MMVA ZG 522 Total Quality

Management
Rajiv Gupta
BITS Pilani
Lecture 15
 Agenda
• Module 1
– Recap of Lecture 14
• Module 2
– Quality Function Deployment QFD
• Module 3
– Failure Mode Effects Analysis FMEA
• Module 4
– Steps in FMEA
• Module 5
– Summary

2
 Session 15
• Begin Module 1
– Recap of Lecture 14

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 Recap of Lecture 14
• In this lecture we discussed quality by design
• Traditional approaches to design are sequential. This
causes gaps in communication, resulting in longer
product development cycles and high cost
• Quality by design requires simultaneous or concurrent
design and development activities
• We need to form multi-disciplinary teams of people
required in the design process to improve
communication
• Ideally the teams should be co-located. However, virtual
teams may also be used.

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 Lecture 15
• End of Module 1

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 Lecture 15
• Begin Module 2
– Quality Function Deployment

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 QFD
• It is a product planning tool used to fulfill customer
expectations.
• It is a disciplined approach to product design,
engineering, and production.
• It can improve engineering knowledge, productivity
and quality and reduce costs, product development
time, and engineering changes.
• It is employed to translate customer expectations
(voice of the customer) requirements to specific
product requirements in terms of engineering or
technical characteristics.

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 Why QFD?
• In general, it is not easy to incorporate the voice of
the customer completely in the product design.
• The problem lies in different interpretations at each
level in the organization and the lack of clarity
regarding the impact of a decision on the customer’s
expectations.
• The result is a frequent departure from what the
customer states as his requirements and what we
provide as the finished product.

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 QFD
Approach

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 Cascading
Requirements
-- in Toyota’s
paint rusting
problem

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QFD Cascade

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House of Quality

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 Steps in Building the House of
Quality
• List Customer Requirements (What’s)

• List Technical Descriptors (How’s)

• Develop Relationship (What’s & How’s)

• Develop Interrelationship (How’s)

• Competitive Assessments

• Prioritize Customer Requirements

• Prioritize Technical Descriptors

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 Customer
Requirements
(What), Design
Requirements
(How),
Relationships and
Importance
Ratings

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 Roof of
House of
Quality
(QFD)

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Plotting
Product
Ratings

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QFD Example
-- Bicycle
Handlebar
Stem Design
(from Textbook)

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 Lecture 15
• End of Module 2

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 Lecture 15
• Begin Module 3
– Failure Mode Effects Analysis FMEA

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 Failure Modes and Effects Analysis
(FMEA)
• It is a proactive and qualitative tool used by Quality,
Safety and Product/Process engineers to improve
reliability (eliminate failures– thus, improve
quality/customer satisfaction).
• It seeks to identify possible failure modes and
mechanisms, the effects or consequences that the
failures may have on performance, methods of
detecting the identified failure modes, and possible
means for prevention.
• Very effective when performed early in
product/process development and by experienced
multi-functional teams.

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 FMEA
• FMEA is a tool that allows you to:
– Prevent system, product and process problems
before they occur
– reduce costs by identifying system, product and
process improvements early in the development
cycle
– Create more robust processes
– Prioritize actions that decrease risk of failure
– Evaluate the system, design and processes from a
new vantage point

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 FMEA encourages --
• Systematic evaluation of a product or process at
specified levels of system complexity.
• Postulation of single point failures, identification of
possible failure mechanisms, examination of
associated effects, likelihood of occurrence, and
preventive measures.
• Systematic documentation (Tabular format) of
potential product or process nonperformance.

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 Reliability
• Reliability is a critical quality characteristic which
measures sustained product-process performance.
• Reliability ,R(t), is defined as the probability of a
product (or process) to perform as expected for a
certain period of time (t), under given operating
conditions, and at a given set of product
performance characteristics (e.g. after 5,000
landings, 100,000 miles, etc.).

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 Failure Mode
• A Failure Mode is:
– The way in which the component, subassembly,
product, input, or process could fail to perform its
intended function
• Failure modes may be the result of upstream
operations or may cause downstream operations
to fail
– Things that could go wrong
– Failure has to take into account all possibilities,
including incorrect usage by the customer
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 What is included in an FMEA
Table?
• What could go wrong? – Failure Mode
• What are the chances of the failure mode
occurring?
• How severe will be the effect of the failure
mode? i.e., what will be the negative impact?
• How easy/difficult is it to detect the failure
mode?

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Determining Risk Priority

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 Lecture 15
• End of Module 3

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 Lecture 15
• Begin Module 4
– Steps in FMEA and FMEA Example

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 Steps in FMEA
• Step 1 - Review the process
• Step 2 - Brainstorm potential failure modes
• Step 3 - List potential effects of each failure
mode
• Step 4 - Assign a severity rating for each
failure mode
• Step 5 – Assign an occurrence rating for each
failure mode
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 Steps in FMEA (contd.)
• Step 6 - Assign a detection rating for each
failure mode and/or effect
• Step 7 - Calculate the risk priority number for
each effect
• Step 8 - Prioritize the failure modes for action
• Step 9 - Take action to eliminate or reduce the
high-risk failure modes
• Step 10 - Recalculate the new RPN as the
failure modes are reduced or eliminated
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 Step 1 – Review the Process
• Step 1 – Review the process
• All the members on the FMEA team need to
understand the product/process.
• It is important to have an accurate blueprint
before the process starts
• Members should physically see the product, or its
prototype
• An expert should be on the team to answer
questions
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 Step 2 – Brainstorm Potential
Failure Modes
• Team members should come prepared with ideas
• During the brainstorming session, more ideas get
generated due to synergy
• Due to product complexity, several brainstorming
sessions may be required, each focussing on one
element at a time
• After the brainstorming session, the ideas should be
grouped into categories for ease of working through

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 Step 3 –List Potential Effects of
Each Failure Mode
• This step is very important as it affects the rest
of the FMEA process
• Enough care must be taken to ensure that as
many effects are taken into account as
possible
• It is helpful to think – if this failure occurs,
what are the consequences?

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 Steps 4, 5, 6
• Steps 4, 5, and 6 require that we assign
numerical values to the severity, occurrence,
and detection ratings

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Step 7 – Calculate the Risk Priority
Number for Each Failure Mode
• The risk priority number (RPN) is calculated by
multiplying the severity rating by the
occurrence rating and by the detection rating
for all items.
• RPN = Severity x Occurrence x Detection

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 Step 8 – Prioritize the Failure
Modes for Action
• The failure modes should be prioritized by the
RPN value
• A Pareto diagram may help in visualizing the
different ratings
• A cut off RPN value may be used to determine
which failure modes will be attended to

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Step 9 – Take Action to Eliminate or
Reduce Impact of Failure Modes
• Using systematic problem solving techniques,
work to reduce or eliminate the potential
failure modes
• Critical failure modes should be eliminated
• Other failure modes may be reduced in terms
of their RPNs
• Generally it is best to attack the likelihood of
occurrence, followed by severity and
detection
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Step 10 – Recalculate the new RPN
Values
• After action has been taken, the new RPN
values should be calculated
• It is expected that the new value is
significantly less than the original value
• Often at least a 50% reduction in RPN values
should be expected

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FMEA Form

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 Lecture 15
• End of Module 4

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 Lecture 15
• Begin Module 5
– Summary

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 Summary of Lecture 15
• In this lecture we discussed quality function
deployment QFD
• QFD is a powerful, systematic tool to convert
the voice of the customer into product and
process design
• QFD employs the house of quality to help
analyze customer requirements and convert
them into design features and process steps in
a systematic fashion
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 Summary of Lecture 15
• We also discussed Failure Mode Effects Analysis
FMEA
• FMEA is a proactive tool that allows us to look at
product and process designs to reduce the impact
of various failure modes
• FMEA looks at the severity of the impact of a
failure mode, its likelihood of occurrence, and the
probability of detection

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 Lecture 14
• End of Module 6

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