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TQM-RMK Group Unit 4
TQM-RMK Group Unit 4
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Document Title
Department: EIE,CSE,EEE& IT
Batch/Year:2018-21/IV
Created by: Faculty of R.M.K. Group of Institutions
Date:30/08/2020
1.TABLE OF CONTENTS
1. Contents
2. Course Objectives
3. Pre Requisites
4. Syllabus
5. Course outcomes
7. Lecture Plan
9. Lecture Notes
10. Assignments
UNIT I
SYLLABUS: Introduction - Need for quality - Evolution of quality - Definitions of
quality - Dimensions of product and service quality - Basic concepts of TQM - TQM
Framework - Contributions of Deming, Juran and Crosby - Barriers to TQM -
Customer focus - Customer orientation, Customer satisfaction, Customer
complaints, and Customer retention
UNIT-2
TQM PRINCIPLES
SYLLABUS: Leadership – Quality Statements, Strategic quality planning, Quality
Councils - Employee involvement - Motivation, Empowerment, Team and
Teamwork, Recognition and Reward, Performance appraisal - Continuous process
improvement - PDCA cycle, 5S, Kaizen - Supplier partnership - Partnering, Supplier
selection, Supplier Rating.
UNIT III
TQM TOOLS & TECHNIQUES I
SYLLABUS: The seven traditional tools of quality - New management tools - Six
sigma: Concepts, Methodology, applications to manufacturing, service sector
including IT - Bench marking - Reason to bench mark, Bench marking process -
FMEA - Stages, Types.
UNIT IV
TQM TOOLS & TECHNIQUES II
SYLLABUS: Quality Circles, Cost of Quality, Quality Function Development
(QFD) - Taguchi quality loss function - TPM - Concepts, improvement needs -
Performance measures.
UNIT-V
QUALITY SYSTEMS
SYLLABUS: Introduction—Benefits of ISO Registration—ISO 9000 Series of
Standards—Sector-Specific Standards—AS 9100, TS16949 and TL 9000-- ISO 9001
Requirements—Implementation—Documentation—Internal Audits—Registration-
ENVIRONMENTAL MANAGEMENT SYSTEM: Introduction—ISO 14000 Series
Standards—Concepts of ISO 14001—Requirements of ISO 14001—Benefits of
EMS.
5. COURSE OUTCOMES
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO1 - - 1 - - 1 1 - - - 3 -
CO2 - - - - - - - 2 3 - 3 -
CO3 - - - - 1 - - - - - 3 -
CO4 - - - - 1 - - - - - 3 -
CO5 - - - - - - - - - 1 3 -
CO6 - - 2 - - - 3 - - - 3 -
UNIT 1 – INTRODUCTION
S. Total Proposed
No. Date Actual Pertaining Taxono Mode of
No. Topic Lecture
Of CO my Delivery
Periods Date Level
Leadership – Quality
1 Statements -Strategic CO2 K2 MD2&
quality planning MD4
Quality Councils-
2 Employee CO2 K2 MD2
involvement
Recognition and
5 CO2 K2 MD2
Reward, Performance
appraisal
6 Continuous process
CO2 K2 MD2
improvement - PDCA
cycle
Supplier Partnering,
8 CO2 K2 MD2
Supplier selection
3 CO3 K2 MD2
New management tools
4 CO3 K2 MD2
MD5
Six sigma applications to
6 manufacturing, service CO3 K2 MD2
sector including IT
MODE OF DELIVERY:
1 CO3 K2 MD1
Quality Circles
2 CO3 K2 MD1
3 CO3 K2 MD2
Cost of Quality
4 CO3 K2 MD2
5
Quality Function CO3 K2 MD2
Development (QFD)
6
MODE OF DELIVERY:
MODE OF DELIVERY:
1. Head to Head
Activity:
Identify a topic in the lesson that is open-ended- suitable for thinking and ask
students to come up with their best.
Pair the students and get them to agree on a response.
Continue until half the group goes head to head with the other half.
Benefits:
Topic : Benchmark
Activity:
At the end of class, set a timer for one minute
Ask students to record their most eye-opening revelation or biggest question
Benefits:
Provide a “conceptual bridge” between successive class periods.
Improve the quality of class discussion by having students write briefly
about a concept or issue before they begin discussing it.
Effective way of involving all students in class simultaneously.
Promote class attendance and attentiveness
3. Chain Document
Activity
write several questions on pieces of paper and pass each to a student
The first student adds a response (use a timer to keep things moving quickly)
Then passes the page along to gather more responses.
Multiple contributions help build more complete understanding.
A digital alternative involves using shared documents that multiple students are
invited to edit.
Then your class can examine the responses and identify patterns and missing
pieces
Benefits
Provides an opportunity for students to examine others' ideas and compare
them to their own thinking.
Examining others' ideas, students build upon them or add new ideas of their
own
4.Mystery quotes
Activity
Identify a topic in the lesson that is open-ended- suitable for discussion
After the students explored a topic,
Show them a quotation about it they’ve never seen before.
Their task is to figure out the point of view of the person behind the quotation
and justify it to the class.
Students can debate this issue in small breakout groups before beginning a
whole-class discussion.
Benefits
Students work with a partner to analyse a piece - a quote, text passage or
section.
The mystery quotes activity is a good introduction to a topic or unit, as it helps
to activate background knowledge
Compare text to experience and begin discussion on a particular topic
9. LECTURE NOTES
UNIT – IV TQM TOOLS AND TECHNIQUES II
QUALITY CIRCLES
The entire structure of Quality circle constitutes the top management, a steering
committee, a Co-ordinator, Facilitator, leader, members and non-members. The
detailed note on each of the members is depicted below.
1. Non-Members:
Quality circle is a voluntary association of persons and all the employees working
in the organisation may not be initially volunteer to join the quality circles. So
non- members (the employees who have not joined quality circles) do not involve
themselves in the small group activities, but they are also important for the
success of quality circles.
For any problem identified and resolved by the quality circles, it would become
difficult for them to implement their own suggestions without the cooperation of
the non-members. Non-members should be enthused to participate in quality
circle activities and gradually change their attitudes and get inclined to join the
quality circles for the betterment of their own accomplishments as well as the
organizational goals.
2. Members:
Members are the heart of the quality circle program and proper use of their
untapped brainpower is the key to its success. Membership is strictly voluntary
and anyone who wishes to join should be welcomed. Members for quality circles
can come from all parts of the society. There is no restriction on the membership.
But the workers, foremen and supervisors are best suited for the formal
membership of quality circles.
Members undergo a formal training and start meeting regularly to discuss work-
related problems. They not only identify, analyse and solve the problems but also
ensure implementations of the recommendations, even if it calls for interaction
with other agencies or levels of management.
Members also contribute towards building a cohesive group culture through which
they intend to achieve the highest standards of performance. Through their
personal conduct and enthusiasm, members help in propagating the quality circles
concept in other areas where they are yet to be launched.
The main activities of circle members include:
i. Regular attendance of meeting,
ii. Active participation in the discussion,
iii. Identification of issues deterring improvement,
iv. Analysis of issues/problems
v. Submission of suggestions for improving quality and solving problems arising
in work related areas.
3. Leader/Deputy Leader:
The quality circle leader is elected by the circle members. He is responsible for
the circle activities. Quality circle leaders are not expected to do all the work
themselves but to involve all the members and sharing the task of getting things
accomplished. If the leader is absent, then deputy leader ensures that all the
meetings and other activities go on uninterruptedly.
Normally members themselves choose their hierarchical supervisor as their leader.
Leaders help keeping the circle meetings on the right track by applying quality
circle techniques to solve quality problems. The leader should have more positive
and constructive attitude in order to get better response from the members. A
healthy approach would be to have leaders and deputy leaders by rotation.
To have a high degree of individual involvement and participation, leaders should
assign tasks to different members and give them necessary guidance. The leader
ensures that every circle member is involved in circle activity with a high degree
of enthusiasm and involvement. He also ensures disciple and decorum during the
meetings and evolves consensus decision-making process. In short, “leader is one
who knows the way, shows the way and goes the way.”
The facilitator is the coordinator, who really makes the program of quality
circle going. He is the senior officer of the department where quality circles are
working. He has a crucial role to play in making the quality circle operation a
success. He is the one who has got the authority to take decisions himself on the
basis of the recommendations made by the quality circles.
By virtue of being high in the organisation hierarchy, he ensures the
proper implementation of the recommendations. Moreover, facilitator is the
personification of the top management’s commitment and support to the activities
of the quality circles.
Facilitator acts as a guide, counsellor, teacher and a catalyst to his group
by extending support to the operations of quality circles. He also lends assistance
and support to the leaders/deputy leader whenever required and helps in training
the members. He should be able to develop confidence in the minds of quality
circle members so that they can always bank upon him for any assistance that
may be required.
Committees are formed to establish and approve the policies and programs of
quality circles. The committee comprises of heads of major functions as members
and the Chief Executive of the organisation as the chairman. The
departmental/steering committee gives the approval to start the program and
offer basic guidelines for the operation of quality circles. The committee also
ensures proper implementation of circle projects and promote quality circle
activities.
The steering committee’s function is to keep quality circles effective and on
target. It ensures that the company does and will continue to support all circle
activities and solutions. The doors for better communication between the
management and the people actually doing the work gets open by the activities of
the departmental committees. The employees get an opportunity to see how the
management operates and help in the decision-making and problem-solving
process within the organization.
The steering committee/departmental committee takes an overview of the
operations of quality circles as a whole. The committee seeks to identify the
problem areas and suggest remedial action, on the basis of the report from the
facilitator. The committee also takes decisions and gives policy guidelines for the
healthy propagation of the concept of quality circles.
The committee also sanctions major programmes and financial support to give
thrust to the promotion of the quality circles.
COST OF QUALITY
Quality costs are defined are those costs associated with the non-
achievement of product or service quality as defined by the requirements
established by the organization and its contracts with customers and society.
Simply stated, quality cost is the cost of poor products or services.
QFD Team:
• When an organization decides to implement QFD, the project manager and team
members need to be able to commit a significant amount of time to it, especially
in the early stages.
• Teams compose of members from marketing, design, quality, finance and
production.
• One of the most important tools in the QFD process is communication.
• Team meetings are very important in the QFD process.
• The team leader needs to ensure that the meetings run in the most efficient
manner and that the members are kept informed.
• The meeting format should have some way of measuring how well the QFD
process is working at each meeting and should be flexible depending on certain
situations.
The above seven steps helps to plan and establish a new product/business and
helps to improve the business for an existing product.
society by the product from the time the product is designed to the time it is
each lead to losses, and these losses can be measured in rupee value. These losses
• Cost to produce,
• Failure to function,
emphasizes the need for incorporating quality and reliability at the design stage,
tolerances, but with wider than usual tolerances, or in other words, where the
design specifies larger variations between the upper and lower control limits to suit
the manufacturing facilities, rather than as required for the matching between two
Quadratic Loss
The quadratic function is shown in figure. In this situation, the loss occurs as soon
as the performance characteristic, y, departs from the target τ.
At τ, the loss is Rs. 0.
At LSL (or) USL, the loss is Rs. A.
The quadratic loss function is described by the equation L = k (y - )2. Where,
L = cost incurred as quality deviates from the target.
y = Performance characteristic
= target
k = Quality loss coefficient.
The loss coefficient is determined by setting ∆ = (y – ), the deviation from the
target. When ∆ is the USL (or) LSL, the loss to the customer of repairing (or)
discarding the product is Rs. A.
Thus,
K = A / (y – )2 = A / ∆2 .
SMALLER – THE – BETTER :
The following figure shows the smaller – the – better concepts.
The target value for smaller – the – better is 0. There are no negative values for
the performance characteristic.
The radiation leakage from a microwave appliance, the response time for a
computer, pollution from an automobile, out of round for a hole etc. are the
performance characteristics for this concept.
The following figure shows the concept of the Larger – the – better.
In the Larger – the – better concept, the target value is ∞ (infinity), which gives
a zero loss. There are no negative values and the worst case is at y = 0. Actually,
larger – the – better is the reciprocal of smaller – the – better. The performance
characteristics in Larger – the – better are bond strength of adhesives, welding
strength etc.
Taguchi Quality Loss Function
Genichi Taguchi is a Japanese quality expert, known for the Quality Loss
Function and for methodologies to optimise quality at the design stage – ―robust
design. Taguchi received formal recognition for his work including Deming Prizes and
Awards. Genichi Taguchi considers quality loss all the way through to the
customer, including cost of scrap, rework, downtime, warranty claims and
ultimately reduced market share.
the results of that work. Performance measures are based on data, and tell a story
the amount, cost, or result of activities that indicate how much, how well, and at
what level, products or services are provided to customers during a given time
period.
measured using numbers. “Activities” mean the work, business processes and
functions of Washington state government agencies. “Results” are what the agency’s
our work.
It’s the right thing to do: We measure many things in our lives outside work.
Course Outcome : 03
Template:
IT Industry
Course Outcome: 03
Template:
Institutions
Government
3. Differentiate TPM & TQM & QMS
Course Outcome : 04
Template:
Course Outcome : 04
Template:
2. Draw the house of quality for a product of your choice and describe the QFD
methodology. (CO4, K2)
The primary planning tool used in QFD is the house of quality. The house of
quality translates the voice of the customer in to design requirements that meet
specific target values and matches those against how an organization will meet
those requirements.
Many managers and engineers consider the house of quality to be primary chart
in quality planning.
Building a House of Quality:
Step1: List Customer Requirements (WHATs)
List Technical Descriptors (HOWs)
Step 3: Relationship Matrix
Step 4: Develop an interrelationship Matrix between HOWs
Step 5: Competitive Assessments
Technical Competitive Assessment:
Step 6: Develop Prioritized customer requirements
Step 7: Develop Prioritized technical descriptors
Unit – IV PART - B
3.Explain the Pillars of TPM and its Benefits. (CO4,K2)
Pillars of TPM:
1) 5S - Sort, straighten, shine, standardize, and sustain
Just like a physical structure starts with a grounded framework, building a strong
TPM process requires a strong foundation in the form of the principles of 5S. This
is a workplace organization method that is simplified into 5 basic steps:
Sort tools, equipment, and materials to identify which of these can be discarded
Straighten and set things in proper order to reduce unnecessary motion and
efficiently travel between working groups and locations
Shine refers to performing necessary housekeeping to clean up the work area
Standardize and schedule activities to systematically form the habits to keep the
workplace organized
Sustain the process and principles for long-term applications
The 5S approach provides a systematic approach to cleaning the workplace,
thereby uncovering underlying problems and challenges.
2) Autonomous maintenance
Maintenance tasks and caring for equipment should start with the people using
the equipment. The empowerment of operators to work on small maintenance
tasks effectively allows the maintenance teams to focus on more specialized
assignments.
Unit – IV PART - B
3) Continuous improvement
Continuous Improvement promotes the attitude of progressing towards zero
losses and zero defects. Through small but continual tweaks to processes, the
overall effectiveness and efficiency of the organization is developed.
4) Planned maintenance
Planned maintenance activities are essential to the prevention of equipment
breakdown. Planned maintenance is performed by periodically evaluating the
condition of equipment to proactively prevent deterioration and mechanical
failures.
5) Quality maintenance
To ensure the satisfaction of the customer, manufacturing processes aim for zero-
defect production. Standards for superior quality, and checks on whether the
standards are being met, should be in place. The goal of quality maintenance is to
identify any possible causes of deviations from zero-defect production.
6) Training
The idea of TPM is that everyone does their part to contribute to the overall
productivity of the production process. In order to achieve optimum performance,
and to build each member’s competence, proper training is required to equip each
one with the theoretical and practical know-how of working with machines and
equipment.
7) Office TPM
A key role that is often overlooked is the administrative department that works
behind the scenes. Like the rest of the production teams and processes, the
management and administrative functions are also subject to productivity
improvement. Tins includes identifying and eliminating losses, and contributing to
the overall performance of the plant.
8) Safety, health, and environment
The last of the eight pillars focuses on creating a safe workplace. The essence of
this pillar is realized when actively applied to each of the other pillars. The
successful implementation of this pillar will contribute to a secure and hazard-free
workplace.
Benefits of TPM
Less unplanned maintenance
Reduced equipment downtime
Lower manufacturing costs
Strengthened workplace safety
PART - B
4.What is Total Productive Maintenance? Discuss the objectives , principle and steps
in introduction of TPM in an organization. (CO4, K2)
Total Productive Maintenance (TPM) is an important and effective tool for the
excellence. Total productive maintenance (TPM) is keeping the current plant and
equipment at its highest productivity level through cooperation of all areas of the
organization.
Objectives of TPM:
Avoiding waste in quickly changing environment
Producing goods without reducing product quality
Reduce costs
Produce a low batch quantity at the earliest possible time
Send only non – defective parts to the customers
Steps involved in TPM
Management learns the new philosophy
Management promotes the new philosophy
Training is funded and developed for everyone in the organization
Areas of needed improvement are identified
Performance goals are formulated
An implementation plan is developed
Autonomous work groups are established.
8.Explain the different types of cost contributing to the cost of quality. (CO4, K2)
Quality cost is defined as the cost associated with the non-achievement of
product/service quality as defined by the requirements established by the
organisation and its contracts with customers and society.
CATEGORIES & ELEMENTS OF QUALITY COST
Preventive Cost Category
Marketing/Consumer/User:
Product/Service/Design Development:
Purchasing:
Operations (Manufacturing or service):
Quality Administration:
.
Returned Goods:
Retrofit and Recall costs
Warranty Claims
Liability Costs
Penalties
Customer or user good will
Lost Sales
Explanation:
A look back in history indicates that the implementation of Six Sigma principles
was pioneered by Motorola Company in 1980s. Motorola has always been a high
tech company, offering highly reliable products. However, by 1870, every business
in which Motorola was engaged in, was already targeted by Japanese.
During that time, Motorola, like many other American companies, was struggling
to keep up with Japanese competition. Motorola’s customers were unhappy with
the product defects and customer support. On the other hand, Japanese had
already built an amazing quality standard that many American companies simply
could not keep up with. As a result, dealing with severe financial pressure,
Motorola had to take action.
The top management summoned the Motorola engineers and sought to reduce the
amount of errors in their products before they were even shipped out of their
factories. They combined all the quality management practices known till that time
and created a methodology that would be the baseline of Motorola’s quality
improvement program. Bill Smith, an engineer and scientist at Motorola, developed a
methodology that would reduce the amount of product defects. He created the
original statistics and formulas initiated the implementation of Six Sigma
methodology..
Convinced in the huge success that this methodology would have, he presented
the ideas to CEO Bob Galvin. Bob came to recognize this approach as the solution
to their quality concerns. They followed the four phase Six Sigma methodology
(measure, analyze, improve and control) and started their journey of
documenting their key processes, aligning those processes to customer
requirements, and installing measurement systems to continually monitor and
improve these processes
By the end of the five year period, every business in Motorola had reached their
targeted scale of improvement. Motorola managers decided to fly to Japan to
better evaluate how their competition was doing, and what they found out was
mind-blowing. They saw that the Japanese companies were doing 2000 times
better than them. This was due to the fact that Japanese had been using similar
technologies for a longer period of time.
The information unveiled in Japan changed the objectives of Motorola again. The
executives became even more ambitious, and decided to set a tenfold target one
more time, but deadline was set for a two year period now. Motorola goal for
1992 was to have 3.4 defects per million opportunities.
After implementing Sig Sigma, Motorola realized how important the methodology
had been in improving their processes. In fact, they have documented more than
$16 billion in saving as a result of Six Sigma adoption. Therefore, they decided to
make the methodology public for every company that wanted to adopt it in their
processes. Since then, tens of thousands of companies around the world have
been considering Six Sigma as a way of doing business.
Explanation:
Benchmarking, a management approach for implementing best practices at best
cost, is a recent concept in the healthcare system. The objectives of this paper are
to better understand the concept and its evolution in the healthcare sector, to
propose an operational definition, and to describe some French and international
experiences of benchmarking in the healthcare sector. To this end, we reviewed the
literature on this approach's emergence in the industrial sector, its evolution, its
fields of application and examples of how it has been used in the healthcare sector.
Benchmarking is often thought to consist simply of comparing
indicators and is not perceived in its entirety, that is, as a tool based
on voluntary and active collaboration among several organizations to
create a spirit of competition and to apply best practices. The key
feature of benchmarking is its integration within a comprehensive and
participatory policy of continuous quality improvement (CQI).
Conditions for successful benchmarking focus essentially on careful
preparation of the process, monitoring of the relevant indicators, staff
involvement and inter-organizational visits.
Explanation:
The examples highlight the need not only for different approaches in the methods
used, but also the selection of measures to reduce quality costs. In the service
sector, a Service Level Agreement approach is used, which takes into account a
service guarantee.
Industrial production has profited from the broad application of the Taguchi loss
function as a way of provid-ing a rationale for investments in quality
improvements and reducing the losses caused by lack of quality. Re-search
has shown that manufacturing's good experience in applying this method could be
successfully replicated in services.
The example from the service sector (public transport) also shows how the method
could be applied to the relationship between a contracting entity and a service
provider based on a service level agreement. The method has found many
applications on the customer/producer interface and is changing the service sector
from a managed to a guaranteed environment, which will be particularly beneficial
for end customers.
4.Implementation of TPM in a Process Industry
Explanation:
Explanation:
Examines the relationship between the ISO 9001 Total Quality Management (TQM)
factors, that are presented in the Baldrige Education Criteria for Performance
Excellence framework (leadership, strategic planning, stakeholder and market focus
measurement and analysis, staff focus and process management), and the
seventh element which is the operational performance results.
The study, which was conducted at the Buraimi University College of Oman,
showed that TQM is applicable to higher education according to the perception of
the staff members. The study also showed that leadership, stakeholder and
market focus and staff focus have a significant positive influence on operational
performance of higher education
Explanation:
Sustainability is a reality and a necessity for everyone in all areas. The changes
that are taking place with respect to environmental sensitivity force organizations
to adopt a new approach to this problem. This has led organizations such as the
International Organization for Standardization (ISO) to develop standards that
help all types of organizations achieve sustainable development, such as the ISO
14000 family of standards. However, the ISO 14000 family of standards is too
generic and does not address specific areas that are highly relevant for
organizations in the search for sustainability, as is the case of the area of
Information Technology (IT). From the area of IT, sustainability and, in particular,
the Green IT philosophy have become slogans for executive, corporate, and
service management. Implementing Green IT initiatives has become a priority for
the environmental awareness of organizations that want to stay ahead of the
curve. That is why, in this study, the application/inclusion of the ISO 14000 family
of standards to IT is carried out.
The results obtained and the validation of this proposal by experts show an
adequate and consistent proposal, which covers all areas related to IT. All this
demonstrates the applicability of the ISO 14000 family of standards to IT through
the Green IT and completes a developed framework that is useful in practice when
implementing the governance and management of Green IT. Likewise, thanks to this
proposal, organizations finally have a standardized guide when implementing Green
IT, as well as when seeking for international and recognized certifications in this
field.
15.CONTENT BEYOND SYLLABUS
8.Quality Assurance
TEXT BOOK:
1. Dale H.Besterfiled, Carol B.Michna,Glen H. Besterfield,Mary B.Sacre,Hemant
Urdhwareshe and Rashmi Urdhwareshe, ―Total Quality Management‖, Pearson
Education Asia, Revised Third Edition, Indian Reprint, Sixth Impression, 2013.
REFERENCES:
1.James R. Evans and William M. Lindsay, "The Management and Control of
Quality", 8th Edition, First Indian Edition, Cengage Learning, 2012.
2.Janakiraman. B and Gopal .R.K., "Total Quality Management - Text and Cases",
Prentice Hall (India) Pvt. Ltd., 2006.
3.Suganthi.L and Anand Samuel, "Total Quality Management", Prentice Hall (India)
Pvt. Ltd., 2006.
4.ISO9001-2015 standards
18. MINI PROJECT SUGGESTIONS
Disclaimer:
This document is confidential and intended solely for the educational purpose of RMK Group of
Educational Institutions. If you have received this document through email in error, please notify the
system manager. This document contains proprietary information and is intended only to the
respective group / learning community as intended. If you are not the addressee you should not
disseminate, distribute or copy through e-mail. Please notify the sender immediately by e-mail if you
have received this document by mistake and delete this document from your system. If you are not
the intended recipient you are notified that disclosing, copying, distributing or taking any action in
reliance on the contents of this information is strictly prohibited.