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www.mindtrain.in ACHUTHAN RAJAGOPAL

Quality for Higher Productivity

Quality Is…

• Meeting Our Customer’s Requirements

• Doing Things Right the First Time;

• Consistency

• Freedom from Defects

• Continuous Improvement


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• Quality is the responsibility of the quality department ?

• (True or False)


False– Quality departments Only measure and report

conformance, demand corrective action, encourage defect prevention, teach quality improvement.

– Quality output is the responsibility of those who get paid doing it.


• Productivity = Output/ Input

Productivity is, for every unit of input what is output.


• Poor Quality Practices• Supervisors not giving clear instructions to workers• Each department working only for itself• Trying to control people through systems and not with

communication.• Not having clear parameters for quality – tolerance limit.• Philosophy “defects and errors are inevitable”; to err is

human.• Fire fighting, not addressing the root cause of the problem.• The “It’s not my problem” attitude

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How to maintain Quality :

• The road to perfect quality is through prevention, not inspection.

• Identifying and eliminating the causes of problems reduces rework, warranty costs, and inspection.

• Creating quality production does not cost money, it saves money.

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How to prevent Quality issues:

Secret of prevention is to look at the design and identify opportunities for error and eliminate those parts/process from the design. “Design For Manufacturability ( DFM)”

Quality for Higher ProductivityDesign For Manufacturability :•Simpler design with fewer parts•Simple production processes•Higher quality and reliability•Easier to repeat production


Evolution of Quality concept :

• Dr. Deming = Quality Circle in 50s and 60s= Involve key operators and take their opinions to

implement quality. Mr. Philip Crosby = “Quality is Free and Zero defects”= “Do it right at the first time”.• TQM = “ Everything we do – Design, set of inputs,

operations, outputs, customer satisfaction”.


• 6 Sigma - Motorola introduced in 1986, • Six Sigma = 3.4 defects per million production!


Sample Fishbone or Ishikawa Diagram


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Aspects of Quality :

• Quality is conformance to requirements ( or Specifications)

• It is cheaper to do things right the first time

• Quality should be in planning, design development, process development, material finalization, machine maintenance and man power training.


Functions of Quality Control• Monitor the quality consistently. • Create Quality awareness by communicating the cost of

quality failures.• Identifying problem areas in order to prevent quality

problems.• Individual workers input for removing the causes of

defects should be considered for quality enhancement.• Genuine recognition for quality output given by the team

of workers.


Functions of Quality Control

• Striving to continuously improve quality.

• Benchmarking certain standard of achievement for the whole organization to follow.

• A quality audit to identify lessons learned that could improve performance on current or future projects.


Five Cost Categories Related to Quality :• Prevention cost: Cost of planning and executing a project so it is

error-free or within an acceptable error range.

• Appraisal cost: Cost of evaluating processes and their outputs to ensure quality.

• Internal failure cost: Cost incurred to correct an identified defect before the customer receives the product.

• External failure cost: Cost that relates to all errors not detected and corrected before delivery to the customer.

• Measurement and test equipment costs: Capital cost of equipment used to perform prevention and appraisal activities.


• DMAIC is a systematic, closed-loop process for continued improvement of Quality by Kaizen methods

• DMAIC stands for:

– Define: – Measure: – Analyze: – Improve: – Control:


Measure

Control

Define

Analyze

Improve

Define: Define customers requirements – Their expectations.

Define the goals, project boundaries.

Define design aspects

Define the Production process


Measure

Control

Define

Analyze

Improve

Measure: Eliminate guesswork and assumptions. Collect data from the customers :

quality attributes, delivery time, their usage parameters etc.


Measure

Control

Define

Analyze

Improve

Analyze: Taking the customer’s requirements

Identify gaps between current performance and goal performance,

Identify sources of variation and root causes of problems in the process.

Prioritize opportunities to improve,


Measure

Control

Define

Analyze

ImproveImprove: Find creative solutions by correcting root causes by innovation, technology and discipline.


Measure

Control

Define

Analyze

Improve

Control: Document the procedure to institutionalize the improvement.

Ensure that the process improvements, are sustained .

CHEANEY SHOES


Benefits of quality• Strengthened competitive position• Adaptability to changing or emerging market conditions • Higher productivity• Enhanced market image• Elimination of defects and waste• Reduced costs and better cost management


Benefits of quality• Higher profitability• Improved customer focus and satisfaction• Increased customer loyalty and retention• Increased job security• Improved employee morale• Improved and innovative processes

Thank you

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