Process Analysis Exam 3

Six sigma concepts

• critical to quality

• defect

• process capability

• variation

• stable operations

• design for six sigma

Total quality management (TQM)

managing the entire organization of products and services that are important to the customer

dimensions of design quality

• performance 

• features

• reliability/durability

• serviceability

• aesthetics

• perceived quality

assumption of cost

• failures are caused

• prevention is cheaper

• performance can be measured

cost of quality

• appraisal cost

• prevention of cost

• internal failure cost

• external failure cost

6 sigma quality

• used to eliminate defects

• reduce variation in processes

• defects per million opportunities

shingo system

• SQC methods do not prevent defects

• defects arise when ppl. make errors

• defects can be prevented by providing workers w/ feedback on errors

Forms of variation

assignable and common

assignable variation

caused by factors that can be clearly identified and possibly managed

Common variation

variation that is inherent in production processes

can you have zero variation

no

traditional view of variation

output between limits is goods, outside is bad

taguchi view of variation

costs increase as variability increases, so seek to achieve 0 defects that will minimize quality costs

Problem statement for toyota case

• current production line ratio is 85% vs. a planned 95% ratio

• car clinic is being used which is against the toyota way

Kanban

demand pulls the product through the manufacturing system

Jidoka

make problems visible and stop producing until problems are fixed

Kaizen

always work on improving a process

Heijunka

make some of every item each product shift

Recommendations of Toyota Case

• contain problem: 

• accommodate problem: firefight and work around problems

• solve problem: obey TPS principles to identify “root cause” and eliminate problem

ISO 900 & ISO 14000

• standards of quality management

• 9000 is international reference for quality

• 14000 is concerned w/ environmental management

Forms of ISO certification

• 1st party: firm audits itself against 9000 standards

• 2nd party: Customer audits its supplier

• 3rd party: qualified standards or certifying agency serves as auditor

Design of experiments (DOE)

stats test to determine cause and effects relationships between process variables and output

Failure made and effect analysis (FMEA)

approach to identify, estimate, prioritize, and evaluate risk of possible failures at each stage in the process