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

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.

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.

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:

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.

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.

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.

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.

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.

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.

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.

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.

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

Implementation of Various quality parameters

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.

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.

Implementation of Various quality parameters

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.

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

Implementation of Various quality parameters