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•Thequalityofaproductisdeterminedbyhowwellitsuitsyourneeds.
-reliability
-durability
-safety
-maintainability
-cost
-?
•Wheredowehavetochangeproductioninanindustrytoimprovequality?
-EVERYWHERE!
-Specifications-clarifywhatisimportantinaproducttherestissecondpriority
-Design-Onlydesignaproducttomeetspecificationsanymoreisawasteof
timeandresources.Forexampleifachemicalcompany‘tunes’theirproduction
foracertainimpurityinarawmaterialasuddenimprovement
mighthurttheirproductquality.
-Production-tomeetthespecifications
-Inspection-ensureconformancetothespecificationsandcorrectproblems.
-ReviewofSpecifications-makesurethespecs.describetheproductwellthe
specsareusefultocustomersetc.
•Twomainapproachestoquality
-inspection-accept/reject
-processcontrol-constantlyexamineinputandoutputandrefineprocess.
•Typicaloptionswhenproductsfailinspection.
-Reworks(highcost)
-Scrap(highcost)
-Sellanyway(upsetcustomerspoorreputation)
-Downgrade(lowerreturns)e.g.trytogetlargestchickeneggsbutwhensmallereggs
areproducedsellforless.
•Whataresomeofthedifferentwaystoinspectprocesses?
1.Gating-Onlyexaminefinalproductforpass/fail.Notveryeffectiveforcorrecting
problems.
2.DesignofExperiments-Variousprocessparameterscanbevaried(e.g.speedsfeeds)
andtheeffectscanbeexaminedtodeterminethebestsettingsforaprocess.
3.StatisticalProcessControl(SPC)-Variousmeasurementsmaybedoneonapartafter
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processingandtheprocesscanbeadjustedtokeepitwithinspec.
4.TotalQualityManagement(TQM)-Trytoimproveemployeeattitude(e.g.Fridaycars)
•Doesitcostmoretoinspecteachprocessinsteadofthefinalproduct?
-RARELY
-Theuseofstatisticsallowsmallpopulationsamplestoproduceenoughdataforaprocess.
Anditismuchcheapertoadjustaprocessbeforeproblemsoccurthanitis
tofixacompletedproduct.
-Considerthegraphbelowthereisabasicmanufacturingcostperpartassociatedwith
anypiece.Ifweconsiderwhathappenswhenselectingqualitylevelsweseethat
toimprovequalitytoget0%rejects(allpartsgood)ourcostsrisesignificantly.On
theotherhandifmorerejectsareproducedtheeconomiclossesrise.Thereisan
optimalpointtochoosewherethequalityleveloftheproductwillgivetheoptimal
economicsense.
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