries,Central secretariat in Geneva, Switzerland,ISO is a non-governmental organization #The international Electro-technical commision(IEC) was established in 1906 #Objective was to facilitate the international coordination and unification of industrial standards #New organization,ISO,began operations on 23 February 1947

The hallmarks of the ISO brand Equal footing-Voluntary,Marketdriven,Consensus,worldwide

#Apart from TC,3 general policy development committees exist #iSO standards are developed by technical committees, comprising of Experts from industrial, technical & business sectors How ISO standards are developed-Technical committee prepares draft document-Draft international standard is circulated to ISO members for comment & balloting-If accepted, with eventual modifications,-Final DIS is circulated to members -If accepted, the document is published as international standard PROCESS APPROACH-A desired result is achieved more efficiently when activities and related resources are managed as a process #Process approach to quality Management is encouraged by ISO 9000 standards, as a means to enhance customer satisfaction by meeting customer requirements #The application of a system of processes within an organisation together with the identification and interactions of these processes and their management can be referred to as process approach. Quality Control-It is focused on providing confidence that Quality requirements will be fulfilled. It is essentially a control loop based on monitoring, feedback and corrective action. Quality Assurance-It is an anticipation & prevention of unfavorable events by the task performers. CORRECTION-Action taken to eliminate a detected Non conformity. ISO published ISO 9000 series of standards for the first time in 1987 These standards are reviewed and revised periodically. The phase-I revision of ISO 9000 series of standards took place in July 1994. The phase-II revision took place in December 2000. Second revision of ISO 9000 series was published by ISO on 15 Dec 2000 3 years time was given for change over from 1994 version to 2000 versio To remove technical barrier-ISO 9001:2000 replaces the old versions viz. ISO 9001:1994, ISO 9002:1994 and ISO 9003:1994 #In the ISO 9000:2000 Series, 1994 family of standards have been reduced to 4 core standards: 1-ISO 9000:2000 Fundamentals and vocabulary,2-ISO 9001:2000 Requirements ,3-ISO 9004:2000 Guidelines for performance improvements,4-ISO 19011:2002 Guidelines for Auditing Quality and/ or Environmental Management Systems Auditing

ISO 9000:2000 & ISO 9004:2000 are intended as guidelines only & can not be used as ref. Standards to audit the adequacy of QMS #FAMILY OF REVISED ISO 9000 STANDARDS ISO 9000 : 2000 QMS Fundamental and vocabulary ISO 9001 : 2000 QMS Requirements ISO 9004 : 2000 QMS Guidelines for performance improvement ISO 19011 : 2002 Guidelines for auditing of QMS and/or EMS DIFFERENCE BETWEEN ISO 9001 AND ISO 9004 ISO 9001:2000

ISO 9004:2000 possible

Certification

Certification not possible

Emphasis on effectiveness Emphasis on meeting customer as well as regulatory requirements

Emphasis on efficiency as well as effectiveness Emphasis on meeting requirements of all interested parties

Other Standards ISO 10005:1995* - Quality Plans. ISO 10006:2003 - Project Management. ISO 10007:2003 - Configuration Management. ISO 10012:2003 - Measurement Control System. ISO 10018*: - Complaints handling. ISO 10019*: - Selection of QMS consultants and use of their services. Technical Reports ISO/TR 10013:2001 - Documentation.

ISO/TR 10014:1998* - Economics of quality. ISO/TR 10015:1999* - Training. ISO/TR 10017:2003 - Statistical techniques. Year 2000 Family of Standards (contd) #Technical Specifications ISO/TS 16949:2002 - QS - Automotive suppliers. ISO/TS 29001:2003 - QS - Petroleum, petrochemical and natural gas Indus ISO/IEC 17025:1999* QS Testing and calibration labs.

ISO 15161:2001 - QS - Food and drink industry.

# Quality Manual- contains regulatory requirements, Quality policy, Introduction of company (nature of work- marketing/manufacturing etc.), Justification of any exclusion of clause #Any manual must consists the following: 1. Title 2. (i) Scope & Field of application, (ii) Structure i.e. level3. Table of contents4. Abbreviation list 5. Introduction of company6. Amendment procedure 7. Amendment records8. Distribution list9. Different clauses
REQUIREMENTS - CL.4- THE DESCRIPTION OF QMS REQUIREMENTS CL. 5 MANAGEMENT RESPONSIBILITY REQUIREMENTS CL. 6 RESOURCE MANAGEMENT REQUIREMENTS CL. 7 PRODUCT REALISATION (PROCESSES) REQUIREMENTS CL. 7.4 PURCHASING REQUIREMENTS CL. 7.5 PRODUCT AND SERVICE PROVISIONS REQUIREMENTS CL. 7.6 CONTROL OF MONITORING AND MEASURING DEVICES REQUIREMENTS CL. 8 MEASURE, ANALYSE AND IMPROVE FOR MONITORING AND MEASUREMENT

# Where any requirement(s) of the standard can not be applied due to the nature of organisation and its product, this can be considered for exclusion, Exclusions are limited to requirements within clause 7, and such, exclusions should not affect the organisations ability, or responsibility, to provide product that meets customer and applicable regulatory requirements.

# Typical Structure of Documentation Quality Manual(Level A)-Quality Management System Procedures(Level B)-Work instructions , process maps and other documents for QMS (Level C)-Forms and Records(Level D) Document contents A : Describes the QMS in accordance with the stated quality policy and objectives. B : Describes the interrelated processes and activities required to implement the QMS C: Consists of detailed work documents. D: Evidences to audit List of Mandatory Documented Procedures 1.Control of Documents (4.2.3).2.Control of Records (4.2.4).3.Internal Audit (8.2.2).4.Control of Nonconforming product (8.3).5.Corrective Action (8.5.2).6.Preventive Action (8.5.3). #List of Records Results of management reviews (5.6.1). Records of education, experience, training and qualifications (6.2.2e). Records to provide evidence that realisation process and resulting product meet requirement (7.1d). Results of customer requirement reviews and actions arising from reviews (7.2.2). Design and development input relating to product requirement (7.3.2). Records of design and development reviews (7.3.4) Results of design and development verification and any necessary actions (7.3.5).

Results of design and development validation and necessary actions (7.3.6). Results of the review of design and development changes and any necessary actions (7.3.7). Results of evaluation of suppliers and any necessary actions arising from the evaluation (7.4.1). Evidence of validated processes (7.5.2d). Traceability (where it is requirement) (7.5.3). #AUDIT IS DONE TO ANS 3 BASIC QUES1-TO WHAT EXTENT IS THE QMS DOCUMENTED?2-TO WHAT EXTENT IS THE DOCUMENTED QMS IMPLEMENTED? 3- TO WHAT EXTENT IS THE QMS PUT INTO PRACTICE IS EFFECTIVE? WHAT AUDIT IS? SYSTEMATIC, INDEPENDENT AND DOCUMENTED PROCESS FOR OBTAINING EVIDENCE AND EVALUATING IT OBJECTIVELY TO DETERMINE THE EXTENT TO WHICH AUDIT CRITERIA ARE FULFILLED #AUDIT IS REQUIREMENT OF IS/IS0 9001:2000(CLAUSE 8.2.2) IT IS REQUIREMENT BY A CERTIFICATION BODY FOR THE PURPOSES OF CERTIFICATION

# AUDITS ARE CARRIED OUT AT TWO LEVELS 1) TO EVALUATE IF THE PRESENT PROCEDURES ARE SUITABLE FOR ACHIEVING ORGANIZATIONAL GOALS AND OBJECTIVES 2) TO EVALUATE COMPLIANCE TO EXISTING PROCEDURES/CRITERIA TYPES OF AUDIT -ADEQUACY AUDIT and COMPLIANCE AUDIT #Certification Bodies-An impartial body either governmental or non governmental, possessing the necessary competence and reliability to operate a certification system. BIS, NQA-QSR, STQC, LRQA, TUV, DNV, BVQI, KPMG, IRQS, SGS, QAS, UAL, ICL

#Accreditation Body- A national body which evaluates the competence of certification body. UKAS- United Kingdom Accreditation Services,RAB- Registrar Accreditation Board in USA NTPC in 2017- 65,000 MW+ portfolio,About11,000MW of hydropower TQM= Quality (Customer Focus), Scientific Approach (Process Focus), All one team (People Focus) UPPER / TOP MANAGEMENT( STRATEGIC QM)-hrm tqm,bs MIDDLE MANAGEMENT(OPERATIONAL -QM)6sig,iso workforce level-workforce-5s,suggestion scheme\ 5s1seiri(cleaning),2seiton(arranging),3seiso(neatness),4shitsuke(discipline/standardize),5seitket sum(ongoing improvement/maintain) Kanban-tool to implement jit Japan-deming model.Iindia - CII-EXIM (based on EFQM), US- MALCOLM BALDRIGE (MBNQA), EUROPE EFQM # DEMING Prize was First Awarded in 1951 by JUSE , EFQM formed 1988, CII Adopts the Model in 1994 BE Model is a non-descriptive framework that recognises that there are many approaches to achieving sustainable excellence Qc- INITIATED IN NTPC : 1984 : REVIVED IN 1997 : FIRST CONVENTION 1997 5s- Started in 1999 partnering with QCFI, Hyderabad and NPC