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Study of quality parameters across various industries
Mentor
Proff. Rakesh jain
Submitted by:
Abhishek Agarwal 2009UME430
Sahaj Agarwal 2009UME435
Rohit Upadhyay 2009UME429
Upendra Yadav 2009UME444
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ABSTRACT
Quality is the first and foremost requirement of
industries in this competitive world today. In order to reduce
time, inventory, cost and to improve the efficiency of current
system company need to follow certain quality parameters.
Quality parameters are not a theoretical concept any more they
need to be implemented and improved with time.
In this project we are focusing on 28 of these quality
parameters and their implementation in certain Indian industries.
This report contains data on these quality parameters from
Hindustan Coca Cola Pvt. Ltd., Hero Moto corp. Pvt. Ltd. and Su-
Kam Power System Ltd.
Each of the quality parameters is being explained and
discussed with respect to the company, and analysis is being done.
Some implementation level was suggested by the quality
managers and workers in the manufacturing line.
Quality parameters of different companies will be
compared and results will be analysed after visiting all the
companies and collection of data.
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INTRODUCTION
Today achieving customer satisfaction is the most
important objective of the organizations and quality management
is the most effective approach to achieve this objective. As the
Japanese conquered the whole world of manufacturing by their
quality management strategies, every other industry in any part of
the world realized the importance of quality and customer
satisfaction.
Every organization worries about their competition and
plan to survive in this competitive market. Quality management
consists of concepts, methods and applications that enable
organizations to reap real benefits from improvement in quality,
performance and competitiveness. Using those tools they can
know their present status among its competition, their
weaknesses and scope of improvement.
Indian organizations have also understood that
improvement in organizational quality performance is necessary
but implementation level is still lower than the awareness level.
Few companies are not properly aware and consider these quality
management activities as time wasting.
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LITERATURE REVIEW
Quality management has aroused great interest among
academicians and researchers all over the world. Many studies
dealing with quality management has been reported in leading
management journals. In the late 19th century pioneers such as
Frederick Winslow and Henry Ford recognized the limitation of
mass production and the importance of quality management. In
1951 Joseph Juran published a Quality Control Handbook. Quality
as a profession evolved during the second half of twentieth
century and has evolved since then. Quality control activities were
predominant in
research papers and journals have been published giving new
quality tools and parameters and improving the previous one and
the benefits of their implementation in various industries. We
have taken few of them to find out the most important quality
tools and parameters to be implemented in industries which are
as follows:
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Quality tools and parameters
(Definitions)
Pareto diagram :
By plotting the cumulative frequencies of the
problems and by applying 80:20 rule find out the most frequently
occurring problems. This rule states that for 80% of errors only
ge the
causes of errors in descending order of their frequencies and
identify those 20% causes of 80% errors.
Fishbone diagram:
It provides a pictorial display of list in which we
identify and organise possible causes of problems, or factors
needed to ensure success of some effort. In this diagram we first
put the primary causes of a problem and them by going deeper
and deeper we identify secondary causes and put them on the
diagram and try to remove those problems.
Control chart:
It is a graphical display of quality characteristic that
has been measured or computed from a sample versus the sample
number. From this we can find out whether the calculations or
measurements are in the limits or not.
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Run chart:
It is same as control chart but it focuses more on
time pattern while a control chart focuses more on acceptable
limits of process.
Histograms:
It is a representation of data in bars to determine
where the greatest amount of variation occurs in process, or to
determine if process specifications are exceeded
Scatter diagram:
It is a graphical depiction of regression analysis and
points out the important relationship between two variables. By
presenting the data on a graph it only shows the relationship,
increasing, decreasing, constant or periodic.
Check sheets:
Used to organise the data and count the defective by
types. They can be in the form of spread sheets arranging data in
matrix form.
Brainstorming:
It is group or individual creativity technique by
which efforts are made to find a conclusion for a specific problem
by gathering a list of ides spontaneously. Persons from different
departments sit together and give their own ideas about the
problem and try to find out the best possible solution from those
ideas.
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Suggestion scheme:
It is a formal mechanism, which encourages
employees to contribute constructive ideas for improving the
organisation. By doing this the employees feels a responsibility
and his importance to the organization and work for its
improvement.
Plan-Do-Check-Act:
It is a standardization of the problem solving process.
In this process firstly we plan the solution according to our
problem. Then we do as per the plan say, after that we check the
results. If the results are convincing enough then we act according
to the plan continuously.
Statistical process control:
It uses the statistical methods to monitor and control
a process. Statistical methods like run chart, control charts,
histogram etc.
5s:
It is the name of workpla
are seiri-sorting, seiton-setting in order, seiso-shine, seiketsu-
standardize, shitsuke-sustain.
Kaizen:
It is a Japanese name for continuous improvement. It
is done by improving the processes in small amounts but
continuously.
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Benchmarking:
It is a method of improving business performance by
learning from other companies and from other departments of the
same company, how to do things better in order to be the best in
the class.
Total productive maintenance:
In this tool the machine operator is trained to
perform day-to-day tasks of simple maintenance and fault-finding.
It reduces the time wastage and after effects of those faults.
Quality function deployment:
It focuses and coordinates skills within an
organization, first to design, then to manufacture and market
goods that customers want to purchase and will continue to
purchase. In this process we ask for customers demand in a
product and then try to implement in our product.
Design of experiment:
It is a method of designing of any information
gathering exercises where variation is present, whether under the
full control of the experiment or not.
Program evaluation and review technique:
It is a method to analyse and represent the tasks
involved in completing the given project.
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Failure mode and effect analysis:
In this method we review as many components,
assemblies and subsystems as possible to identify failure modes
and their causes and effects. We firstly disintegrate the product in
various parts and then try to find the causes of error and rate their
severity, occurrence and detection and calculate Risk priority
number (RPN) by formulae: RPN= S*O*D. the one with the
maximum RPN is most dangerous and we firstly remove that
cause of error.
Business process re-engineering:
It is a process of fundamental rethinking and radical
redesign of business process to achieve quantum leap
improvements in business results.
Process mapping:
It is a method of documentation of activities
involved in defining what a business identity does, who is
responsible, for what standard a business process should be
completed, and how the success of a business process can be
determined.
Measurement system analysis:
By taking different measurements and compiling it we
identify the component of variation in the measurements and try
to find out the causes for that irregularity or variation.
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6 sigma:
It is a management mandated and directed
improvement program focused on breakthroughs in financial
performance and customer satisfaction.
ISO 9000:2000 :
It is a family of standards related to quality
management system and designed to help organisations ensure
that they meet the needs of customer and other stakeholders
while meeting statutory and regulatory requirements related to
the product.
Just in time:
produce and
deliver finished goods just-in-time to be sold, sub-assemblies just-
in-time to be assembled into finished goods and purchase
materials just-in-time to be transformed into fabrication parts .
ISO 14000:
It provides practical tools to companies looking to
identify and control their environmental impact and constantly
improve their environmental performance. It is also a certification
which is given to the companies who follows the standards given
by ISO for environmental performance.
Value stream mapping:
In this method we design and analyse the flow of
materials and information required to bring a product or service
to the customer.
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Force field analysis:
It helps to make decision by analysing the forces for
and against a change. Can be used for two purposed: to decide
whether to go ahead with the change and to increase your chances
of success by strengthening the forces supporting the change and
weakening those against it.
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Research Objective
The main objective of our report is to understand the
quality management and its role towards business survival and
competitiveness. For this we will:
Study the quality parameters followed in industries.
Checking the extent of these parameters (by collecting the
data) and its effects.
Analyzing the measures and suggesting possible
improvements for optimum output.
Comparing the data of various industries visited and find out
the level of implementation of quality tools and parameters
and benefits they got from that.
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Hindustan Coca Cola Pvt. Ltd.
Type of Industry- Food Processing Industry
Products- Coca-cola, sprite, limca, thumsup,fanta, maaza, kinley (water and soda), minuite maid
Products manufactured in Hindustan Coca-Cola kaladera, Jaipur- Coca-Cola, Sprite, ThumsUp, Limca, Fanta
Turn-over-1100 cr.
Industry Scale- large scale
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Implementation of Various quality parameters
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Outcomes
Mostly all the parameters used being a food processing industry with huge competition in the market.
Japanese system used throughout the chain- from logistics to manufacturing to the sales and marketing (production and post-
production as well).
Shop floor was clear and clean with appropriate safety parameters used.
Not effective free flow due to some breakdown problems- mostly problems in the machinery.
Future prospect- Implementation of 6-sigma and proper free flow processing.
Removal of wastage the primary goal for production.
Very good use of all the standards and almost has all the verified standards needed for the industry.
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Su-Kam Power Systems Limited
Products inverters, UPS, battery, transformers, solar panel and
industrial power solution.
It is a manufacturing company with five factories in India (one at
Gurgaon and four at Baddi).
It is a medium scale company with a turnover of 700 crore.
We visited the Gurgaon plant where they only manufacture
inverters and transformers of different capacities.
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Implementation of Various quality parameters
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Outcome
Being an electronic and electrical company, needs an higher
level of quality products as lot of risk is involved in its
operations.
Company knows about the parameters but implementation level
is poor (internal audits, no fear).
Customer centered company and quality is being checked and
improved on customer feedback (outsourcing is done).
Line managers are not concerned and consider it a waste of
time. According to them real work is what machine does.
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Hero Motocorp Pvt. Ltd.
Industry type- Automobile Manufacturing Industry
Scale Large
Products- Hero Bikes- Splendor , Splendor Plus , CD Dawn,
CD Deluxe ,Passion Pro , NXG.
Turnover $ 4.4 billion
Plant Locations Dharuhera , Gurgaon , Haridwar .
Plant Visited - Dharuhera
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Implementation of Various quality parameters