this sidebar does not print quick start … for pizza 1. identify the customer wants: identify the...

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INTRODUCTION

How to launch a new Pizza production unit: The best possible answer is building house of quality as shown below

CASE STUDY

QFD APPLICATIONS

QFD is applied in a wide variety of services, consumer products, military

needs (such as the F-35 Joint Strike Fighter and emerging technology products.

The technique is also used to identify and document competitive marketing

strategies and tactics. QFD is considered a key practice of Design for Six

Sigma (DFSS -as seen in the referenced roadmap). It is also implicated in the

new ISO 9000:2000 standard which focuses on customer satisfaction.

Results of QFD have been applied in Japan and elsewhere into deploying the

high-impact controllable factors in Strategic planning and Strategic

management (also known as Hoshin Kanri, Hoshin Planning, or Policy

Deployment).

Acquiring market needs by listening to the Voice of Customer (VOC), sorting

the needs, and numerically prioritizing them (using techniques such as the

Analytic Hierarchy Process) are the early tasks in QFD. Traditionally, going to

the Gemba (the real place where value is created for the customer) is where

these customer needs are evidenced and compiled.

References

Summers, Donna C. S (2011). Lean six sigma: Process improvement tools and

techniques, Pearson Prentice Hall, Boston.

Joseph, P. (2008). where did QFD get its terrible name. Retrieved from:

http://www.qfdonline.com/archives/where-did-qfd-get-its-terrible-

name/

Livingstone, J. (2008). What’s the use. Retrieved from:

http://www.qfdonline.com/archives/whats-the-use/

Joseph, P. (2008). Save time by voting blind. Retrieved from:

http://www.qfdonline.com/archives/saving-time-by-voting-blind/

Terniko, J (1997). Step by step customer driven design. St. Lucie press. Houston.

Day, R, G. (1993). Quality function deployment – linking a company with its

customers. ASQC quality press.

Tapke, J. (n.d.). House of quality. Retrieved from:

http://www.public.iastate.edu/~vardeman/IE361/f01mini/johnson.pdf

POSTER CREATED BY

MOHAN HARISH MATURI

SWETHA KOTLA

SWATHI VARNA

SATYA RAVI KIRAN ADAPA

From the department of: School of Technology

Instructor: Dr. Suhansa Rodchua

Definition: QFD (Quality Function Deployment) is a process of determining

customer requirements and translating them into the attributes that each

functional area can understand and act on.

History of QFD: QFD began nearly 30 years ago in Japan as a quality system

focused on delivering products and services that satisfy customers. It believes

that to efficiently deliver value to customers, it is necessary to listen to the

voice of customer throughout the product or service development process.

House of Quality: One of the tools of QFD is house of quality. It is a

graphic technique for determining the relationship between customer desires

and product.

House of quality is a diagram resembling a house, used for defining the

relationship between customer desires and the product capabilities. As

discussed it is a part of QFD and it utilizes a planning matrix to relate what the

customer wants to how a product is going to meet those wants.

Kano’s requirements: It is a theory od product development and customer

satisfaction model developed by Prof. Noriakai Kano. According to him there

are 3 types of customer requirements to consider and they are like

1. Normal requirements are typically what we get by just asking customers

what they want. These requirements satisfy in proportion to their presence in

the product or service.

2. Expected requirements are often so basic that the customers may fail to

mention them, until we fail to perform them. They are basic expectations

without which the product or service may cease to be of value, their absence

is very dissatisfying.

3. Exciting requirements are difficult to discover because they are beyond

the customers expectations. Their absence doesn’t dissatisfy and their presence

excites.

A Product of Excellence

QFD FOR PIZZA

1. Identify the customer

wants: Identify the main features that any

customer desires in a Pizza and rate

accordingly.

2. Identify how the product

will satisfy the customer’s

wants: In this step, firm’s manager try to

reflect the customer’s desires and

demand into their company product.

Like as shown in figure

- Low relationship (1)

- - Medium relationship (3)

- - High relationship (6)

G = good

F = fair

P = poor

Good taste 6

Low price 5

Low fats and healthy 4

Appetizing appearance 3

Fresh and Hot delivery 2

Good texture 1

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Pizza color 3 x 1 3

App. Weight, size, etc. 6 x 6 + 3 x 3 45

Low fatty eatables 6 x 4 + 3 x 2 30

Optional eatables 5 x 1 + 3 x 2 11

Delicious and Fresh

toppings 3 x 1 + 3 x 3 12

Density of toppings 1 x 6 + 3 x 2 12

Good taste 6

Low price 5

Low fats and healthy 4

Appetizing appearance 3

Fresh and Hot delivery 2

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3. Identify relations between

our how’s: In this step, organization's matrix

between our how’s.

For example, in my cases, some how’s

are related to one-another. According

to our diagram, we got the following

relations.

4. Develop importance

ratings: This step is quite difficult and longer.

In this step, first we will draw the

relationship matrix between the how’s

and the wants, then we determine the

importance ratings for our final work

to be started. As a last step compare

with pizza companies.

Our importance rating 3 45 30 11 12 12

Technical attributes Technical attributes

Technical evaluation Technical evaluation

Final House of Quality Diagram of Pizza

http://www.facebook.com/pages/PosterPresentationscom/217914411419?v=app_4949752878&ref=ts

http://www.qfdonline.com/archives/where-did-qfd-get-its-terrible-name/



























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DES IG N G U IDE




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Functions of Poka - Yoke

(The British Standards Institution, 2008).

Poka-Yoke:

Poka-Yoke is a Japanese term and is a synonym for Error proofing which has it’s origin from to Japanese words, Yokeru(to avoid) and Poka

(inadvertent errors)It is a technique that prevents incorrect parts from being assembled and this can be used to identify the flaws. Poka-Yoke truly

first step in genuine error proofing.(iSixSigma, 2015)

Objectives:

Mistake proofing is required to prevent flaws in the process. Poka-Yoke is one such mechanism used to mistake Proof an entire process enhancing

that there are flawless conditions that exist before commencement of any process, to prevent the defects initially and to make the system perfect. If

not, Poka-Yoke acts/functions as defective/Scrutinizing function(ManageMentor,n.d)

Misconception:

There is a lot of misconception among people of various industries that Poka-Yoke is a technique/tool that can be operated by either as optical

inspection system or guide pins or limit switches or automate shut offs only by the engineering dept. But this is ironic in using Poka-Yoke since

this was actually intended to improve any process until it attains zero defects and can be used by people from any department. This flexibility is

using Poka-Yoke makes it versatile in using among different domains. (ManageMentor,n.d)

When and where do errors occur?

Errors occur in almost all industries and services including our day-to-day life and errors are said to be occurring when there is(miscalculation)

between the expected value and actual value concerned with output (Summers, D. C. (2011).

What are the types of errors?

Errors occurs in various domains be it in assembly or in sales, marketing. Errors are generally diagnosed using why-why diagram and there are

four elements that tend to create errors in the processes. They are Men, Method, Machinery and Material. The use of Poka-yoke mechanism in any

process is generalized and explained in the form of a diagram as shown below.

Parameters/examples used as error proofing devices

Guide pins: to assure that parts can be assembled in correct way

Limit switches: They sense the presence or absence of part

Mistake proofing jigs: Detect defects immediately, upstream process ensuring the correct part reach the process

Counters: verify whether the correct number of steps taken or not

Check list: reminds operators to do certain actions(Khameshra,2013).

Introduction Advantages

Encourages individual accountability for excellence.

Discovers and eradicates defects as early as possible in the process.

Presents immediate response, thus minimizing the time for remedial

action.

Creates a process of consecutive verification for each procedure.

Presents self-check actions which provide quicker review than

consecutive verification.

Makes sure that proper circumstances exist before the actual creation,

and prevents defects from taking place.

Doesn’t just identify the causes of errors but eliminates the causes as

well.

Elimination of defects ultimately increases customer satisfaction.

The focal point is on waste reduction in defects and

processing(Whatissixsigma.net,n.d).

Disadvantages

Error–proofing requires many devices like barcodes, radio frequency

identification, and barrier system which are expensive to implement

(Buckley, 2012).

It is not 100% effective, as it cannot eliminate all defects.

Requires special experienced trainer (Vicario, 2011).

Conclusion

Error-proofing releases workers from repetitive activities by giving them an

opportunity for maximizing their building quality roles, in the process, by

decreasing product deficiencies and the related cost of rework. Therefore, in a

long term, it can ultimately lead to significant improvements in overall project

productivity.

References

Buckley, R. L. (2012). No Eraser Needed - Mistake Proofing Your Business. Shady Brook Press.

Gtiachu, 2014. Standardize mistake proofing process. Retrieved from:

https//:gitachud.hubpges.com/hub/Poka-How-to-Standardize-the-Mistake-Proofing-Process

Isixsigma,2015. Poka-Yoke. Retrieved from:

http://www.isixsigma.com/dictionary/poka-yoke/

Khamesra,2013. . Poka-Yoke mistake proofing. Retrieved from:

http://www.slideshare.net/animeshkhamesra/poka-yoke-mistake-proofing-26424292 by

Managementor,n.d. Enlightenmentor poka-yoke. Retrieved from:

http://www.themanagementor.com/EnlightenmentorAreas/mfg/QM/pokayoke.htm

Ross, G. (2013). Poka-Yoke the office. Retrieved from http://www.leankaizen.co.uk/poka-yoke.html

Summers, D. C. (2011). Lean Six Sigma Process Improvement Tools And Techniques . New Jersey:

Pearson.

The British Standards Institution (2008, September). Mistake Proofing Techniques. Retrieved from

https://workspace.imperial.ac.uk/insolex/Public/19%20Mistake%20Proofing%20Techniques.pdf

Vicario, S. D. (2011, April 12). Case Study O2 - Discussion Part 1 - Mistake-Proofing Tools. Retrieved

from http://www.traqprogram.ca/index.php/en/continuing-education/case-studies/item/394-case-study-o2-

discussion-part-1-mistake-proofing-tools

Whatissixsigma.net, n.d. Advantages of using mistake proofing method. Retrieved from:

http://www.whatissixsigma.net/mistake-proofing-poka-yoke/

IndM 4230 - Lean Quality Management, School of Technology

Created by

Goutham Medarametla

Sai naga varun teja Potu

Tafie Dozaghi

Instructors: Dr. Suhansa Rodchua

Strategies Make it harder to create the error.

Make it possible to reverse the error.

Make it obvious that the error has occurred.

Detect the deviations from procedures or fixed

values(Khameshra,2013).

Design:

Design process so that it tolerates the error and doesn’t result in

outputs with defects.

Design process to decrease complexity, error free and

versatile/flexible in use.(Khameshra,2013).

Approaches to Mistake Proofing

Control approach:

Shuts down the process when error occurs

High capability of achieving Zero defects.(Khameshra,2013).

Warning approach:

Signals the operator to stop the process and correct the problem

or check for a problem.

Lights and sounds to bring attention to the problem.

.(Khameshra,2013).

Examples

1) The 3 Pin Plug: 3 pin plugs are designed so that the plug can

only be put into a socket in one way. This prevents us from an

electric shock and potential death (Ross, 2013).

2) USB Device: USB devices are designed so that it can only be put

into computer’s slot in one way(Gitachu, 2014).

POKA-YOKE(ERROR PROOFING)

Acknowledgement





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Value Stream Process Mapping is a lean manufacturing technique

most popular in the automotive industry categorically used to

document, analyze and improve the flow of materials along with

the information that may be used to complete a product or provide

a service eliminating wastes (Muda). VSM is capable of streamlining

any manufacturing process if done effectively in four steps, aptly

identifying the value stream, make current state of the process,

diagnosing each problem end and finally by implementing the

changes. Even the most efficient and profitable companies believe

on doing the VSM at least seven times to achieve accurate results

(Hines, Rich, Esain1999).

INTRODUCTION

PURPOSE and OBJECTIVES

VSM ‘s main focus is to provide optimum value to the

customer through the true usage of a value creation

process with the minimum wastage in design (concept to

customer), build (order to delivery) and sustain (in-use

through life-cycle to service). Taiichi Ohno had developed

material and information flow mapping as a standard

method for mapping for the Toyota production system, this

was later practiced as VSM (Belokar & Kharb, 2012). There

is always a grave & constant concern for automotive

manufacturers over improvising on quality, the delivery &

reducing costs as this would make them more competitive

in the market. The most common problems that auto

makers face are delayed deliveries, longer queues detail

parts, high work in process inventories and improper

efficient use of production lines. These problems increase

the overall cost of production (Singh A & Singh H, 2013).

USES OF VSM IN AUTOMOTIVE INDUSTRY

Aerospace is a very complex, expensive, technologically sophisticated & redundant

manufacturing businesses. Often aerospace companies tend to plan their production

way ahead of their actual production schedule. This is because of the mandatory

planning and typical lean manufacturing practices that are followed while assessing

and forming the processes for the flow of manufacturing material and its

information. In a typical aerospace assembly manufacturing, the VSM can help

identify wastes as shown in Figure 4. This was a VSM implementation example from

TATA - Sikorsky Corporation JV in India while setting up S-92 helicopter assembly line

which had paid of reduction of a lot of costs.

USES OF VSM IN AEROSPACE MANUFACTURING INDUSTRY

CONCLUSION VSM has been proven a greatly useful practice to eliminate some

wastes in a every cycle & eventually improves lean practices to be

part of the culture. Identity opportunities are often triggered by a

business requirement for a product or service. The objectives of

VSM is to achieve reduction of wastes in every part of the

manufacturing processes i.e inventory, quality assurance, human

effort, procurement process manufacturing space & the time to

market the product.

REFERENCES Baudins, M. (2013, October 25). Where do "Value Stream Maps" come from?

Retrieved April 11, 2015, from http://michelbaudin.com/2013/10/25/where-do-

value-stream-maps-come-from/

Belokar, R.M, Kumar, V., & Kharb, S. (2012). An Application of Value Stream

Mapping In Automotive Industry: A Case Study. International Journal of

Innovative Technology and Exploring Engineering, 1(2), 152-157.

Handfield, D. (2011, January 26). Supply Chain Management, SCM, SCRC

Supply Chain Resource Cooperative, Poole College of Management, North

Carolina State University. Retrieved April 12, 2015, from

http://scm.ncsu.edu/scm-articles/article/the-procurement-process-creating-a-

sourcing-plan-procurement-a-tutorial

Lian, Y., & Van Landeghem, H. (2007). Analysing the effects of Lean

manufacturing using a value stream mapping-based simulation

generator. International Journal Of Production Research, 45(13), 3037-3058.

Peter Hines, Nick Rich and,Ann Esain. (1999). Value stream mapping A

distribution industry application. Benchmarking, 6(1), 60-77. Retrieved from

http://search.proquest.com/docview/217372763?accountid=6143

Singh, H., & Singh, A. (2013). Application of lean manufacturing using value

stream mapping in an auto-parts manufacturing unit. Journal of Advances in

Management Research, 10(1), 72-84.

Sustainametrics - Profitable Green Strategies. (n.d.). Retrieved April 10, 2015,

from http://sustainametrics.com/index.php/page/display/lean_green

PRESENTED BY

VSM helps improve productivity and eliminates wastage by the

usage of lean principles in any particular process. VSM is visual

oriented lean tool which identifies, demonstrates and decreases

wastage in the process and works on implementation in four major

steps as shown below in Figure 2. (Belokar & Kharb, 2012).

VALUE STREAM PROCESS MAPPING

Figure 1. Value Stream Process Mapping (Sustainametrics, n.d.)

Figure 2. Four major Steps of VSM Implementation (Belokar & Kharb,

2012).

VSM is made possible by using certain VSM class symbols namely

basic flow unit entities and flows, Physical entities, Buffer

entities, Flow control entities and Data table & Measurement. VSM

typically is capable of gathering and displaying a far broader range

of information compared to other typical process maps, VSM can

be used at a broader level involving end to end processes from

receiving raw material to finished products (Lian, & Van

Landeghem, 2007).

CHAITANYA KRISHNA | HANEESH VULAVALA

April 18, 2015

IndM 4230 Lean and Quality Management

Instructor: Dr. Suhansa Rodchua

School of Technology | University of Central Missouri

Figure 3. Yasuhiro Modern’s Toyota Production system based on VSM

(Baudin, 2013)

VSM tends to be at higher level than other process maps which not only is used to identify where to focus on future projects but also allows us to

work on subprojects and stay on tune with the Kaizen events. A VSM system map not only takes into account the activity of the product but also

the information system and its management into perspective that support the basic processes, this can be handy especially when we are trying to

gain an insight to better decision making flows and working upon reducing cycle times (Lian, & Van Landeghem, 2007).

Figure 4. The frequency of wastes categories that are identified

in a manufacturing cycle

Figure 6. Typical Procurement process while making a Sourcing plan

using VSM Concept (Handfield, 2011).

Performing VSM activity takes serious skill, expertise and perseverance to achieve the goal

of turning all activities and processes lean in each of the functions to obtain its “Value

Stream”. In aerospace, the costs spent on each process has a huge impact on the overall

budget of the program due to its opulent nature. VSM involves following the production path

from End-to-End by drawing the visual representation of each process at the current state &

find improvements and recommendations to be more efficient and effective both

individually and collectively to satisfy the customer demand. Figure 5. Typical VSM activity by function


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