TQM & Product Development 18 06 2013

TQM 1
Quality Management Best Practice

EMPC02 - Product, Service and Process Development
Dr. ttia !omaa
"ndustrial Engineering Pro#essor $ Consultant
Engineering and Science Services - merican %niversity in Cairo
20&'
Plan
Check
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TQM 2
Contents)
Overview
Quality Management
ISO 9001:2008
Quality Control Tools
Quality Improvement Tools
Kaian !pproa"#
Si$ Sigma !pproa"#
%ean !pproa"#
%ean Si$ Sigma !pproa"#
Case Stu&ies
EMPC02 - Product, Service and Process Development
TQM 3
*it to use %p to standards Minimum Cost
The degree to which a product or service meets specified requirements.
Customer Satis#action
+ ,ig-ts .Scope o# /or0 1Specs2, Quality, Quantity, 3ime, Price4
5-at is Quality6
The totality of features and
characteristics of a product or
service that bear on its ability to
satisfy stated or implied needs.
ISO 840 ! ISO "000
TQM 4
7ong 3erm Continuous "mprovements
Quality "mprovements
E##iciency "mprovements
Min. De#ects
Min. 5asters 8 7osses
Si9 Sigma pproac-
7ean pproac-
7ean-Si9-Sigma pproac-
Si9 Sigma Plus Si9 Sigma Plus
5-at is 3QM6
TQM 5
Discuss :rie#ly, t-e #ollo/ing ;uality
management tools, using a guide e9ample<
Discuss :rie#ly, t-e #ollo/ing ;uality
management tools, using a guide e9ample<
Main Points:
Sel# Study) .'0=4
-Product ,elia:ility
->?@P Study
*inal E9am .'0=4
ProAect .B0=4
&. Product 8 Process 8 Service De#ine
2. Quality Dimensions
'. Process Plan
B. Quality ssurance vs. Quality Control
+. Q8QC C-ec0 7ist
C. Seven QC tools
D. Process Capa:ility nalysis
E. ,elia:ility nalysis
F. ,oot Cause nalysis
&0. Cause $ E##ect Diagram
&&. *ailure Mode E##ect nalysis
&2. >?@P Study
&'. Quality *unction Deployment
&B. "mprovement 3ools
&+. Gey Per#ormance "ndicators .GP"4
&C. 7ong 3erm Continuous "mprovement
&. Product 8 Process 8 Service De#ine
2. Quality Dimensions
'. Process Plan
B. Quality ssurance vs. Quality Control
+. Q8QC C-ec0 7ist
C. Seven QC tools
D. Process Capa:ility nalysis
E. ,elia:ility nalysis
F. ,oot Cause nalysis
&0. Cause $ E##ect Diagram
&&. *ailure Mode E##ect nalysis
&2. >?@P Study
&'. Quality *unction Deployment
&B. "mprovement 3ools
&+. Gey Per#ormance "ndicators .GP"4
&C. 7ong 3erm Continuous "mprovement
TQM 6
Quality Management
TQM 7
*it to use %p to standards Minimum Cost
The degree to which a product or service meets specified requirements.
+ ,ig-ts .Scope o# /or0 1Specs2, Quality, Quantity, 3ime, Price4
5-at is Quality6
The totality of features and
characteristics of a product or
service that bear on its ability to
satisfy stated or implied needs.
ISO 840 ! ISO "000
TQM 8
5-at is Quality6
Meeting customer e9pectation
Doing ,ig-t 3-ing ,ig-t *irst 3ime and every 3ime
+ ,ig-ts .Scope o# /or0, Quality, Quantity, 3ime, Price4
TQM 9
'imensions o( Quality Customer Satis#action
>o/6
Balance
Benc-mar0ing6
TQM 10
'imensions o( Quality
Garvins Eight Dimensions of !a"it#
Performan$e %% &rimar# o&erating $hara$teristi$s
'eat!res %% "itt"e e(tras
)e"ia*i"it# %% &ro*a*i"it# of s!$$essf!" o&eration +non%fai"!re,
-ithin a given time s&an
.onforman$e %% meeting &re%esta*"ishe/ stan/ar/s
D!ra*i"it# %% "ength of !sef!"ness0 e$onomi$a""# an/ te$hni$a""#
1ervi$ea*i"it# %% s&ee/0 $o!rtes#0 $om&eten$e0 an/ ease of re&air
2estheti$s %% &"easing to the senses
Per$eive/ 3!a"it# %% in/ire$t eva"!ations of 3!a"it# +e4g40 re&!tation,
TQM 11
Process Description
Manpo/er
Materials
Met-ods
Mac-ines
Money .Cost 4
Process
,esources 6
*inal Product 6
Management 3ools 6
Customers 6
Suppliers 6
Quality .*it to use 4
Delivery 3ime .Due date 4
Price
Scope o# /or0 .Specs 4
Process 8 Product 8 ProAect 8 Service, H etc .
Quantity .Iolume 4
@:Aectives 6
Constraints 6
TQM 12
Quality Management
Systematic pproac- To Achieve Certain Quality at Low Cost
Systematic pproac- *or 7ong 3erm Continuous "mprovements
Process ctivities
TQM 13
Site
5o&
Mi//"e
6&erationa"
Planning
Control
Quality
Policy
Quality
Policy
"nspection
*eed:ac0
"nspection
*eed:ac0
!a"it# Management 1#stem
7ho"e%1#stem Process Approach to Quality
TQM 14
Q8QC *orm
!a"it#
2ss!ran$e
!a"it# P"anning
!a"it# .ontro"
Planning
Control
Quality
Policy
Quality
Policy
"nspection
*eed:ac0
"nspection
*eed:ac0
!a"it# Management 1#stem
7ho"e%1#stem Process Approach to Quality
TQM 15
1) Quality Inspe"tion *QI+
2) Quality Control *QC+
,) Quality -lanning *Q-+
.) Quality !ssuran"e *Q!+
#hat is the difference between
8rainstorming:
TQM 16
Quality Control
"nspection
Quality Planning
Quality ssurance
TQM 17
Quality Management
"nspection
Quality
Control
Quality
ssurance
3QM
Salvage, sorting, grading, blending, corrective actions,
identify sources of non-conformance
Develop quality manual, process performance data, self-
inspection, product testing, basic quality planning, use of
basic statistics, paperwor control!
Quality systems development, advanced quality planning,
comprehensive quality manuals, use of quality costs,
involvement of non-production operations, failure mode
and effects analysis, SP"!
Policy deployment, involve supplier # customers, involve
all operations, process management, performance
measurement, teamwor, employee involvement!
TQM 18
TQM
Inspection!
Testing
Inspection!
Testing
,eactive
.5-at >appened nalysis4
Proactive
.5-at "# nalysis64
Blame
orientated
Empo/erment
TQM 19
1) Quality /it To 0se 0p To Stan&ar& *'imensions o( Quality+
2) Inspe"tion !"tual -er(orman"e Measure *Tools 1 !""epte& 2 3e4e"te&+
,) QC Control o( !"tual -er(orman"e !"tion *Corre"tive 2 -roa"tive+
.) Q- Stan&ar& In(ormation 1 Quality -lans (or Spe"i(i" -ro4e"t
5) Q! Stan&ar& In(ormation6 Quality -lans6 Quality -oli"y /or long term
7) QMS Common Quality System 2 Strategy
8) ISO 9001 International Stan&ar& (or QMS
8) TQM %ong Term Continuous Improvement :
Quality System 1 System Quality
Quality Management 1 Management Quality
#hat is the difference between
8rainstorming:
TQM 20
$%
$&
$'
$(S
ISO
"00)
T$(
$*I
TQM 21
Main Points:
&. Product 8 ProAect 8 Process 8 Service De#ine
2. Pro:lem Statement $ Main @:Aectives
'. Quality Dimensions
B. Process Plan
+. Quality ssurance vs. Quality Control
C. Q8QC C-ec0 7ist
D. Seven QC tools
E. Process Capa:ility nalysis
F. ,elia:ility nalysis
&0. ,oot Cause nalysis
&&. Cause $ E##ect Diagram
&2. *ailure Mode E##ect nalysis
&'. >?@P Study
&B. Quality *unction Deployment
&+. "mprovement 3ools
&C. Gey Per#ormance "ndicators .GP"4
&. Product 8 ProAect 8 Process 8 Service De#ine
2. Pro:lem Statement $ Main @:Aectives
'. Quality Dimensions
B. Process Plan
+. Quality ssurance vs. Quality Control
C. Q8QC C-ec0 7ist
D. Seven QC tools
E. Process Capa:ility nalysis
F. ,elia:ility nalysis
&0. ,oot Cause nalysis
&&. Cause $ E##ect Diagram
&2. *ailure Mode E##ect nalysis
&'. >?@P Study
&B. Quality *unction Deployment
&+. "mprovement 3ools
&C. Gey Per#ormance "ndicators .GP"4
&. G"?EJ pproac-
2. Si9 Sigma pproac-
'. 7ean pproac-
B. 7ean Si9 Sigma pproac-
+. 3PM pproac-
&. G"?EJ pproac-
2. Si9 Sigma pproac-
'. 7ean pproac-
B. 7ean Si9 Sigma pproac-
+. 3PM pproac-
Continuous "mprovement
TQM 22
-ro9lem Statement:
pply Si+ Sigma problem solving methodology to insure that the welding process
is achieving Si+ Sigma quality levels of less than ,.4 defects per million for all
critical welding parts.
(ain Ob-ectives.
&roduce welding parts that meet the customer requirements and ma+imi/e the
resource utili/ation.
ST'01'21S ! %O13S.
P" &&0B, 5elding o# pipelines and related #acilities.
&ro-ect. 4as &ipe 5ine 6 0 inch 6 )0 7m 8rom Site 9 to Site :
&rocess. 3lectric 'rc #elding
ProAect 8 Process De#ine
TQM 23
Quality Concept)
$he degree to which a product or service meets specified requirements!
%&it to use ' &it to standard ' at minimum cost(
Quality Concept)
$he degree to which a product or service meets specified requirements!
%&it to use ' &it to standard ' at minimum cost(
Quality Dimensions)
Quality dimensions are the parameters and specifications for customer
requirements # needs!
Quality Dimensions)
Quality dimensions are the parameters and specifications for customer
requirements # needs!
!antitative Dimensions !a"itative Dimensions 1tan/ar/s 9 .o/es
$hicness
)ield strength
$oughness
*elding profile AP+ ,,-.
"n arc /elding #or e9ample<
TQM 24
1:P6. ; Meas!rement :nstr!ments
&rocess (ap
S
" P @ C
,e;uirements ,e;uirements
Measures Measures
Suppliers "nputs @utputs Customers
Input Boundary Output Boundary
Process
Measures
,e;uirements
Process Plan)
Process plan defines the ey steps # stages which must be taes to achieve
the target process!
Process Plan)
Process plan defines the ey steps # stages which must be taes to achieve
the target process!
TQM 25
&rocess (ap
%ustomers Outputs &rocess Inputs Suppliers
&rocess %hart
TQM 26
Pro$ess .hart
@perations
"nspection
3ransportation
Delay
Storage
1#m*o"s:
1!&&"ier
.!tting
8.1 hr
7e"/ing
52.0 hr
)a-
Materia"s
Finishing
20.4 hr
Painting
25.3 hr
'ina"
Pro/!$ts
.ll dimensions are in mm4
500
500
500
Product Description)
/elded /ater tan0
open on one side.
3 /a#
6r/er
/!e /ate
21 /a#
+20
s-eets
+2
plates
&02
tan0
&0&
tan0
&00
tan0
5elding
&+E& rods
'2 0g
TQM 27
Suppliers "nputs Process Customers @utputs
Production
Planning
Department
*or /rder
Process Sheet
Drawings
0aw 1aterials
$ools
Products
0ight Quantity
0ight Quality
0ight $ime
Storage
1aret
"ustomer
Pro$ess ma&
+f"o- $hart,
0eceive
*2/ #
Drawings
Drawings
"hecing
Preparation of
Shop drawings
Quantity
Survey
Submittal to
the 3ngineer
for Approval
Detailed
Planning
Procurement of
0esources
34ecution
of *ors
Q
u
a
l
i
t
y

"
o
n
t
r
o
l
"ompletion of
the *2o
3lements
Pro$ess Ma& +1:P6. .hart,
TQM 28
!a"it# 2ss!ran$e vs4 !a"it# .ontro"
Quality ssurance Quality ssurance
n overall management
plan to guarantee t-e
integrity o# data
.3-e 1system24
Quality Control Quality Control
!a"it# 2ss!ran$e +2, 1#stem oriente/
!a"it# .ontro" +., Pro/!$t oriente/

series o# analytical
measurements used to assess
t-e ;uality o# t-e analytical data
.3-e 1tools24
Q and QC are po/er#ul tec-ni;ues
TQM 29
Q8QC C-ec0 7ist)
Quality Assurance 2 Quality "ontrol checlist is used to ensure the quality of a
product 2 process! +t defines set of tass # inspections to be performed in
different stages of the product2process!
Q8QC C-ec0 7ist)
Quality Assurance 2 Quality "ontrol checlist is used to ensure the quality of a
product 2 process! +t defines set of tass # inspections to be performed in
different stages of the product2process!
Q 8 QC C-ec0list #or rc 5elding Process)
Phase :tem 1tat!s 3esponsi9ility
8efore
7e"/ing
"hec 1etal Sheets %type, si5e, defects, etc(
"hec *elding 3lectrode %type, grade, humidity, etc(
"hec *elding 1achine # $ools
"hec *elding "onditions %angle, amp, temp!, area, etc(
"hec Process %cleaning, area, safety, etc!(
D!ring
7e"/ing
"hec *elding Procedure
"hec *elding Positions
"hec *orer 3fficiency %sills, safety, etc(
2fter
7e"/ing
6isual +nspection %profile, si5e, surface defects, etc(
+nspect *elding Quality
&inal +nspection
Quality Documentation
Comments)
TQM 30
Continuous
improvement
Quality Control System
Be#ore
During
#ter
TQM 31
QC 3-roug-out Production Systems
Inputs
%onversion Outputs
2aw (aterials ,
&arts* and
Supplies
&roduction
&rocesses
&roducts and
Services
%ontrol %harts
and
'cceptance Tests
%ontrol %harts
and
'cceptance Tests
%ontrol %harts
$uality of
Inputs
$uality of
Outputs
$uality of
&artially %ompleted
&roducts
TQM 32
Statistical Process Control .SPC4
! met#o&ology (or monitoring a pro"ess to i&enti(y spe"ial "auses o(
variation an& signal t#e nee& to ta:e "orre"tive a"tion)
Seven QC tools:
14 '"o-$hart
24 .he$< sheet
34 =istogram
44 Pareto .hart
54 1$atter /iagram
64 .ontro" $hart
74 .a!se%an/%effe$t /iagram
/o"us: Quality "ontrol

TQM 33
7 8asi$ too"s of !a"it# .ontro"
&- *lo/c-art .Process s-eet4
'- >istogram
C- Scatter diagram
2- C-ec0 s-eet . De#ect *re;uency4
B- Pareto C-art .Sorting4
+- Cause-and-e##ect diagram
D- Control c-art
TQM 34
5elding Process ,ates)
;ee:
<
Total
=oints
>um9er o(
3e4e"te&
1
2
,
.
5
7
8
8
9
10
))
)
),
Total
De#ect *re;uency)
< 'e(e"t
'es"ription
'e(e"t
/re?uen"y
!
Incomplete Joint
@
Improper Fusion
C
Overlap
'
Insufficient Penetration
A
Pits
/
Porosity
B
Vertical Crack
C
Under Bead Crack
I
Irregular Weld
;
Oters
TQM 35
!a"it# .ontro" 5oo"s:
3-e ;uality in#ormation #or pipe line /elding is as #ollo/s)
#ee7
<
Total
=oints
0umber of
2e-ected
#ee7
<
Total
=oints
0umber of
2e-ected
1 1000 120 11 1100 120
2 1100 110 12 1200 120
3 1000 100 13 1200 100
4 1200 110 14 1300 120
5 1100 105 15 1300 120
6 1000 100 16 1300 120
7 1100 100 17 1400 130
8 1000 110 18 1400 130
9 1000 120 19 1500 140
10 1100 110 20 1500 140
Based on this information, discuss the following:
1 !re"uency Analysis # Control Chart
$ %igma &e'el ( %ummary report
TQM 36
;ee: -ro&u"tion 3e4e"te& 3 D Comment
1 1000 120 12)0 Ma$)
2 1100 110 10)0
, 1000 100 10)0
. 1200 110 9)18
5 1100 105 9)55
7 1000 100 10)0
8 1100 100 9)09
8 1000 110 11)0
9 1000 120 12)0
10 1100 110 10)0
11 1100 120 10)9
12 1200 120 10)0
1, 1200 100 8),, Min)
1. 1,00 120 9)2,
15 1,00 120 9)2,
17 1,00 120 9)2,
18 1.00 1,0 9)29
18 1.00 1,0 9)29
19 1500 1.0 9),,
20 1500 1.0 9),,
EF 1190 117)25 9)8.
S 17.)012 12)1, 0)9.,
Min 1000 100 8),
Ma$ 1500 1.0 12)0
5elding Process
,eAected ratio
E.'' K &2.00=
verage L F.EB =
,ange L &2-E.'' L '.CD
Standard Dev. L 0.FB'
,eAected ratio
E.'' K &2.00=
verage L F.EB =
,ange L &2-E.'' L '.CD
Standard Dev. L 0.FB'
Production rate
&000 K &+00
Moint8/ee0
verage L &&E0
Production rate
&000 K &+00
Moint8/ee0
verage L &&E0
Quality ,ate L &00 K F.E+
L F0.&+ =
& S CE.2D=
N F0.&+
2 S F+.B+=
' S FF. D'=
Sigma 7evel O &.E&
./it-out &.+ S S-i#t4
Sigma 7evel O 2.E0
./it- &.+ S S-i#t4
Quality ,ate L &00 K F.E+
L F0.&+ =
& S CE.2D=
N F0.&+
2 S F+.B+=
' S FF. D'=
Sigma 7evel O &.E&
./it-out &.+ S S-i#t4
Sigma 7evel O 2.E0
./it- &.+ S S-i#t4
TQM 37
"lass 7imit &requency
8!9-9!: ,
9!:-;!< <
;!<-;!; 9
;!;-,-!= :
,-!=-,,!> <
,,!>-,<!- <
$otal ? <-
're3!en$# 2na"#sis
TQM 38
0
5
10
15
20
9 10 11 12
're3!en$#
Rejected %
n
x
=
Mean L F.E+
!
" #
$
=

n
x mean
Standard deviation L 0.FC&

B
e
f
o
r
e

I
m
p
r
o
v
e
m
e
n
t
TQM 39
Upper Control Liit ean ! 3 stde"
Lo#er Control Liit ean ! 3 stde"

$ean
Rejected %
%ee&
NP L F.EB SL0.FB'
%C7 L 9P Q ' S L &2.CD %C7 L 9P - ' S L D.0
Comment) All the points are within the control limits! Comment) All the points are within the control limits!
TQM 40
>
'
(
c
e
l
l
e
n
t

)er* good
+ood
Fair
6!t of $hart
)e?e$te/ @
7ee<
TQM 41
7ea<ness Points:
1%
2%
3%
4%
5%
2$t!a"
Performan$e
%%% @
Aosses
%%% @
1trength Points:
1%
2%
3%
4%
5%
)e$ommen/ations:
1%
2%
3%
4%
5%
GP" ,eport K @ne Page Management
Gey Per#ormance "ndicators #or decision ma0ing process
&ro-ect. 4&5 6 0 inch 6 )0 7m 8rom Site 9 to Site : &rocess. 3lectric 'rc #elding
$uality 2ate. &rocess %apability. Sigma 5evel.
TQM 42
Process Capa:ility ,atios
. Desired Per#ormance4 8 .ctual Per#ormance 4
Ioice o# Customer
Ioice o# Process
3-is curve is t-e
distri:ution o# data
#rom t-e process
3-e s-aded areas
represent t-e
percentage o# o##-spec
production
Process per#ormance is
not necessarily centered
:et/een t-e spec limits
T#e "apa9ility in&e$ is &e(ine& as:
Cp G *allowa9le range+27 GT *Toleran"e+2 7G *0S% H %S%+27
TQM 43
C
p
R &.0
C
p
L &.0
C
p
S &.0
N
N
N
7S7 %S7
7S7 %S7
.Jot capa:le(4
.Capa:le4
.>ig- Capa:le4
Process capa:ility is t-e a:ility o# t-e process to meet t-e desired ;uality
Process Capa:ility)
+t is a method of measure used to determine if the process is capable to
produce the required quality level # customer specifications or not!
Process Capa:ility)
+t is a method of measure used to determine if the process is capable to
produce the required quality level # customer specifications or not!
TQM 44
Process Capa:ility $ Si9 Sigma
Process Capa:ility $ Si9 Sigma
Ao-er
s&e$ifi$ation
Mean
B&&er
s&e$ifi$ation
1i( sigma
'o!r sigma
5hree sigma
Comina"
va"!e
.&< D 1 @ot "apable
.&< E 1 "apable at >
.&< E 1433 "apable at .
.&< E 1467 "apable at :
Cp0 SL 2 Capa:le at C
Process Process
Capa:ility $ Capa:ility $
Design *or C
Sigma
TQM 45
$he upper and lower specification limits for a component are -!,:- cm! and -!,<- cm!,
with a process target of !,>: cm! $he process standard deviation is -!--. cm! and the
process average is -!,>9 cm!
Dis$!ss the &ro$ess $a&a*i"it# in/e(
$he upper and lower specification limits for a component are -!,:- cm! and -!,<- cm!,
with a process target of !,>: cm! $he process standard deviation is -!--. cm! and the
process average is -!,>9 cm!
Dis$!ss the &ro$ess $a&a*i"it# in/e(
!estion:
"ustomer AS7 ? -!,: 7S7? -!,< $arget 1ean ? 1 ? -!,>:
Process S ? -!--. 1ean ? 4B ? -!,>9 %CD E 1, the process mean is shifted(
"p ? %AS7 F 7S7( 2 = S ? %-!,:--!,<(2=G-!--. ? ,!<: E ,
"pu ? %AS7 F 1( 2 > S ? %-!,: F -!,>:(2>G-!--. ? , ?
"pl ? %1 -7S7( 2 > S ? %-!,>:--!,<(2>G-!--. ? ,!: E,
"pl E "pu, since the process mean is not centered!
"ustomer AS7 ? -!,: 7S7? -!,< $arget 1ean ? 1 ? -!,>:
Process S ? -!--. 1ean ? 4B ? -!,>9 %CD E 1, the process mean is shifted(
"p ? %AS7 F 7S7( 2 = S ? %-!,:--!,<(2=G-!--. ? ,!<: E ,
"pu ? %AS7 F 1( 2 > S ? %-!,: F -!,>:(2>G-!--. ? , ?
"pl ? %1 -7S7( 2 > S ? %-!,>:--!,<(2>G-!--. ? ,!: E,
"pl E "pu, since the process mean is not centered!
Pro$ess $a&a*i"it# in/e( F Ao-er va"!e +.&0 .&!0 .&", F 1
5his means0 the &ro$ess is *are"# $a&a*"e to a$hieve the /esire/4
Pro$ess $a&a*i"it# in/e( F Ao-er va"!e +.&0 .&!0 .&", F 1
5his means0 the &ro$ess is *are"# $a&a*"e to a$hieve the /esire/4
=o- to im&rove the &ro$ess $a&a*i"it#G
:m&rove the maintenan$e &rogram4
:m&rove the mista<e &roofing +Po<a%Ho<e,
:m&rove the man&o-er s<i""s thro!gh a/van$e/ training &"an4
=o- to im&rove the &ro$ess $a&a*i"it#G
TQM 46
5idt- o# landing
strip
&82 5idt-
o# landing
strip
"# pilot al/ays lands
/it-in &82 t-e landing strip
/idt-, /e say t-at -e -as
Si9-sigma capa:ility.
&00
+0
2+
2+
TQM 47
)e"ia*i"it# I .riti$a" to 3!a"it#
Probability of 5ero failure
Probability that the product, service or part will function as

e4pected
System ,elia:ility nalysis
Parallel structure) ,s L & K.&-,&4T .&-,24T .&-,'4 T ..H
Series or c-ain structure) ,s L ,& T ,2 T ,' T H..
,s L
0.F+T0.E+T0.F0
L 0.D L D0=
,& L 0.F+
,2 L 0.E+
,' L 0.F0
,2
0.E+
,'
0.F0
,&
0.F+
,s L
&- .&-0.F+4 T
.&-0.E+4 T .&-0.F04
L 0.FFF2+ L FF.F2+=
TQM 48
!estion :
&our subsystems have the following reliabilitiesH
0A ? 0I ? !;- and 0" ? 0D ? !;:!
$he four subsystems are connected as shown!
Dis$!ss the s#stem re"ia*i"it#4
&our subsystems have the following reliabilitiesH
0A ? 0I ? !;- and 0" ? 0D ? !;:!
$he four subsystems are connected as shown!
Dis$!ss the s#stem re"ia*i"it#4
Since A # I are parallel, 0%AI( ? , F J %,-0a( G %,-0b(K ? -!;; ? ;; L
Since " # D are parallel, 0%"D( ? , F J %,-0c( G %,-0d(K ? -!;;8: ? ;;!8:L
Since AI # "D are series, 0%AI"D( ? 0%AI(G0%"D( ? -!;98:<: ? ;9!8:L
Since A # I are parallel, 0%AI( ? , F J %,-0a( G %,-0b(K ? -!;; ? ;; L
Since " # D are parallel, 0%"D( ? , F J %,-0c( G %,-0d(K ? -!;;8: ? ;;!8:L
Since AI # "D are series, 0%AI"D( ? 0%AI(G0%"D( ? -!;98:<: ? ;9!8:L
1#stem re"ia*i"it# +-hi$h means the &ro*a*i"it# of Jero fai"!re, F 98475@
5his means0
1#stem re"ia*i"it# +-hi$h means the &ro*a*i"it# of Jero fai"!re, F 98475@
5his means0
=o- to im&rove the s#stem re"i*i"it#G
=o- to im&rove the s#stem re"i*i"it#G
TQM 49
,oot Cause nalysis is a systematic approach to get to the true
root causes of the problems!
5-at is ,oot Cause nalysis .,C46
#>:?#>: T3%>0I$@3
Pro:lem
+ 5-yUs
,oot Cause
Vou Can
Control
TQM 50
,oot Cause nalysis .,C4
Manpo/er
S0ills
Material
Environmental
5or0ing
Conditions
Mac-ine $
3ools
Met-od o#
5or0
,oot Cause nalysis)
+t is a method based on why-why technique to find the root cause of a
problem, and then define the remedy to prevent this problem in future!
M*hat happened analysisNO
,oot Cause nalysis)
+t is a method based on why-why technique to find the root cause of a
problem, and then define the remedy to prevent this problem in future!
M*hat happened analysisNO
TQM 51
;el&ing
'e(e"t
;el&ing
'e(e"t
Manpower S:ills
Ma"#ine
Met#o&
Materials
;or:ing Con&itions
Anvironmental
Cause $ E##ect Diagram .C$E4) 1"s-i0a/a Diagram or *is-:one diagram2
+t is used to present the priorities of root causes for a certain problem2defect!
Cause $ E##ect Diagram .C$E4) 1"s-i0a/a Diagram or *is-:one diagram2
+t is used to present the priorities of root causes for a certain problem2defect!
TQM 52
Method Manpower
Material
Machinery
Drill Drill
Overtime Overtime
Steel Steel
Wood Wood
Not Maintained Not Maintained
Too many
defects
Too many
defects
Tired Tired
Old Old
Slow Slow
.a!se%an/%Effe$t Diagram or 'ish*one /iagram
E##ect
Cause
TQM 53
Pro:lem
*ailure
Mode
Cause
E##ect
Ishi7awa
/ailure Mo&e A((e"t !nalysis */MA!+
;#at I(
tool used to evaluate
potential #ailure modes and t-eir causes.
*ailure Mode E##ect Cause
Proactive ction .,is0 Plan4
5-at "#
nalysis6
TQM 54
*ailure Mode E##ect nalysis)
+t is a method based on ris assessment to predict the different failure modes
for the process, and then define the remedy to prevent this modes in future!
M*hat +f analysisNO
*ailure Mode E##ect nalysis)
+t is a method based on ris assessment to predict the different failure modes
for the process, and then define the remedy to prevent this modes in future!
M*hat +f analysisNO
*ailure Mode E##ect Cause Proactive ction
.Q8QC4
Slow Speed /verlap -
-
Pigh Speed +ncomplete Qoint -
-
+nconstant
Speed
+rregular weld -
-
*ME #or 5elding Process
TQM 55
'D is a strategi$ 3!a"it# &"anning too" to trans"ate the
$!stomer re3!irements to /esign in/i$ators ; target 3!a"it#
&"an0 .Design #or C Sigma4 - &FD0
!a"it# '!n$tion De&"o#ment +'D,
! te"#ni?ue (or i&enti(ying "ustomer re?uirements an& mat"#ing
t#em wit# engineering &esign an& per(orman"e parameters
Q&D is a planning tool used to fulfill customer e4pectations! +t can
be applied to manufacturing and service industries!
Q&D is a planning tool used to fulfill customer e4pectations! +t can
be applied to manufacturing and service industries!
More t-an &000 "nternational Company)
3oyota, &FDD *ord, &FDE
"BM, &FE2 Boeing, &FE'
Jo0ia, &FEC
TQM 56
Q*D) Quality *unction Deployment
+t is a tool used to translate the customer requirements to design indicators #
target quality planR as Mstrategic quality planning toolO
Q*D) Quality *unction Deployment
+t is a tool used to translate the customer requirements to design indicators #
target quality planR as Mstrategic quality planning toolO
CUSTOMERS
NEEDS
C
U
S
T
O
M
E
R
S
PRODUCT
FEATURES
C
U
S
T
O
M
E
R
S
N
E
E
D
S
PROCESS
FEATURES
P
R
O
D
U
C
T
F
E
A
T
U
R
E
S
SMART
Quality Plan
P
R
O
C
E
S
S
F
E
A
T
U
R
E
S
TQM 57
)ouDve been assigned
temporarily to a Q&D team!
$he goal of the team is to
develop a new camera
design!
Iuild a Pouse of Quality!
S ,;9.-,;;. $21aer "o!
=o!se of !a"it# E(am&"e
TQM 58
< Customer >ee&s Importan"e
! %igt &eigt '()
$ *asy to use +()
, -elia.le $/)
+ *asy to old steady $()
/ 0o dou.le e1posures $()
' Color correction !/)
2 -educe 3i4e !/)
5 Improve Po&er *ff6 !()
7 %o& Cost !()
!( Product Colors /)
!! Product 8ssem.ly /)
!$ Oters ,)
Customer Jeeds)
*ocus on
,e#erence, Benc-mar0ing, Standards
TQM 59
< Customer
>ee&s
Importan"e CowI Class
!
$
,
%igt &eigt
*asy to use
-elia.le
,
$
!
9 8luminum Parts
9 8uto Focus
9 8uto *1posure
#flas"
9 8uto Film advance
9 8uto Potograp
9 *rgonomic design
#-edesign 3tructure"
8
B
B
C
C
C
Engineering .hara$teristi$s +Pro/!$t Design, I )!"e 80920
TQM 60
.!stomer )e3!irements ; :m&ortan$e +)!"e 80920,
=% =igh re"ationshi&K M% Me/i!m re"ationshi& A% Ao- )e"ationshi&
Customer
Requirements
Customer
Importance
Taret !alues
Light weight
Easy to use
Reliable
3
2
1
TQM 61
Customer
Requirements
Customer
Importance
Taret !alues
Light weight
Easy to use
Reliable
Aluminum
Parts
Auto
Focus
Auto
Exposure
3
2
1
Engineering .hara$teristi$s +Pro/!$t Design, I )!"e 80920
TQM 62
)e"ationshi& Matri(
Customer
Requirements
Customer
Importance
Taret !alues
Light weight
Easy to use
Reliable
Aluminum
Parts
Auto
Focus
Auto
Exposure
3
2
1
Relationship between
customer attributes &
engineering characteristics
(rooms)
TQM 63
)e"ationshi&
"# "ih relationship M# Medium relationship $# $ow Relationship
Customer
Requirements
Customer
Importance
Taret !alues
Light weight
Easy to use
Reliable
Aluminum
Parts
Auto
Focus
Auto
Exposure
3
2
1
"
TQM 64
B
u
d
g
e
t

*
l
e
9
i
:
i
l
i
t
y

=
&00
&0
0 +0 &00
3ec-nical *le9i:ility =
+0
0
C
D
B
5arget La"!es +Priorit# 1#stem, +20 80 .0 D,
TQM 65
5arget La"!es +Priorit# 1#stem,
Customer
Requirements
Customer
Importance
Taret !alues
Light weight
Easy to use
Reliable
Aluminum
Parts
Auto
Focus
Auto
Exposure
3
2
1
A B B
Target values for engineering
characteristics (basement);
key output
"
TQM 66
&.
Sort
+S
2.
Set in order
'.
S-ine
B.
StandardiWe
+.
Sustain
! Systemati" !pproa"# (or Jisual Control 1 ;or:pla"e
Organiation in or&er to improve sa(ety6 ?uality an& pro&u"tivity
! Systemati" !pproa"# (or Jisual Control 1 ;or:pla"e
Organiation in or&er to improve sa(ety6 ?uality an& pro&u"tivity
+ S, Mapanese 3ool, &FD0
+ Pillars o# Iisual Control $ 5or0place @rganiWation
1Productivity "mprovement 3ool2
TQM 67
7hatMs 5M1G
7hatMs 5M1G
1ometimes $a""e/ 51 N 1 or O61P 1ometimes $a""e/ 51 N 1 or O61P
Sa#ety *irst (
Sa#ety *irst ( .in everyt-ing /e do(4
TQM 68
8efore
2fter
TQM 69
8efore
2fter
TQM 70
Po<a%Ho<e +Mista<e%Proofing,
An approach for mistae-proofing processes
using automatic devices or methods to avoid
simple human or machine error!
Defect warning system
1ae it impossible to mae mistaes
+nitial term was baa-yoe, which means

Tfool-proofingD
+mprove quality and reliability
"an eliminate both human and mechanical

errors
1higeo 1hingo
A %trategy for
Performance
)*cellence
5or0 to ac-ieve de#ect prevention
not de#ect detection
TQM 71
Po<a%Ho<e E(am&"es:
TQM 72
Pro$ess for Mista<e Proofing
Descri:e De#ect and De#ect ,ate
Determine De#ect 7ocation
Study t-e Process *lo/
@:serve t-e Process
"denti#y Errors and Determine Cause
Determine Prevention Met-od
3est8,e-test in E9treme Conditions
TQM 73
)i,ration -lar
.eperat/re
-lar
Qi/o<a E(am&"es:
TQM 74
Qi/o<a E(am&"es:
TQM 75
GaiWen is a tool originally used :y 3oyota to #oster continued
improvement /it-in its 3oyota Production System.
"t :egan as XQuality Circles,X a means o# #actory s-op #loor employees
solving ;uality issues /it-in a structured team #rame/or0,
using speci#ic ne/ tools.
"t is a process :ased on improving Sa#ety, Quality, and Delivery, :y t-e
elimination o# /aste .muda4 in its many #orms.
"t is no/ used around t-e /orld :y many companies and -as :een
adapted to suit t-eir individual needs and customs.
Philosophy that sees to mae never-
ending improvements to the process
of converting inputs into outputs!
Gai C-ange
?en Better
C-ange #or Better
GaiWen Continuous "mprovement
TQM 76
RaiJen Aean 1i( 1igma
Qa&anese -or/
for $ontin!o!s
im&rovement
7aste re/!$tion
.#$"e time re/!$tion
:nventor# re/!$tion
Lariation )e/!$tion
Defe$t Prevention
Data%/riven De$isions
.ontin!o!s Pro$ess :m&rovement +.P:,
TQM 77
Improve Quality!
Customer Company/Supplier
7hat is 1i( 1igmaG
2 s#stemati$ a&&roa$h to minimiJe /efe$tsS
Cear Tero Defe$ts O344 PPMP4
De#ects
5he Bse 6f 1i( 1igma
8# i/entif#ing fa$tors -hi$h are $riti$a" to 3!a"it#0 -e $an:
)e/!$e &ro$ess variationS
:m&rove $a&a*i"itiesS
:n$rease sta*i"it#S
7or< to-ar/s TE)6 DE'E.514
&FED Motorola
introduced Quality
Program no/ 0no/n
as Si9 Sigma.
TQM 78
@pper Specification 5imit
A@S5B
5ower Specification 5imit
A5S5B
Y ' Sigma
Y C Sigma
'.B PPM
Most current met-odologies operate at ' to B sigma, allo/ing Z 2+= loss
o# revenue :ecause o# #ailure rates due to de#ects
*or any process, variation is t-e main reason #or poor per#ormance...
Iariation is a driver o# de#ects
Iariation is t-e 0ey #ocus o# Si9 Sigma
TQM 79
7hat is 1i( 1igmaG
-#ilosop#y
% 2 management strateg# to ma(imiJe the 3!a"it# rate4
% .riti$a" 5o !a"it# +.5, .riteria4
% Pro$ess 'or .ontin!o!s :m&rovement4
-rogram
Statisti"ally 9ase& Quality -rogram
Culture
%ea&ers#ip6 Teamwor: 6 C#ange management6
%ong term "ontinuous improvement
Boal
2 goa" of near &erfe$tion in meeting $!stomer re3!irements
*,). 'e(e"ts per Million Opportunities+
Origin
1988 Motorola
!pproa"#
-roa"tive approa"#
'M!IC 'e(ine 6 Measure6 !nalye6 Improve 6 Control
Tools
Statisti"al ?uality tools 1 Quality improvement tools
C[ L Jear Per#ection(
Critical-3o-Quality .C3Q4) "s a measure o# /-at is important to a
customer.
TQM 80
Si9 Sigma pproac- or .DM"C4)
+t is a systematic problem solving approach, to minimi5e the defects!
%Define F 1easure F Analysis F +mprove F "ontrol(
Si9 Sigma pproac- or .DM"C4)
+t is a systematic problem solving approach, to minimi5e the defects!
%Define F 1easure F Analysis F +mprove F "ontrol(
DM2:. Pro$ess DM2:. Pro$ess % % *ive P-ase "mprovement Process
TQM 81
Eliminate the Gap!
Customer Company/Supplier
Lean
7hat is AeanG
A systematic approach to minimi5e the waste in process
7ean is about understanding what is important to the customer

7ean is all a:out continuous
/aste elimination
7ean) principle driven, tool :ased p-ilosop-y t-at #ocuses on
eliminating /aste so t-at all activities8steps add value
#rom t-e customerPs perspective.
TQM 82
7ean pproac-)
+t is a systematic problem solving approach, to minimi5e the wasters!
+t based on eliminating of the main seven waters %@on-value-Added Activities(!
7ean pproac-)
+t is a systematic problem solving approach, to minimi5e the wasters!
+t based on eliminating of the main seven waters %@on-value-Added Activities(!
1
1
6
6
7
7
5
5
4
4
3
3
2
2
6ver&ro/!$tion
5rans&ortation
7aiting
:nventor#
6ver%&ro$essing
Bnne$essar#
movement
)e-or<
7215E 7215E
1
1
6
6
7
7
5
5
4
4
3
3
2
2
TQM 83
Aean 1i( 1igma
7ean tools and techniques are used to standardi5e wor and remove
waste and non value-added activities!
Si4 Sigma tools and techniques are used to attac the variation present in
processes!
Si$ Sigma:
-emove variation from processes
:esign more capa.le processes
Focus on parts 2 pro"ess

%ean:
-emove &aste; re&ork; inventory
Improve flo&; velocity
Focus on system
1i( 1igma Ls4 Aean
"ntegration Management $ 7eader $ 3eam/or0
7ean Si9 Sigma Drivers 7ean Si9 Sigma Drivers
TQM 84
LEAN
Understanding of process
flow and points of waste
Value Stream Mapping activities

and Lean events to reduce waste
Quick Hit improvements
Speed and efficienc! focused
Standardi"ation
1Eliminate 5aste2
Variation reduction
Structured met#od for ongoing

improvements$ %&ontrol 'lan(
Use of continuous data and

metrics to drive improvement
S)* S)+MA
1Eliminate Iariation2
L
E
A
N

S
)
*

S
)
+
M
A
Lean Si, Sigma addresses t#e following ke! areas-
.#o is !our customer/
)s !our service improving/
How do !ou measure improvement/
S#ow me t#e data0
.#at is Lean Si, Sigma/
TQM 85
.om&aring 1i( 1igma0 Aean0 56.
Program 1i( 1igma Aean 5hin<ing 5heor# of .onstraints
5heor# )e/!$e
variation
)emove
-aste
Manage
$onstraints
Application
Uuidelines
Define
1easure
Analy5e
+mprove
"ontrol
+dentify value
+dentify value stream
&low
Pull
Perfect
+dentify constraint
34ploit constraint
Subordinate constraint
3levate constraint
0epeat cycle
&ocus Pro*"em
'o$!se/
'"o-
'o$!se/
1#stem
.onstraints
TQM 86
5PM Goa"s: Tero Aosses
TE)6 *rea</o-ns
TE)6 /efe$ts
TE)6 s&ee/ "osses
TE)6 a$$i/ents
Iision) 3otal li#e cycle
e;uipment management
5ota" Pro/!$tive Maintenan$e0 Qa&anese $on$e&t0 1951
5PM is a Aean too" to o&timiJe the effe$tiveness of
man!fa$t!ring e3!i&ment an/ too"ing4
5PM is a Aean too" for !a"it# an/ Pro/!$tivit#
5PM in three -or/s0
5ota" All individuals in the organi5ation woring together!
Pro/!$tive Production of products that meet or e4ceed
customerDs e4pectations!
Maintenan$e Veeping equipment and plant in good condition
at all times!
TQM 87
Aean Enter&rise
Aean Enter&rise
Lita" Ain<s: Aean0 1i( 1igma an/ .hange Management
C
C
Quality
7ean
C-ange
Management
6
Speed

CP
Sa#ety
Sa#ety *irst (
Proactive
5or0#orce
Sa#ety and +S toget-er
integrated and aligned
people and processes .
TQM 88
Quality Management System
*or 1rc 5elding Process2
Case Study
TQM 89
DM2:. Pro$ess DM2:. Pro$ess % % *ive P-ase "mprovement Process
Si$ Sigma Improvement Met#o&ology
TQM 90
Define Meas!re 2na"#Je :m&rove .ontro"
Pro<ect = Product
Process = Operations
-ro9lem Statement
>ain O.<ectives
3tandards = Codes
%ea&er 1
Teamwor:
Process Overvie&
Brainstorming
Voice of te Customer
Bencmark = ?oals
>ain @argets
Auality Circles
Process >ap #3IPOC"
:efect %ist
Brainstorming
-C8
'ata /orms
'ata Colle"tion:
Production -ates
:efect FreBuency
Pareto 8nalysis #8;B;C"

3ule 80220 Class !
Brainstorming
-C8
F>*8
Cause C *ffect
:iagram
FreBuency 8nalysis
Control Carts
Process Capa.ility
3igma %evel; D etc6
Con"lusion:
3trengt Points
Weakness Points
3e"ommen&ations
Improvement -lan:
/ 3
J38
>etod of 3tatement
A8 = AC Cecklist
A8=AC :oc6
3afety Plan
@raining Plan
*!"tual 2
-lanne&+
K-Is:
Auality -ate
Process Cap6
3igma %evel
Si$HSigma Improvement Met#o&ology 3oa& Map
ISO 9001 *8+ Measurement6 !nalysis6 an& Improvement
TQM 91
Iusiness "ase Statement
Problem Statement
Uoal Statement
Scope of *or
Pro?e$t Came:
Mi"estones
Define --2--2--
1easure --2--2--
Analy5e --2--2--
+mprove --2--2--
"ontrol --2--2--
$eam 1embersH
ProcessH
$eam 7eaderH
$eam 1embersH
Si$ Sigma -ro4e"t
TQM 92
'e(ine Stage : *&rocess 1escriptionB
ProWect 2 Product
Process 2 /perations
Pro*"em 1tatement
1ain /bWectives
Standards 2 "odes
7eader # $eamwor
Process /verview
Irainstorming
6oice of the "ustomer
Ienchmar
1ain $argets
Quality "ircles
Process 1ap %S+P/"(
ProWect 2 Product
Process 2 /perations
Pro*"em 1tatement
1ain /bWectives
Standards 2 "odes
7eader # $eamwor
Process /verview
Irainstorming
6oice of the "ustomer
Ienchmar
1ain $argets
Quality "ircles
Process 1ap %S+P/"(
Iy the end of Define, you should be able to
describe for your "hampionH
F *hat ey process is involved %including its
Suppliers, +nputs, /utputs, and
"ustomers(
F *hat about the process output is
important to customers
F *hat customers currently thin of the
process and its output
F *hy this proWect is important to your
organi5ation and what business goals the
proWect must achieve to be considered
successful
F *ho the players are on the proWect
%sponsors, advisors, team leader, team
members(
F *hat limitations %budget, time, resources(
have been placed on this proWect
TQM 93
TQM 94
-ro9lem Statement:
pply Si+ Sigma problem solving methodology to insure that the welding process is
achieving Si+ Sigma quality levels of less than ,.4 defects per million for all critical
welding parts.
(ain Ob-ectives.
&roduce welding parts that meet the customer requirements and ma+imi/e the
resource utili/ation.
ST'01'21S ! %O13S.
P" &&0B, 5elding o# pipelines and related #acilities.
TQM 95
#elding $uality Teamwor7 *Quality !ssuran"e Team+
5eader. #elding 5eader S7ills. %ertified #elding
Teamwor7. #elding 3ngineers* $uality 3ngineer* 1esign 3ngineer* D etc.
(eeting 8requency. #ee7ly* Two hours
#elding
3ng.
1esign
3ng.
$uality
3ng.
7eader
@rganiWation Structure
Quality
Manager
"nspection
Engineer
QC
Engineer
Q
Engineer
Design
Manager
5elding
Manager
ProAect
Manager
TQM 96
%urrent Situation A0)0B
'verage $uality 2ate E "F.G H 1efect 2atio E .GH
%urrent Situation A0)0B
'verage $uality 2ate E "F.G H 1efect 2atio E .GH
Ienchmar7ing.
>istory 'nalysis Internal Ienchmar7 $uality 2ate E "8.G H
International Survey 3+ternal Ienchmar7 $uality 2ate E ""." H
Ienchmar7ing.
>istory 'nalysis Internal Ienchmar7 $uality 2ate E "8.G H
International Survey 3+ternal Ienchmar7 $uality 2ate E ""." H
Targets.
(edium term Ane+t yearB from "F.G to "8.G H
5ong term Ane+t , yearsB from "F.G to ""." H
Targets.
(edium term Ane+t yearB from "F.G to "8.G H
5ong term Ane+t , yearsB from "F.G to ""." H
%hange (anagement. #hy J >ow to be proactiveK
Importance of $ualityK %ost of $ualityK %onsequenceK
%hange (anagement. #hy J >ow to be proactiveK
Importance of $ualityK %ost of $ualityK %onsequenceK
Strategic Ob-ectives AS('2TB
:ear 0)) 0) 0), 0)4
$uality 2ate H L "8.G L "".0 L "".G L "".""
Strategic Ob-ectives AS('2TB
:ear 0)) 0) 0), 0)4
$uality 2ate H L "8.G L "".0 L "".G L "".""
TQM 97
RP: +Primar# Metri$,
*elding Defect 0atio *elding Defect 0atio
-L -L
,L ,L
<L <L
>L >L
.L .L
:L :L
=L =L
8L 8L
A
u
g
-
;
;
S
e
p
-
;
;
/
c
t
-
;
;
@
o
v
-
;
;
D
e
c
-
;
;
Q
a
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-
-
-
&
e
b
-
-
-
1
a
r
-
-
-
A
p
r
-
-
-
1
a
y
-
-
-
Q
u
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-
-
-
Q
u
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-
-
-
A
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-
-
-
S
e
p
-
-
-
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1
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2
a
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H
Iaseline Iaseline
Actual Actual
/bWective /bWective
TQM 98
&rocess Overview
&rocess. Electric rc 5elding
(ain Ob-ective Improve the quality rates of the welding process
$he mar of a good welder is the ability to identify weld defects
and adWust the welding parameters to eliminate them!
TQM 99
A pool of molten metal is formed near electrode tip, and as electrode is moved
along Woint, molten weld pool solidifies in its wae
8asi$ $onfig!ration of an ar$ -e"/ing &ro$ess4
2r$ 7e"/ing
TQM 100
Preparation of the
welding area
Preheating
Qoining and
"ooling
Pro$ess 1e3!en$e Pro$ess 1e3!en$e : :
TQM 101
7e"/ing Positions
*73 *73
>@,"?@J37 >@,"?@J37
IE,3"C7 IE,3"C7
@IE,>ED @IE,>ED
"JC,ES"J! D"**"C%73V
TQM 102
'ive 5#&es of Qoints
Butt
7ap
3
Corner
Edge
TQM 103
Sa#e Practices
5elders need protection #rom)
F rcPs rays
F 5elding #umes
F
Spar0s
F Contact /it- -ot metal
TQM 104
Di"!tion Lenti"ation
"ontaminant
should travel
away from
breathing
5one!
7ocal e4haust
ventilation
may be more
effective!
Poor *air
!ood Best
TQM 105
Suppliers "nputs Process Customers @utputs
Production
Planning
Department
*or /rder
Process Sheet
Drawings
0aw 1aterials
$ools
Products
0ight Quantity
0ight Quality
0ight $ime
Storage
1aret
"ustomer
Pro$ess Ma& +1:P6. .hart,
Pro$ess ma&
+f"o- $hart,
0eceive
*2/ #
Drawings
Drawings
"hecing
Preparation of
Shop drawings
Quantity
Survey
Submittal to
the 3ngineer
for Approval
Detailed
Planning
Procurement of
0esources
34ecution
of *ors
Q
u
a
l
i
t
y

"
o
n
t
r
o
l
"ompletion of
the *2o
3lements
TQM 106
Pro$ess .hart
@perations
"nspection
3ransportation
Delay
Storage
1#m*o"s:
1!&&"ier
.!tting
8.1 hr
7e"/ing
52.0 hr
)a-
Materia"s
Finishing
20.4 hr
Painting
25.3 hr
'ina"
Pro/!$ts
.ll dimensions are in mm4
500
500
500
Product Description)
/elded /ater tan0
open on one side.
3 /a#
6r/er
/!e /ate
21 /a#
+20
s-eets
+2
plates
&02
tan0
&0&
tan0
&00
tan0
5elding
&+E& rods
'2 0g
TQM 107
,adiograp-y o# /eld
Aoints
:ns&e$tion ; 5esting
Lis!a" ins&e$tion
6isually e4amining the weld for surface defects
Con/estr!$tive eva"!ation
Ases various methods that do not damage the
specimen
Destr!$tive testing
1ethods in which the weld is destroyed during
the test or to prepare the specimen
AS13 I>,!> # I>,!. design standards
AP+ :8- inspection standards
@A"3 0P-,=;-<--< standard for
cathodic protection
TQM 108
Pro$ess :ns&e$tion 1#stem
"nspection
3ools
Parameters
*re;uency
Q8QC *orms)
"nspection Plan
Inputs Inputs
&rocess &rocess Outputs Outputs
? ? ? ? ? ?
? ? ? ? ? ?
? ? ? ? ? ?
TQM 109
29.: 2 .he$<"ist for !a"it# an/ .ontro"
29. .he$<"istU
152CD2)D19.6DE14
7EAD:CG 5E.=C:BE14
7EAD:CG P)6.EDB)E14
7EADE)1 B2A:':.25:6C 5E154

TQM 110
Meas!rement 1tage
A&rocess InformationB
Defect 7ist
0oot "ause Analysis
Data &orms
Data .o""e$tion:
Production 0ates
Defect &requency
Defect 7ist
0oot "ause Analysis
Data &orms
Data .o""e$tion:
Production 0ates
Defect &requency
TQM 111
Main De#ects)
V Defe$t Des$ri&tion )oot .a!se
!
@
C
'
A
/
B
C
I
TQM 112
Main De#ects)
TQM 113
B
C
D
E
*
!
>
"
Main De#ects)
TQM 114
Main De#ects)
V Defe$t Des$ri&tion )oot .a!se
!
+ncomplete Qoint
@
+mproper &usion
C
/verlap
'
+nsufficient Penetration
A
Pits
/
Porosity
B
6ertical "rac
C
Ander Iead "rac
I
+rregular *eld
TQM 115
$he depth of the weld is less
than specifications!
)*cessi'e heat
)*cessi'e speed+
,he weld metal is not
completely fused to -ase
metal or passes are not
completely fused+
Description .oot Cause
Incorrect angle
Incorrect manipulation
Insufficient heat
/eld material flows o'er, -ut
is not fused with the -ase
metal+
%low speed
'e(e"t 3oot Causes
B
C
,oot Cause nalysis
TQM 116
*eld bead does not e4tend
to the desired depth!
&ow heat
&ong arc
Incorrect 0oint design
%mall indentions in the
surface of the weld
%mall 'oids throughout the
weld material+
)*cessi'e gas in the
weld 1one+
2oisture
.ust
Dirt
Accelerated cooling
D
E
*
'e(e"t 3oot Causes
TQM 117
Asually visible cracs on
the surface or through the
weld
Accelerated cooling
Constrained 0oint
%mall weld 'olume
Cracks in the transition
1one -etween the weld
and -ase metal
Induced hydrogen
Incompati-le electrode or
wire
Accelerated cooling
2isshapen and3or
une'en ripples
Inconstant speed
Incorrect manipulation
Incorrect welder settings
!
>
"
'e(e"t 3oot Causes
TQM 118
De#ect ,oot Cause nalysis
V Defe$t )oot .a!ses )eme/#
!
Incomplete Joint
@
Improper Fusion
C
Overlap
'
A
Pits
/
Porosity
B
Vertical Crack
C
Under Bead Crack
I
Irregular Weld
TQM 119
De#ect ,oot Cause nalysis
V Defe$t Dete$tion 2&&roa$h .omment
!
Incomplete Joint
@
Improper Fusion
C
Overlap
'
A
Pits
/
Porosity
B
Vertical Crack
C
Under Bead Crack
I
Irregular Weld
TQM 120
5elding Process ,ates)
;ee:
<
Total
=oints
>um9er o(
3e4e"te&
1
2
,
.
5
7
8
8
9
10
))
)
),
Total
De#ect *re;uency)
< 'e(e"t
'es"ription
'e(e"t
/re?uen"y
!
Incomplete Joint
@
Improper Fusion
C
Overlap
'
A
Pits
/
Porosity
B
Vertical Crack
C
Under Bead Crack
I
Irregular Weld
;
Oters
TQM 121
5elding Process
;ee:
<
Total
=oints
>um9er o(
3e4e"te&
;ee:
<
Total
=oints
>um9er o(
3e4e"te&
1 1000 108 11 1,00 1,0
2 1500 1.5 12 1000 108
, 1200 125 1, 1000 108
. 1000 108 1. 1.00 1.0
5 1,00 125 15 1,00 1,5
7 1.00 1,5 17 1500 155
8 1000 125 18 1000 108
8 1100 115 18 1000 109
9 1100 115 19 1200 125
10 1200 125 20 1100 110
'e(e"t
Co&e
'e(e"t
/re?uen"y
!
100
@
.0
C
10
'
70
A
100
/
1200
B
.0
C
522
I
2.
K
20
Total ))M
Total ,M00 =oint
TQM 122
2na"#sis 1tage
*Quality Control Tools+
Pareto Analysis
0ule 9-2<-
0oot "ause Analysis
"ause # 3ffect Diagram
&13A
&requency Analysis
"ontrol "hart
Process "apability
Process Sigma 7evel
.on$"!sion:
Strength Points
*eaness Points
0ecommendations
Pareto Analysis
0ule 9-2<-
0oot "ause Analysis
"ause # 3ffect Diagram
&13A
&requency Analysis
"ontrol "hart
Process "apability
Process Sigma 7evel
.on$"!sion:
Strength Points
*eaness Points
0ecommendations
TQM 123
5elding Process
;ee:
<
Total
=oints
>um9er o(
3e4e"te&
;ee:
<
Total
=oints
>um9er o(
3e4e"te&
1 1000 108 11 1,00 1,0
2 1500 1.5 12 1000 108
, 1200 125 1, 1000 108
. 1000 108 1. 1.00 1.0
5 1,00 125 15 1,00 1,5
7 1.00 1,5 17 1500 155
8 1000 125 18 1000 108
8 1100 115 18 1000 109
9 1100 115 19 1200 125
10 1200 125 20 1100 110
'e(e"t
Co&e
'e(e"t
/re?uen"y
!
100
@
.0
C
10
'
70
A
100
/
120
B
.0
C
52
I
2.
K
20
Total GMM
Total ,M00 =oint
TQM 124
'e(e"t
Co&e
'e(e"t
/re?uen"y
!
100
@
.0
C
10
'
70
A
100
/
120
B
.0
C
52
I
2.
K
20
Total
577
Sorting
'e(e"t
Co&e
'e(e"t
/re?)
3atio
D
Cumulative
3atio D
'e(e"t %evel
/ 120 <,!< <,!<-
! 100 ,8!8 >9!98
A 100 ,8!8 :=!:.
' 70 ,-!= =8!,.
C 52 ;!< 8=!>9
@ .0 8!, 9>!.>
B .0 8!, ;-!:>
I 2. .!< ;.!8>
K 20 >!: ;9!<>
C 10 ,!9 ;;!;;
Total
577 !(( E !(()
-!3ATO !>!%KSIS
TQM 125
'e(e"t
Co&e
'e(e"t
/re?uen"y
!
100
@
.0
C
10
'
70
A
100
/
120
B
.0
C
52
I
2.
K
20
Total
577
Sorting
'e(e"t
Co&e
'e(e"t
/re?)
3atio
D
Cumulative
3atio D
'e(e"t %evel
/ 120 <,!< <,!<- !1
2
! 100 ,8!8 >9!98 !2
A 100 ,8!8 :=!:. !,
' 70 ,-!= =8!,. !.
C 52 ;!< 8=!>9 !5
@ .0 8!, 9>!.> @1
8
B .0 8!, ;-!:> @2
I 2. .!< ;.!8> @,
K 20 >!: ;9!<> C.
.
C 10 ,!9 ;;!;; C5
Total
577 !(( E !(()
-!3ATO !>!%KSIS
TQM 126
-!3ATO !>!%KSIS
'e(e"t
/
!
E
'
C
@
B
K
I
C
<,!<
,8!8
,8!8
,-!=
;!<
8!,
8!,
.!<
>!:
,!9
TQM 127
'e(e"t
/
C
Class
Class B
Class C
!
E
D
>
B
B
"
K
-!3ATO !>!%KSIS
TQM 128
'e(e"t
Co&e
'es"ription 'e(e"t
/re?)
3atio
D
Cumulative
3atio D
3oot Causes
/ Porosity 120 <,!< <,!<- 34cessive gas
Accelerated cooling
! +ncomplete
Qoint
100 ,8!8 >9!98 34cessive heat
34cessive speed
A Pits 100 ,8!8 :=!:. 34cessive gas
Accelerated cooling
' +nsufficient
Penetration
70 ,-!= =8!,. 7ow heat
7ong arc
C Ander bead
"rac
52 ;!< 8=!>9 +ncompatible electrode
Accelerated cooling
3oot Causes /or Top /ailures
TQM 129
%evel 1 %evel 2 %evel , %evel . %evel 5 %evel 7 %evel 8
;el&ing
'e(e"t
+',
Porosit#
+2,
:n$om&"ete
Qoint
+E,
Pits
+D,
:ns!ffi$ient
Penetration
+=,
Bn/er *ea/
.ra$<
Brain Storming !roup SiWe ' to +
5-y-5-y6
TQM 130
,oot Cause nalysis .,C4
Manpo/er
S0ills
Material
Environmental
5or0ing
Conditions
Mac-ine $
3ools
Met-od o#
5or0
TQM 131
;el&ing
'e(e"t
;el&ing
'e(e"t
Manpower S:ills
Ma"#ine
Met#o&
Materials
;or:ing Con&itions
Anvironmental
TQM 132
.a!se an/ Effe$t Diagram
'ish*one Diagram
TQM 133
Pro:lem
*ailure
Mode
Cause
E##ect
Ishi7awa
tool used to evaluate
potential #ailure modes and t-eir causes .
*ailure Mode E##ect Cause
Proactive ction .,is0 Plan4
5-at "#
nalysis6
TQM 134
*ailure Mode E##ect Cause Proactive ction
.,is0 Plan4
Slow Speed /verlap -
-
Pigh Speed +ncomplete Qoint -
-
+nconstant
Speed
+rregular weld -
-
TQM 135
;el&ing
'e(e"t
;el&ing
'e(e"t
Manpower S:ills
Ma"#ine
Met#o&
Materials
;or:ing Con&itions
Anvironmental
TQM 136
;ee: -ro&u"tion 3e4e"te& 3 D %omment
1 1000 108 10680
2 1500 1.5 9678
, 1200 125 106.2
. 1000 108 10680
5 1,00 125 9672 (in.
7 1.00 1,5 967.
8 1000 125 12650 (a+.
8 1100 115 106.5
9 1100 115 106.5
10 1200 125 106.2
11 1,00 1,0 10600
12 1000 108 10680
1, 1000 108 10680
1. 1.00 1.0 10600
15 1,00 1,5 106,8
17 1500 155 106,,
18 1000 108 10680
18 1000 109 10690
19 1200 125 106.2
20 1100 110 10600
5elding Process
,eAected ratio
F.C2 K &2.+0=
verage L &0.+ =
,eAected ratio
F.C2 K &2.+0=
verage L &0.+ =
Production rate
&000 K &+00
Moint8/ee0
verage L &&E0
Production rate
&000 K &+00
Moint8/ee0
verage L &&E0
Quality ,ate EF.+ =
& S CE.2D=
2 S F+.B+=
' S FF.2D=
Sigma 7evel O &.E S
Quality ,ate EF.+ =
& S CE.2D=
2 S F+.B+=
' S FF.2D=
Sigma 7evel O &.E S
TQM 137
0
5
10
15
20
9 10 11 12
're3!en$#
Rejected %
n
x
=
Mean L &0.+
!
" #
$
=

n
x mean
Standard deviation L 0.CBE

B
e
f
o
r
e

I
m
p
r
o
v
e
m
e
n
t
TQM 138
8
9
10
11
12
13
0 5 10 15 20 25
5ee0
,eAected =
B
e
f
o
r
e

I
m
p
r
o
v
e
m
e
n
t
TQM 139
Lo#er Control Liit ean 0 3 stde"

$ean
Rejected %
%ee&
B
e
f
o
r
e

I
m
p
r
o
v
e
m
e
n
t
TQM 140
Data a#ter
deleting point
D .ratio &2.+=4
;ee: -ro&u"tion 3e4e"te& 3e4e"te& 3atio
1 1000 108 10680
2 1500 1.5 9678
, 1200 125 106.2
. 1000 108 10680
5 1,00 125 9672
7 1.00 1,5 967.
F 1000 125 12650
8 1100 115 106.5
9 1100 115 106.5
10 1200 125 106.2
11 1,00 1,0 10600
12 1000 108 10680
1, 1000 108 10680
1. 1.00 1.0 10600
15 1,00 1,5 106,8
17 1500 155 106,,
18 1000 108 10680
18 1000 109 10690
19 1200 125 106.2
20 1100 110 10600
TQM 141
Lo#er Control Liit ean ! 3 stde"

$ean
Rejected %
%ee&
TQM 142
>
'
(
c
e
l
l
e
n
t

)er* good
+ood
Fair
6!t of $hart
)e?e$te/ @
7ee<
TQM 143
7ea<ness Points:
1%
2%
3%
4%
5%
2$t!a"
Performan$e
%%% @
Aosses
%%% @
1trength Points:
1%
2%
3%
4%
5%
)e$ommen/ations:
1%
2%
3%
4%
5%
&ro-ect. 4&5 6 0 inch 6 )0 7m 8rom Site 9 to Site : &rocess. 3lectric 'rc #elding
$uality 2ate. &rocess %apability. Sigma 5evel.
TQM 144
:m&rove 1tage
.Quality "mprovement 3ools4
:m&rovement P"an:
: S %6isual "ontrol(
QSA %Qob Safety Analysis(
1ethod of Statement
QA 2 Q" "heclist
Safety Plan
$raining Plan
:m&rovement P"an:
: S %6isual "ontrol(
QSA %Qob Safety Analysis(
1ethod of Statement
QA 2 Q" "heclist
Safety Plan
$raining Plan
TQM 145
Q 8 QC C-ec0list #or rc 5elding Process)
Phase :tem 1tat!s 3esponsi9ility
8efore
7e"/ing
"hec 1etal Sheets %type, si5e, defects, etc(
"hec *elding 3lectrode %type, grade, humidity, etc(
"hec *elding 1achine # $ools
"hec *elding "onditions %angle, amp, temp!, area, etc(
"hec Process %cleaning, area, safety, etc!(
D!ring
7e"/ing
"hec *elding Procedure
"hec *elding Positions
"hec *orer 3fficiency %sills, safety, etc(
2fter
7e"/ing
6isual +nspection %profile, si5e, surface defects, etc(
+nspect *elding Quality
&inal +nspection
Quality Documentation
Comments)
@ur Quality !oal) ?ero De#ect
500
500
500
500
500
500
TQM 146
.ontro" 1tage
*Key -er(orman"e In&i"ators+
;&I 'ctual &lanned Ienchmar7 4ap H %omment
'e(e"t 3atio
-ro"ess Capa9ility
Sigma %evel
)e$ommen/ations:
1%
2%
3%
4%
5%
TQM 147
*elding Defect 0atio *elding Defect 0atio
-L -L
,L ,L
<L <L
>L >L
.L .L
:L :L
=L =L
8L 8L
A
u
g
-
;
;
S
e
p
-
;
;
/
c
t
-
;
;
@
o
v
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;
;
D
e
c
-
;
;
Q
a
n
-
-
-
&
e
b
-
-
-
1
a
r
-
-
-
A
p
r
-
-
-
1
a
y
-
-
-
Q
u
n
-
-
-
Q
u
l
-
-
-
A
u
g
-
-
-
S
e
p
-
-
-
/
c
t
-
-
-
@
o
v
-
-
-
D
e
c
-
-
-
1
e
f
e
c
t

2
a
t
i
o

H
Iaseline Iaseline
Actual Actual
/bWective /bWective
RP: +Primar# Metri$,
TQM 148
Study 3argets)
,eAected = ,eAected =
B.AF 1145
A.AF 940
A.AF 245
A.AF 440
B.AF 445
B.AF 740
Pro$ess not $entere/
an/ not sta*"e
Pro$ess $entere/
an/ sta*"e
2//itiona" im&rovements
ma/e to the &ro$ess
R ' =
R C =
&0.+=
Current
&C00
&B00
&&E0
Production rate
Moint8day
Production rate
Moint8day
R0.&=
&E00
7ong
3erm
TQM 149
5raining P"an
Advanced training including testing are required for critical processes and
special techniques such asH
@raining Course Budget :uration 3tart Finis -esponsi.le
Pipe %ine Welding
Welding 3tandards=Codes
Welding >etrology
0:@ for Pipe %ine
Welding
TQM 150
Aeaning into 1i( 1igma Aeaning into 1i( 1igma
+&a&er*a$<, +&a&er*a$<,
by by Barbara Wheat Barbara Wheat, ,
Chuck Mills Chuck Mills, ,
Mike Carnell Mike Carnell
3-e !old Mine 3-e !old Mine
-
-y !reddy Ball4 and 2ichael Ball4 -y !reddy Ball4 and 2ichael Ball4
-
,he 5old 2ine: a 6o'el of &ean ,he 5old 2ine: a 6o'el of &ean
,urnaround deftly wea'es together the technical ,urnaround deftly wea'es together the technical
and human pieces of implementing lean and human pieces of implementing lean
manufacturing in an engaging story that readers manufacturing in an engaging story that readers
will find -oth compelling and instructi'e+ will find -oth compelling and instructi'e+
*here can + learn more about 7ean Si4 Sigma N
$hese > boos are quic readsX
2eferencesDD
TQM 151
&+&
Need more information 6
2eferencesDD
TQM 152
'lso...you might consider.
www.M?sigma.com
www.si+sigma.co.u7
www.si+sigmasystems.com
www.isi+sigma.com
2eferencesDD
Ueorge, 1ichael! %<--<(! 7ean Si4 SigmaH "ombining Si4 Sigma Quality with 7ean
Speed, @ew )orH 1cUraw-Pill!
0other, 1! and Shoo, Q! %<-->(! 7earning to SeeH 6alue Stream 1apping to
"reate 6alue and 3liminate 1uda, Irrooline, 1AH $he 7ean +nstitute!
Pande, P, @euman,0!P!, and "avanagh,0!0! %<---(! $he Si4 Sigma *ay, @ew
)orH1cUraw Pill!
Iossert , Qames! % Quly <-->( M7ean and Si4 Sigma--Synergy 1ade in PeavenO
Quality Progress!
Uoldratt, 3liyahu 1!, %,;;.(! $he UoalH A Process of /ngoing +mprovement, second
edition! Ureat Iarrington, 1AH @orth 0iver Press!
*omac, Qames P! and Daniel $! Qones! %<-->(! 7ean $hiningH Ianish *aste and
"reate *ealth in )our "orporation! @ew )orH Simon # Schuster!
TQM 153
Made in Egypt -
K .
TQM 154

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7 , , 32 8
1!ggestions
!estions
.omments
Dr+ Attia 9ussien 5omaa
Industrial )ngineering Professor : Consultant
attiagomaa;yahoo+com or attiagomaa;aucegypt+edu
,el: <1###=$>(?=
Copyrig-ts $ More "n#ormation, Please contact :
@seful %cience !or the
%ake of Allah
/eAre here to help youB
,hank you for your attentionB

TQM &amp; Product Development 18 06 2013

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TQM 1

Quality Management Best Practice

Quality Control Tools

Quality Improvement Tools

Si$ Sigma !pproa"#

%ean Si$ Sigma !pproa"#

!a"it# 2ss!ran$e +2, 1#stem oriente/

!a"it# .ontro" +., Pro/!$t oriente/

/o"us: Quality "ontrol

Standard deviation L 0.FC&

Probability of 5ero failure

Probability that the product, service or part will function as

Defect warning system

1ae it impossible to mae mistaes

+nitial term was baa-yoe, which means

+mprove quality and reliability

"an eliminate both human and mechanical

A systematic approach to minimi5e the waste in process

7ean is about understanding what is important to the customer

-emove variation from processes

:esign more capa.le processes

Focus on parts 2 pro"ess

-emove &aste; re&ork; inventory

Improve flo&; velocity

Value Stream Mapping activities

Quick Hit improvements

Speed and efficienc! focused

Structured met#od for ongoing

Use of continuous data and

5PM Goa"s: Tero Aosses

TE)6 s&ee/ "osses

Iusiness "ase Statement

7EADE)1 B2A:':.25:6C 5E154

Standard deviation L 0.CBE

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TQM & Product Development 18 06 2013

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