unit one.docx

8/14/2019 Unit One.docx

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Means of productionrefers to physical, non-human inputs used in productionthe factories, machines,

and tools used to produce wealth.

Engineering is cause and technology is the effect.

Engineering is a lot of theory. Technology or technologists do more hands on applications.

Engineering is the application of scientific and technical knowledge to solve human problems. Engineers

use imagination, judgment and reasoning to apply science, technology, mathematics, and practical

experience. The result is the design, production, and operation of useful objects or processes

Technology refers to all tools and procedures and their interconnections

Overview:

Deals with descriptions. Data can be observed but not measured. Colors, textures, smells, tastes,

appearance, beauty, etc. Qualitative Quality

Overview:

Deals with numbers. Data which can be measured. Length, height, area, volume, weight,

speed, time, temperature, humidity,sound levels, cost, members, ages, etc

Quantitative Quantity

Example 1:

Oil Painting

Qualitative data:

blue/green color, gold frame smells old and musty

texture shows brush strokes of oil paint peaceful scene of the country masterful brush strokes

Example 1:

Oil Painting

Quantitative data:

picture is 10" by 14" with frame 14" by 18"

weighs 8.5 pounds surface area of painting is 140 sq. in. cost $300

Production Technology:


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A system for scheduling the manufacture of products and managing stock inventory that aims to

optimize costs, minimize inventory and maintain a steady work flow. The modern production technology

that might be used by a manufacturing business can identify production blockages and sense capacity

constraints, and it does not usually operate at full capacity if sufficient inventory to meet demand

already exists.

Production technology is the study, development and implementation of sources, and invention of

products as well as the improvement in current products.

Planning, implementation, and control of industrial production processes to ensure smooth and efficient

operation. Production management techniques are used in both manufacturing and service industries.

Production management responsibilities include the traditional five M's: men , machines, methods,

materials, and money, product, price,promotion,place,pepole,

product,plant,process,programme,people

Metrology : The science that deals with measurement. A system of measurement.

The primary goal of statistical quality control is to maintain and improve processes through techniques

such as sampling and process improvement projects, which reduce variations in product. Statistical

process control uses control charts to monitor changes in processes, machinery, labor or the

environment. Inspections and sampling determine when a process is outside of the control parameters,

which can result in a reduction in quality

Q. 1)Concept of qaulity ?

We have all probably felt that sense of disappointment when something we have

purchased does not live up to expectations. It could be a CD that is scratched and

does not play properly, a new car with a number of rattles or the customer service

department who dont return your call. At the heart of meeting such expectations is the

notion of quality.

People define quality in many ways. Some think of quality as superiority or excellence,

others view it as a lack of manufacturing and service defects, still others think of quality

as related to product features or price. A study that asked managers of 86 firms in the

eastern United States to define quality produced several dozen different responses

including

Perfection

Consistency

Eliminating wastes

Speed of delivery

Compliance with policies and procedures

Providing a good, sable product

Doing it right the first time


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Pleasing customers

Total customer service and satisfaction

Reduce the total cost of the Product

The quality movement can trace its roots back to medieval Europe, where craftsmen beganorganizing into unions called guilds in the late 13th century.

Until the early 19th century, manufacturing in the industrialized world tended to follow thiscraftsmanship model. The factory system, with its emphasis on product inspection, started inGreat Britain in the mid-1750s and grew into the Industrial Revolution in the early 1800s.

In the early 20th century, manufacturers began to include quality processes in quality practices.

After the United States entered World War II, quality became a critical component of the wareffort: Bullets manufactured in one state, for example, had to work consistently in rifles madein another. The armed forces initially inspected virtually every unit of product; then to simplifyand speed up this process without compromising safety, the military began to use sampling

techniques for inspection, aided by the publication of military-specification standards andtraining courses in Walter Shewharts statistical process control techniques.

The birth of total quality in the United States came as a direct response to the qualityrevolution in Japan following World War II. The Japanese welcomed the input of AmericansJoseph M. Juran and W. Edwards Deming and rather than concentrating on inspection, focusedon improving all organizational processes through the people who used them.

Definition of Quality

Books, Quality Gurus,

Quality Institutes

Definition of Quality

Joseph M Juran Quality is fitness for use

Eugene Lodewick

Grant & Richard S

Leavenworth

Quality is convenient to think of all matters related to Q of

manufactured product in terms of these functions of ---

specification, production and inspection.

Phil ip B Crosby Quality is conformance to requirement, it is respect toHumanity.

W Edwards Demin g Quality should be aimed at the needs of the consumer present

and future.

Armand V

Feigenbaum

Quality is the total product and service characteristics of

marketing, engineering, manufacturing and maintenance

through which the product and service in use will meet the

expectation of the customer.


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Shigeru Mizuno Product quality encompasses those characteristics which the

product must possess, if it is to be used in the intended manner.

Genechi Teguch i Quality is the loss (from function variation and harmful effects) a

product causes to society after being shipped, other than any

losses caused by its intrinsic functions.

ISO 9000 Planned and systematic actions necessary to provide

adequate confidence that a product or service will satisfy given

requirements for quality.

American National

Standards Insti tute

Totality of the features and characteristics of a product that

bears on its ability to satisfy the stated or implied needs.

The Taylor System

Late in the 19th century the United States broke further from European tradition and adopted anew management approach developed by Frederick W. Taylor. Taylors goal was to increase

productivity without increasing the number of skilled craftsmen. He achieved this by assigningfactory planning to specialized engineers and by using craftsmen and supervisors, who had beendisplaced by the growth of factories, as inspectors and managers who executed the engineers

plans.

Taylors approach led to remarkable rises in productivity, but it had significant drawbacks:

Workers were once again stripped of their dwindling power, and the new emphasis onproductivity had a negative effect on quality.

To remedy the quality decline, factory managers created inspection departments to keepdefective products from reaching customers. If defective product did reach the customer, it wasmore common for upper managers to ask the inspector, Why did we let this get out? than to

ask the production manager, Why did we make it this way to begin with?

Quality controls, is a process by which entities review the quality of all factors involved in production.

Quality control (QC) is a procedure or set of procedures intended to ensure that a manufactured

product or performed service adheres to a defined set of quality criteria or meets the requirements of

the client or customer.

This approach places an emphasis on three aspects


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1) Elements such as controls, job management, defined and well managed processes performance and

identification of records

2)Competence, such as knowledge, skills, experience, and qualifications

3)Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team

spirit, and quality relationships.

Customer :- Automotive mirror manufacturer

Challenge:-Maintain quality control to keep continuous

supply of products to avoid line shutdown

Solution:-Anixters technical services teams stringent quality control measures.

Results

Randomly tested products regardless

of source location

Standardized fasteners used in production

Manufactured parts to specification

Benefits

Achieved zero parts per million defects

Expanded quality offerings/Stand as good quality product

Reduced shipping and freight time and costs

Challenge, Meet or exceed regulatory requirements and release product as quickly as possible.

Solution, Lab associates implement 5S principles, sorting material and equipment, setting everything in order by storing it incommon and highly visible locations, standardizing labels and driving sustainability with daily, weekly and monthlychecklists.

ResultsQC labs achieved zero observations following their most recent FDA audit. The inspectors even used the laboratories

5S processes to train their staff in best manufacturing practices. From a customer point of view, testing lead times

remains constant at industryleading levels of less than five days, despite a five-fold increase in output for critical

drugs.

increase the production rate, cost is reduced, testing leadtime reduced.

.Sort, Sort in order, shine,standardize,sustiability.


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Quality Control Objective : Improved company income,Cost reduction, Interchangability,Optrimum

Quality at min price,customers satifications,Quality mindness


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Quality Characteristics:

Appearance (dimension, chemical, sensory), performance, length of life, dependability, reliability,

durability, smell, taste, feel, sound, price.


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The cost of carrying out company quality function (meeting the quality needs of the customer) know as cost of quality

Value of Quality: with superior quality the company can earn higher share of market, firmer prices,few returns and complaint from the customers. It is this effect on income which makes quality to have

value. Hence makes the return direct or indirect gained by the manufacturers due to mission of

quality control.

Value of quality composed of:

1) Value inherent in the design

2) Value inherent in the conformance to that design.

The value inherent in the design usually called as grade. Grade is the variation in the

specification for the same functional use. Difference in grade may involve difference in:

Life of the product, appearance, interchangeability, reliability, versatility, ability to take occasional

overloads luxury features etc.

Quality Specification: A specification is a definition of design. The design remains a concept mind of

the designer until the he defines it through verbal description, sample, drawing etc. The quality

specification includes,


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1) Specification of tolerance on various parts.

2) Material specification.

3) Process specification.

4) Method of test

5) Criteria for acceptance and rejection

6) Method of use. One Specification may be necessary or separate specification may be

necessary to desired quality characteristics in the material, parts products etc.

Need of specification

1) It helps the manufacturing departments to know what exactly is to be produced.

2) The raw material, process, equipments, skill etc. required producing the product of designed

quality.

3) To discriminate between defective and non defective products.

4) To decide test standards, inspections and test devices required.

5) To decide what is the exact requirements of the buyers.

Once a definition is available any one of the parties in the industries can communicate any

other and use the shorthand description to define a complex product.

Inspection: means checking of the material, products or components of products at various stages in

manufacturing. It includes 1) The interpretation of a specification. 2) Measurements of the product.

1) Receiving Inspection 2) In process Inspection 3) Finished good inspection 4) To maintain

customer relationship 5) Gauge Maintains 6) Test Equipments maintains 7) Decision of

Salvage.

Inspection means checking the characteristicsof a product to ensure that conformity to a set

of specifications is met. Sometimes it meanschecking 100% of a batch of product;sometimes it means checking only somesamples (in that latter case, it is exactly thesame as "statistical quality control".

Quality control usually means only checkingthe conformity of products already made. It

comprises inspection and other tests such aslab tests. Some people use quality control todesignate some more upstream activities thataim at preventing quality issues (usuallythese activities are called "qualityassurance").


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Acceptance Function Prevention Function

Finished Good Data analysis for design of experiments.

Only inspection Several Procedure and methods

Special Instrument needed No special needed


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The cost of carrying out company quality function (meeting the quality needs of the customer) know as cost of quality

Value of Quality: with superior quality the company can earn higher share of market, firmer prices,few returns and complaint from the customers. It is this effect on income which makes quality to have

value. Hence makes the return direct or indirect gained by the manufacturers due to mission of

quality control.

Value of quality composed of:

3) Value inherent in the design

4) Value inherent in the conformance to that design.

The value inherent in the design usually called as grade. Grade is the variation in the

specification for the same functional use. Difference in grade may involve difference in:

Life of the product, appearance, interchangeability, reliability, versatility, ability to take occasional

overloads luxury features etc.

Quality Specification: A specification is a definition of design. The design remains a concept mind of

the designer until the he defines it through verbal description, sample, drawing etc. The quality

specification includes,


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7) Specification of tolerance on various parts.

8) Material specification.

9) Process specification.

10)Method of test

11)Criteria for acceptance and rejection

12)Method of use. One Specification may be necessary or separate specification may be

necessary to desired quality characteristics in the material, parts products etc.

Need of specification

6) It helps the manufacturing departments to know what exactly is to be produced.

7) The raw material, process, equipments, skill etc. required producing the product of designed

quality.

8) To discriminate between defective and non defective products.

9) To decide test standards, inspections and test devices required.

10)To decide what is the exact requirements of the buyers.

Once a definition is available any one of the parties in the industries can communicate any

other and use the shorthand description to define a complex product.

Inspection: means checking of the material, products or components of products at various stages in

manufacturing. It includes 1) The interpretation of a specification. 2) Measurements of the product.

2) Receiving Inspection 2) In process Inspection 3) Finished good inspection 4) To maintain

customer relationship 5) Gauge Maintains 6) Test Equipments maintains 7) Decision of

Salvage.

Inspection means checking the characteristicsof a product to ensure that conformity to a set

of specifications is met. Sometimes it meanschecking 100% of a batch of product;sometimes it means checking only somesamples (in that latter case, it is exactly thesame as "statistical quality control".

Quality control usually means only checkingthe conformity of products already made. It

comprises inspection and other tests such aslab tests. Some people use quality control todesignate some more upstream activities thataim at preventing quality issues (usuallythese activities are called "qualityassurance").


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Acceptance Function Prevention Function

Finished Good Data analysis for design of experiments.

Only inspection Several Procedure and methods

Special Instrument needed No special needed


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Quality assurance (QA) refers to the planned and systematic activities implemented in a quality system so

that quality requirements for a product or service will be fulfilled. It is the systematic measurement,

comparison with a standard, monitoring of processes and an associated feedback loop that confers error

prevention. This can be contrasted with Quality "Control", which is focused on process outputs. Two

principles included in QA are: "Fit for purpose", the product should be suitable for the intended purpose;

and "Right first time", mistakes should be eliminated. QA includes management of thequality of raw

materials, assemblies, products and components, services related to production, and management,

production and inspection processes

Assurance Function

Special techniques are needed
http://en.wikipedia.org/wiki/Quality_%28business%29http://en.wikipedia.org/wiki/Quality_%28business%29


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Inspection planning market quality determination

Collecting data can be easy and fun. But sometimes it can be hard to tell other people about what you

have found. Thats why we use statistics. Two kinds of statistics are frequently used to describe data.

They are measures of central tendency and dispersion. These are often called descriptive statistics

because they can help you describe your data.

Mean, median and mode

These are all measures of central tendency. They help summarize a bunch of scores with a single

number. Suppose you want to describe a bunch of data that you collected to a friend for a particular

variable like height of students in your class. One way would be to read each height you recorded to

your friend. Your friend would listen to all of the heights and then come to a conclusion about how tall

students generally are in your class But this would take too much time. Especially if you are in a class of

200 or 300 students! Another way to communicate with your friend would be to use measures of central

tendency like the mean, median and mode. They help you summarize bunches of numbers with one or

just a few numbers. They make telling people about your data easy.

Range, variance and standard deviation

These are all measures of dispersion. These help you to know the spread of scores within a bunch of

scores. Are the scores really close together or are they really far apart? For example, if you were

describing the heights of students in your class to a friend, they might want to know how much theheights vary. Are all the men about 5 feet 11 inches within a few centimeters or so? Or is there a lot of

variation where some men are 5 feet and others are 6 foot 5 inches? Measures of dispersion like the

range, variance and standard deviation tell you about the spread of scores in a data set. Like central

tendency, they help you summarize a bunch of numbers with one or just a few numbers

An external customerof an organization is a customer who is not directly connected to that

organization.[7][8]
http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200152.E2.80.9353-7http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200152.E2.80.9353-7http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200152.E2.80.9353-7http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200152.E2.80.9353-7http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200152.E2.80.9353-7


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An internal customeris a customer who is directly connected to an organization, and is usually

(but not necessarily) internal to the organization. Internal customers are usuallystakeholders,

employees,orshareholders,but the definition also encompassescreditorsandexternal

regulators.[9][8]

Strengthened competitive position Adaptability to changing or emerging market conditions and to environmental and other

government regulations Higher productivity Enhanced market image Elimination of defects and waste Reduced costs and better cost management Higher profitability Improved customer focus and satisfaction

Increased customer loyalty and retention Increased job security Improved employee morale Enhanced shareholder and stakeholder value Improved and innovative processes

Instatisticsandprobability theory,standard deviation(represented by the symbol)shows how much

variation or "dispersion"exists from the average (mean,or expected value). A low standard deviation

indicates that the data points tend to be very close to themean,whereas high standard deviation

indicates that the data points are spread out over a large range of values.

thedescriptive statistics,the rangeis the length of the smallest interval which contains all thedata. It is calculated by subtracting the smallest observation (sample minimum)from the greatest(sample maximum)and provides an indication ofstatistical dispersion.

It is measured in the same units as the data. Since it only depends on two of the observations, it isa poor and weak measure of dispersion except when the sample size is large.

Variance is the sum of the square of the deviation from the arithmetic mean divided by the no.Of observation. ` n` in the other words variance is the square of the sta. deviations.

Standard deviation is a number that tells you approximately how far the values in a data set deviate

from the mean (the average).

wo types of process data:

1. Variable: continuous data. Things we can measure. Example includes length, weight,time, temperature, diameter, etc.

2. Attribute: discrete data. Things we count. Examples include number or percent defectiveitems in a lot, number of defects per item etc.
http://en.wikipedia.org/wiki/Stakeholder_%28corporate%29http://en.wikipedia.org/wiki/Stakeholder_%28corporate%29http://en.wikipedia.org/wiki/Stakeholder_%28corporate%29http://en.wikipedia.org/wiki/Employeehttp://en.wikipedia.org/wiki/Employeehttp://en.wikipedia.org/wiki/Shareholderhttp://en.wikipedia.org/wiki/Shareholderhttp://en.wikipedia.org/wiki/Shareholderhttp://en.wikipedia.org/wiki/Creditorhttp://en.wikipedia.org/wiki/Creditorhttp://en.wikipedia.org/wiki/Creditorhttp://en.wikipedia.org/wiki/Regulator_%28economics%29http://en.wikipedia.org/wiki/Regulator_%28economics%29http://en.wikipedia.org/wiki/Regulator_%28economics%29http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200153-9http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200153-9http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200153-9http://en.wikipedia.org/wiki/Statisticshttp://en.wikipedia.org/wiki/Statisticshttp://en.wikipedia.org/wiki/Statisticshttp://en.wikipedia.org/wiki/Probability_theoryhttp://en.wikipedia.org/wiki/Probability_theoryhttp://en.wikipedia.org/wiki/Probability_theoryhttp://en.wikipedia.org/wiki/Sigmahttp://en.wikipedia.org/wiki/Sigmahttp://en.wikipedia.org/wiki/Sigmahttp://en.wikipedia.org/wiki/Statistical_dispersionhttp://en.wikipedia.org/wiki/Statistical_dispersionhttp://en.wikipedia.org/wiki/Statistical_dispersionhttp://en.wikipedia.org/wiki/Meanhttp://en.wikipedia.org/wiki/Meanhttp://en.wikipedia.org/wiki/Meanhttp://en.wikipedia.org/wiki/Meanhttp://en.wikipedia.org/wiki/Meanhttp://en.wikipedia.org/wiki/Meanhttp://en.wikipedia.org/wiki/Descriptive_statisticshttp://en.wikipedia.org/wiki/Descriptive_statisticshttp://en.wikipedia.org/wiki/Descriptive_statisticshttp://en.wikipedia.org/wiki/Sample_minimumhttp://en.wikipedia.org/wiki/Sample_minimumhttp://en.wikipedia.org/wiki/Sample_minimumhttp://en.wikipedia.org/wiki/Sample_maximumhttp://en.wikipedia.org/wiki/Sample_maximumhttp://en.wikipedia.org/wiki/Sample_maximumhttp://en.wikipedia.org/wiki/Statistical_dispersionhttp://en.wikipedia.org/wiki/Statistical_dispersionhttp://en.wikipedia.org/wiki/Statistical_dispersionhttp://en.wikipedia.org/wiki/Statistical_dispersionhttp://en.wikipedia.org/wiki/Sample_maximumhttp://en.wikipedia.org/wiki/Sample_minimumhttp://en.wikipedia.org/wiki/Descriptive_statisticshttp://en.wikipedia.org/wiki/Meanhttp://en.wikipedia.org/wiki/Meanhttp://en.wikipedia.org/wiki/Statistical_dispersionhttp://en.wikipedia.org/wiki/Sigmahttp://en.wikipedia.org/wiki/Probability_theoryhttp://en.wikipedia.org/wiki/Statisticshttp://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200153-9http://en.wikipedia.org/wiki/Customer#cite_note-FOOTNOTETennant200153-9http://en.wikipedia.org/wiki/Regulator_%28economics%29http://en.wikipedia.org/wiki/Regulator_%28economics%29http://en.wikipedia.org/wiki/Creditorhttp://en.wikipedia.org/wiki/Shareholderhttp://en.wikipedia.org/wiki/Employeehttp://en.wikipedia.org/wiki/Stakeholder_%28corporate%29


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