AUTHOR: JONEY

CLASS CODE: IE673 DL

DUE DATE: 05/09/2014

ELearning Pack ID: IE673-Spring-2014-63-32

ALL CONTENT OF THIS ASSIGNMENT 5 IS SUBMITTTED BY JONEY; THE TEMPLATES USED ARE DERIVED FROM THE ELEARNING PACK PRODUCED BY DR. PAUL RANKY.

COLLABORATIVE COMPANIES: Grand Packing, IVD Technology, Muratec and Buckhorn Inc.

CONTENTS:

1. Introduction and Objectives of the Project

2. A brief description of the methodologies applied

3. The Main Body of the project

I) Part Zero (Rework Assignment 0 through four)

II) Part One

A) RFID in CIMpgr Process Models

B) RFID in CORA

C) RFID in PFRA Model

III) Part Two

a) TQM Audit & Audit Issues

b) Panorama Navigation Map

IV) Part Three

a) Video Conferencing Session JONEY & MARTHA

b) Social Networking Part of Assignment 5

4. Summary

5. Further work needed/proposed

6. References and Bibliography

7. Appendix

8. Grade

1. Introduction and Objectives of the Project:

Joney Solutions is an eco-friendly company which employs the best practices to recycle packaging products from its suppliers to its customers. Our main objective is to reduce carbon footprint on the planet by applying TQM methods in each and every process. This company has an immense reputation and will strive to offer incredible benefits to its customers and the community as a whole. Its main collaborative companies are Buckhorn Inc., IVD Tech, Brand packaging and Muratec. These companies are also quality and eco-oriented. Sustainability is the main core value of our 5+ company.

Our main focus is to provide high quality packaging materials to our clients with a new feature of traceability and also to audit our processes with the help of TQM Audit steps.

We will use the RFID tags to tag each of our products as they come from supplies and as they are processed and shipped to our clients. We will also work on the RFID data to trace our products and ensure that we are recycling all the components that can be recycled at all stages of production.

We will perform a TQM audit on all our processes to check whether we are complying with the ISO 9001:2008 principles and take corrective steps when necessary.

2. A brief description of the methodologies applied:

As recommended by Dr. Paul Ranky and for the purposes of this assignment, we are going to use the Radio Frequency Identification (RFID) tags which will help us trace our components that enter our facility. We will also conduct a TQM audit to ensure that we are following quality standards that meets our client’s expectations.

These RFID tags are electronic tags which read information with the help of an antenna and store information. The data is then transferred to a computer where information can be viewed and products can be traced. This is a great technology for traceability. It is real time and does not involve human involvement. IVD Tech will collaborate with our partners to implement this technology.

In addition audit is a systematic and independent examination to determine whether quality activities and related results comply with planned processes and arrangements, and whether or not these arrangements are implemented effectively, and are suitable to achieve management objectives of our 5+ company.

Audits can be conducted for internal or external purposes. Audits help to implement and enforce the continual improvement principle for the organization, to encourage overall performance improvement processes as a permanent, long-term, continuous objective of Joney Solutions.

3. The Main Body of the Project:

I) Part Zero

This class has taught me a lot of new concepts which are of great value to my processes and product:

Assignment 0: No improvement required

Assignment 1: Dr. Ranky’s comments: Assign 1 has syntax errors, also a layer is missing; also the soc. netw. is missing: Reworked ( including purpose, viewpoint and social networking included in the assignment but the link wasn’t Highlighted properly and it is now improved.

Assignment 2: Dr Ranky’s Comments: The CORA analysis of the results is slim and the soc. netw. Is missing

The CORA Analysis has been improved with highlighted link to Social Networking.

MIDTERM: No improvement required

Assignment 3: Dr. Ranky’s Comments: good, but the analysis of the results should be improved; at present a bit thin. I have improved on the Analysis of Results by including a R-Chart that is out of control.

Assignment 4: Dr. Ranky’s Comments: is also good, but you should have more entries in the PFRA chart and then analyze the results in more detail:

II) Part One

A) RFID in CIMpgr Process Models:

As we have learned from previous chapters, a complete CIMpgr model is a set of diagrams which systematically illustrate the object-to-object relationships between the objects, this include their functions and entities. Our 5+ company plans to introduce RFID tags in the CIMpgr process model to help us trace our components as they enter the warehouse from our suppliers. Once the products enter our warehouse, we send them through a Material Inspection team so that they could be inspected and separated into different categories if need be. At this stage, we will have RFID tags on the products and the RFID scanner with scan all the products as they are inspected and separated. The data from the scanner will be used for tracing each product and ensuring that it is quality controlled, free of any contamination and if recyclable or it is disposed. The RFID tags will be removed before the materials goes Q & A or recycling but the scanner will be attached to the recycling machines which will be able to detect which products were inspected or recycled. This way we will be able to keep track of our incoming inventory and ensure that products are free from bio contamination and above all that we are sustainable at all times.

These processes are critical and will benefit our customers and company immensely. We can tell our suppliers to use RFID tags in their inventory when they are shipping out raw materials to our company as

well our collaborative companies when shipping packaging products to our customers. By so doing, we will be able to keep track of their products being used by other customers and will be able to collect the used products in a timely manner. We will be able to increase our sales of recycled raw materials to our main customers. Our main customers will also benefit because they will come to know from the RFID tags if the product they sold has completed its useful life. They will then sell new products to their customers thereby increasing their sales.

B) RFID in CORA

The benefits of the RFID technology in Cora cannot be overstated. In the CORA spreadsheet, we will specify RFID as an engineering solution to meet our customers’ needs. When suppliers process our orders or our clients request packaging products or dispose used packages with one of our collaborative companies it is indicated in our systems. This tells us what quantities and exactly what kind of packages our company will have to recycle. Based on our customers’ requirements of packaging solutions, we will be products products whose raw materials are free of bio contamination and cost effective.

Implementing RFID tags has many benefits to our company and our customers. Our 5+ company will be able to meet the demands of the market in a timely fashion by delivering high quality packaging products which our customer’s demand. This will increase our customers’ satisfaction and help us get more business from them. From the customers’ perspective, they will be able to meet the demands of their products in the market by getting timely supply of raw materials from us while keeping the environment safe,

Click here for CORA Spreadsheet

C) RFID in PFRA Model

RFID tags critical in reducing risks at all levels in the PFRA model. By introducing RFID tags to the control systems, we will be able to monitor the performance of the control systems in terms of checking whether our processing plant is operating at full capacity and meeting the needs of our customers. This will help in reducing risks arising from of control systems stand down and our 5+ company will avoid analyzing wrong data. The RFID tags will help process data correctly and help us in making informed decisions.

The RFID tags will benefit our 5+ company and our customers. As a team, if we get accurate information on whether the plant running at full capacity, this therefore means that we are able to provide high quality packaging solutions to our customers in an environmentally friendly way . Our company’s reputation with respect to sustainability will increase and people will have more confidence in our processes and performance.

Click here for PFRA Spreadsheet

III) Part Two

a) TQM Audit & Audit Issues:

Quality audit is the process of systematic examination of a quality system carried out by an internal or external quality auditor or an audit team. It is an important part of organization's quality management system and is a key element in the ISO quality system standard, ISO 9001.

Assignment 0:

At this stage of the assignment, our 5th company was set up and we documented what quality focus processes we had to use in the packaging services and our main goal was to provide eco-friendly packaging solutions to our customers at affordable costs; Our Company is going to design packaging solutions that is reusable with better Green characteristics. We plan to recycle products like tungsten and plastic and other various products using non-toxic materials which will not contaminate the factory workers slowing down production. These new methods packaging and recycling helps save the earth by reducing the landfills required to burry these products, while at the same time we also create green sustainable packaging products which increases overall sales and helps our company stay competitive in relation to its competitors.

Assignment 1:

In this assignment we had to develop Joney Solution’s modular, object-oriented TQM system model/ process model in CIMpg. and we also learnt to streamline our processes with CIMpgr modeling using Concurrent Engineering (CE) methods along with methods to increase its durability and sustainability in our company 5+ packaging company . This technique helps us meet the requirements of the customers as well eco-friendly processes. This increases process functionality and improves reliability. Analyzing these modeling processes has helped our team understand and define the logical decisions made by Joney solutions and its collaborative companies.

Assignment 2:

In the course of this assignment we learnt about the component oriented TQM related customer requirements analysis to find out the needs of the customers and how we can deliver best packaging solutions to them. This method is very helpful in not only listing the requirements of the customers but the engineering solutions as well. We have also learned new successful methods and adapted new technologies and designs for making out products more effectively reusable. We will have to source the best packaging raw materials free from contamination , recyclable and green materials which will be processes through a energy saving, non-toxic facilities to provide our clients with easy to use, and green packaging products. These products will be decomposed systematically with different methods and treatments as described previously to make green products which meet the requirements of the customers.

Assignment 3:

This assignment gave us an insight and an understanding about improvement methodologies using Process Control Methods. We developed technologies and methods to process packaging materials and waste disposal, plastic of different compositions and with different methods. We also developed more eco-friendly methods in recycling these products. We had a clear understanding of the objective of creating and maintaining these processes; controlling the processes to make sure that the processes don’t go out of control on the boundaries selected. We also used a quantitative and computational solution to keep processes in control. We could not have achieved this without using the Control Charts for Variables and Attributes provided in the e-Book by Professor Ranky.

Assignment 4:

This assignment was quality driven and we realized that for quality to be achieved we need to perform risk analysis methods. In addition, this assignment helped us to identify the risks associated with certain failure modes in the manufacturing packaging processes using the newly developed Process Failure Risk Analysis (PFRA) method. This tool is used to identify the potential failure modes. Most importantly, these failure modes are addressed before they even occur. The PFRA methods helped identify any potentially toxic process within Joney Solutions. This helps us bring in more green products in our 5+ company.

Audit Issues:

Reading Chapter 20 in the Ebook by Professor Ranky on TQM we learn how to answer auditing background questions related to packaging processing and learn how to run audits for it. Auditing has many requirements call for following established and consistent auditing principles, which comply with international ISO standards.

By making our packaging products more sustainably green and non-toxic, this will definitely help us reduce its adverse impact on the environment and make the world a better place for our generations to come. To achieve and maintain customer satisfaction from our clients we need to continuously improve our current processes and products and also try inventing new technologies with the help of our collaborative companies like IVD Technology.

The ISO, international organizations of standardization has established an ISO19011:2002 to provide guidance on how the audits should be planned, performed, reported and recorded. We will follow these systematic processes according to a checklist of process steps. The following are some auditing challenging questions that must be addressed.

1. Who should be audited?

All packaging processes, product and new technologies at Joney Solutions and its collaborative companies have to be audited for green/sustainable compliance.

2. Why should we audit?

Auditing our processes will help us find out about all products in our 5+ company that are bio contaminated which will help us find methods to reduce its toxic effect on our employees, customers and the environment as a whole.

3. What type of audit should be conducted? An internal Audit will be conducted by our 5th company audit team because they understand our systems for management review and other internal purposes. Moreover, the internal process so that it may form the basis for our company’s self-declaration of conformity with the ISO standards.

4. What should be the depth and scope of the audit?

Scope will include the physical location of our 5+ company as well as the time period to be covered during the audit. The scope will consist of activities and processes that our company follows; they have to maintain not making harmful products and check the toxicity so that there is no harm to the environment. We will emphasis the following relations:

Customer Focus

ISO 9001:2008 Standard Conformity

Quality Assurance/control

Sustainable Green Focus

5. When should audit take place?

There is an audit schedule for Joney solutions but the schedule is subject to change may be because of the introduction of or changes to packaging raw materials, products, equipment’s or processes. Increase complaints from our customers could trigger an audit or consistent product failure as well. Sometimes randomly auditing will be conducted with notice for performance standards.

6. Who will perform the audit?

Auditing will be conducted by a team consisting of persons who possesses the required competence to conduct an audit supported by technical experts in Environmental Biotechnologies. One of the auditors of the audit team will be appointed as the audit team leader based on experience. Our main goal is to make our products green and non-toxic so Environmental Engineers preferably will do the auditing of our processes.

7. Is the audit schedule prepared?

The audit schedule may be planned for a specific time frame and directed towards a specific purpose. However our company will follow a very basic and effective audit schedules and when need arises.

Our management system auditing stages include the following;

Audit Initiation-

This is when to appoint audit leader, audit objectives, determine feasibility of the audit and finally establish the initial (formal or informal) with the audited. The workers will have the opportunity to interact with auditing team while monitor processes together.

Document Review-

The basic process models, the CORA or the PFRA records are maintained and these records are checked with the previous audit records. This way they will know what has changed from the previous audit and

what changes have to be made further in the processes. Comparison of the audit report will help us determine if the audit is necessary or to suspend it.

Preparing for an onsite audit- on-site

This is important because at this stage the audit objective is defined and the audit criteria and reference documents are reviewed. The plan must be reviewed and accepted by our client prior to the commencement of the onsite audit activities.

Conducting an on-site audit-

At this stage, meetings should be held from time to time because communication is critical among audit team members. Meetings will help them to exchange information, assess audit progress and reassigning tasks amongst members. Also, we are maintaining records of all our audits either in excel files or recording it using panorama technology we will know exactly how much of toxic products are there and the different types of toxic components they release so that we can monitor this on these excel sheets and with the help of numeric or graphs introduce processes to minimize this toxicity. Only verifiable information will be treated as audit evidence.

Audit reporting-

Reports will be the responsibility of the auditing team and it should provide a fair, accurate, concise and clear record of the audit. All the audit reports have to be saved in an orderly manner and they should be safe location so they can be referenced and compared to previous records and the processes can be kept in control.

Audit completion-

Documents relating to the audit will be maintained for 3 years and destroyed according to our 5+ company policy. In addition, except required by law audit team members should maintain strict confidentiality of the audit report. This audit information is very important and has to be maintained for future use.

Audit follow up-

Follow up is required because the conclusion indicated that corrective, preventive and improvement action be taken. There will be more than one audit each year all the materials collected in the first audit will be monitored again the same year. The completion and effectiveness of the corrective action should be verified.

b) Panorama Navigation Maps:

Dr.Paul Ranky and his brother developed this technology; it is very user friendly and can be very useful for our 5+ company principally in our auditing environment, understanding our packaging processes, for modeling as well as for improving our processes.

These 3D pictures with a 360 degrees view will enable Joney Solutions and its collaborative companies to identify and understand complex processes or customer requirement though out our 5+ company.

This technology has the ability to zoom in, the audio capability, video and 3D graphical interface means that it can attract the attention of the end user through audio sound and view every aspect of processing remotely or from any part of the world. This is very critical as every audit team member to understand the process model through visual or virtual environment in real time.

More over a lot of information or data can be compressed into each interactive module by using live process or models which supports sustainable green engineering reducing the use of paper as well waste reduction. These 360 degrees pictures can be used by our engineers to capture and analyze complex high speed process such as automation process for quality audit.

IV) Part Three

a) Video Conferencing Session JONEY & MARTHA

Our video conference commenced at 9 pm and during video conference we shared ideas about cost effective recycling in an eco-friendly environment. We used Skype because it is a friendly application and below are three screen shots during my conversation with Martha. The following are some keys questions and answers that were accomplished during our VC session.

1. What was the purpose of our video conferencing session?

The primary objective of our video conferencing is to discuss process design of our projects; in addition we have to discuss about ways and means of creating a collaborative sustainable green as well as quality audit teams spirit practices in our companies. We went further to discuss process audits and continuous improvement of processes with the aid of CIMpgr, CORA, PFRA and Control charts.

2. What software did we use for the VC and How?

As I mentioned earlier, we used Skype and Martha was on campus while I was at home. It saved me time of driving 4 miles from Orange and by so doing reducing the fuel cost that I would have incurred if I had to drive to school. In addition reduces the pollution or emissions from the car to the atmosphere.

3. What we discuss and achieved during the VC session?

Prior to our Video conference, we both went through each other’s webpage just to have an insight about our projects. Thereafter, Martha started by asking how I get raw materials for my company and further questioned about our processes from start to finish. She was so keen on green sustainability and she wanted to know how we collaborate with our partners companies to implement eco-friendly processes.

I also asked questions about her company and how many employees she thought she could start up with and various how she is plans to implement green sustainability. She explained all these to me and she was very knowledgeable in her explanation.

I would say that the benefit of this VC was mutual because we discussed about the importance of the CIMpgr diagrams, the CORA, PFRA and the Control Charts. We also agreed that the RFID technology would be an idle tool to use in our companies especially monitoring processes remotely.

4. How did we like the video-conferencing approach for collaborative problem solving?

Indeed I would say it was really interesting because this was the first time I was Skype in an academic setting. This reminded us that our companies can use social networking to collaborate from any part of the world in real time. This reminded us about the Navigation tool developed by Dr. Ranky which in enables us to view processes from different locations in virtual mode.

5. What were the challenges?

Technical problems were one of the challenges we faced and I guess one of us had a lower bandwidth than other and we were disconnected twice and we didn’t foresee this happening. This often resulted to poor quality sound and video quality.

We agreed that in a business setting the VC may pose a serious security breach because you are not sure who is following your conversation from the other end.

Finally, as you can see the screen shots below, Skype will not permit the users to adjust the mini screen so the images are equal. There is always an enlarged screen and the little screen at the corner.

6. What worked well and what did not and why?

The fact that we could see and talk to each other in real time was really cool. In addition it saved me money and time and at the same time reduced the monoxide production because I didn’t have to drive. This is something we really agreed upon that if our companies and their collaborative companies use video conferencing for meetings it will save a lot of resources including the environmental impact. The only thing that did not work well was the fact that at work moment my home started ringing and caused some distraction for a few minutes.

7. In comparison to face-to-face visit VC, what is the estimated carbon foot print saving to the environment? How did I calculate this result?

One of the carbon foot print reduction was saving paper because we did not use any paper during the video conference.

Total CO2 Produced = Driving Miles Traveled / Miles per Gallon * CO2 Produced per Gallon Burned

The Video Conference saved the environment 16 lbs. of CO2 and saved me $ 5.95 and this carbon footprint is calculated by

The following inputs:

Number of cars that had to drive =1

The average one-way trip length in miles = 4 x 2 based off my physical address 248 Reynolds Ter Orange NJ 07050

1000 lbs. CO2 cost $5.95

8. What are the green engineering benefits of using VC?

It is evident that every time we travel by car the car produces enormous amounts of CO2 which has a negative impact on the environment. So by using Video Conference instead of face to face meetings, we are saving the environment from these gases. Our web and video conferencing will further support green initiatives and greenhouse gas reduction efforts.

b) Social Networking Part of Assignment 5

4. Summary:

We can epitomize that Joney Solutions has benefited from all the technologies from the EBook; this is evidenced by the fact that our company has been able to conduct meaningful audits and improved toxic free packaging raw materials and green finished products through the RFID technology. The CIMpgr model, CORA Matrix and PFRA Spreadsheet enabled our company and its collaborative companies to improve product quality, customer satisfaction and achieved Total quality management at all levels of production. We were able to focus on developing engineering solutions that supported green sustainable

engineering and our audit teams inspected the process identifying processes that do not meet quality requirements and are eco-friendly.

5. Further work needed/proposed:

We have learned from this project that it’s vital for any organization to constantly conduct internal audits of its processes so that we can identify those processes that not ISO 2001:2008 standards compliant. For our processes to comply with such standards, Joney Solutions had audit teams that inspected and modified our processes constantly.

However, it is highly recommended our company continues to collaborate with IVD Technology because of its technological advancements to improve our processes. It is also recommended that more collaborative effort with Brand Packaging through its training www.packagingthatsells.com direct customer input can be accomplished in order to increase market share. Finally, improved collaboration with Buckhorn Inc. and Muratec in the implementation of the RFID technology will go a long way to improve product quality, manufacturing process improvement, customer satisfaction and above all our emphasis on green sustainable packaging solutions will become more affordable.

6. References and Bibliography:

ELearning Pack or eBook provided for the class

http://www.terrapass.com/event-conference-carbon-footprint-calculator/

http://www.praxiom.com/iso-new.htm

http://www.buckhorninc.com/

http://www.brandpackaging.com/

http://www.ivdtechnology

www.iso.org/iso/home.htm

www.cimwareukandusa.com

7. Appendix:

8. Grade:

I have exploited all the resources provided for in the course as per the check off list and rework for previous sections done as per Dr. Ranky’s comments. So I will reward myself with an ‘A’.