IE 530

QUALITY ENGINEERING

Prepared byDr. Mohamed Abdel Fattah Sharaf

King Saud universityCollege of engineering

Industrial engineering Department

IE 530 Quality Engineering 3Catalog Data An understanding of the basic concepts of quality, An appreciation of the functions

served by a quality management system; the ability to design quality into products so as to satisfy both internal and external customer The study of frequency

distributions and probability models in quality control. Preparation and use various control charts. Design for Six Sigma: A roadmap for product development.

Construction of different sampling plans. Methods to quality improvement and analysis of quality costs. Application of computer in the above area.

Level I.E. M. Sc program courseTextbook Design for Six Sigma, Kai Yang & Basem S. EI-Haik, McGraw-Hill, 2003.Reference Introduction to Statistical quality control, 4th ed., D. C. Montgomery, John

Wiley & Sons, Inc., 2001. Certified Manager of Quality/Organizational Excellence”, 3rd edition

by Russell T. Westcott. ASQ Quality Press.

Learning Objectives

To introduce students to the use of statistical methods and other problem- solving techniques required in the area of quality control. The ability to control process performance using appropriate statistical tools. The ability to diagnose quality problems and develop sustainable improvement. To enable students to know how to measure the quality characteristics. In addition, to introduce students to apply the qulity improvement tools. In additional to road map to enterprise quality. Overview of quality management methodologies.

Use of Six Sigma Fundamentals ( DMAIC)

Topics (classes)

1. Introduction to quality control 1 classes1. Fundamentals of statistics for quality control

2. The basic concepts of quality 1 classes1 classes

1. Control charts for variables 2 classes1. Control charts for attributes 2classes

1. Processes capability 3 classes1. Acceptance sampling

2. Design quality into products so as to satisfy both internal and external customers

3 classes2 classes

1. Methods of quality improvement 3classes1. Quality costs

2. An appreciation of the functions served by a quality management system;

1 classes1 classes

1. Introduction to Total Quality Management (TQM), Six Sigma, Balance Score Card (BSC), ISO 9001, and Kazien.

2. Six Sigma ( Fundamentals of DMAIC, DFSS), Design of Six Sigma Deployment.

2 classes8 classes

Project work

a-measuring some jobs in lab , and b- Collecting data from some factories.

Then, use those data in computer programming to construct control charts. c- Six Sigma Project

Computer Usage

Minitab software package

Learning outcomes

1. Describe the history and importance of quality control .

2. Learn the statistical tools need to use in the quality control area .

3. Learn the main differences between variable and attribute control charts .

4. Learn how to construct the different types of control charts and how to interpret them.

5. Learn how to use contro charts to monitor the processes .

6. Learn how to determine the capability of the process and how to use the findings to analyze the control limits of the process .

7. Learn how to perform the qualification tests for the process.

8. Understand the Operating Characteristic Curve and prepare the acceptance sampling plan

9. Learn how to prepare the acceptance samples for control charts.

10. Diagnose quality problems and develop sustainable improvement.

11 Describe the main principals of the Six Sigma, TQM, BSC, ISO9001 and Kaizen .

12 Describe the main principals of Six Sigma, how to develop product based on fundamentals of Six Sigma.

13 Learn and understand how to use Minitab software package in the quality area

14 Work in teams and communicate effectively through class discussions, real case project from industrial, and presentation.

Estimated Category Content

Engineering Science : 2 credit hours or 67%Engineering Design: 1 credit hour or 33%

Prepared by Dr. Mohamed Abdel Fattah Sharaf

Preparation Date

March 2008

The Dialectic of QualityThe Dialectic of Quality

Product Standards

Statistical Methods

Quality Control

CustomerFocus

QualityAssurance

HumanFactors

QualityEngineering

ProcessAnalysis

QualityManagement

SystemsEngineering

Six

Sigma

Service Quality Gap Model

Five ways service quality can fail...

Tools for Managers

Statistical Process Control

Six Sigmaسيجما6

اسلوب تطبيق خالل االستخدام دائمة القياسات بعضسيجما 6

Sigma quality level= 0.8406+ )ln(*221.237.29 ppm

بأسلوب الخاصة الرياضية العالقات سيجما 6بعض :•Number of operation steps=m•Defects=D•Unit=U•Opportunities for a defect= O•Yield=Y•Total opportunities: TOP=U*O•Defects per unit: DPU=D/U•Defects per unit opportunity: DPO=DPU/O=D/(U*O)•Defects per million opportunity: DPMO=DPO*1000000

Process Capabilityالعمليات قدره

• The Relationship between a Process and the Requirements of its Customer

• How Well Does the Process Meet Customer Needs?

A Vision and Philosophical commitment to our consumers to offer the highest quality, lowest cost products

A Metric that demonstrates quality levels at 99.9997% performance for products and processes

A Benchmark of our product and process capability for comparison to ‘best in class’

A practical application of statistical Tools and Methods to help us measure, analyze, improve, and control our process

What is Six Sigma

A Six Sigma process – A Six Sigmaprocess is one that has at least six

standard deviations between the process mean and the nearest specification limit when centred.

+/- 6 sigma 99.9996% *

Mean Value

Lower Design Specification Upper Design Specification

*Distribution shifted +/- 1.5

1.5 1.5

DMAIC Process

Metrics (Ys) linked to CTQs

Define the ProblemProject Objective

Project GoalPROCESSPROCESS

X1

X2

X3

X4

Y1

Y2

Y3

Establish Controls on the critical Xs so the improvements will be maintained

Identify ways to improve the process and validate the solution

Measure and Analyze data and process performance to determine the critical

variables and root cause of the problem

DMAIC Process training Methodology

DMAIC Process training Methodology

Six Sigma The Concept

Deployment

Actions Required to Institutionalize a Quality Process

– TOP DOWN COMMITMENT AND INVOLVEMENT• Set the example, be active in the audit process

– MEASUREMENT SYSTEM TO TRACK PROGRESS• At both macro and micro levels

– TOUGH GOAL SETTING (REACH OUT!!)• Benchmark Best-In-Class -- audit often

– PROVIDE THE REQUIRED EDUCATION• The “Why” and “How To”

– SPREAD THE SUCCESS STORIES

Promoting Customer Satisfactions by Applying Six Sigma:

An Example from the Automobile Industry

5sKey to work place improvement

Putting 5s to WorkWho does not like a

-Clean-Orderly

-Disciplined

Environment ? At home & At work !!!

5s AIMS at achieving this state

5-S• Seiri - sort out

• Seiton -systematic arrangement

• Seiso - Scrub clean, Spic & Span

• Seiketsu – Standardize - State the rules

• Shitsuke - Self-discipline (Follow rules)

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

1st Step of 5s

SEIRI •Sorting of all items

•Segregate Necessary from Unnecessary

•Take action on Unnecessary

Step Zero - of 5s

Identify strategic Spots & take Photos / Video – To Capture Current Status

• Red Tagging & Red Tag Areas (set Rules first)• Heaps to Come out – 10 trucks (in a factory)

Red Tag To,

•Stock

•Facilities

•Locations / Space

•Documents

•Computer Files

•Machines

•Stationary

•Not People !!

When In Doubt, Throw It Out !

Seiri• Classify into: wanted, ?

and unwanted• Discard unwanted• Create red tag area

for ? items• Move ? Items to red tag

area• Put red tag on

unmovable ? items

•Wanted but not here•Wanted but not in this Qty•Wanted but not now •Not Wanted at all

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

Total Quality Management

Outline

• Meaning of Total Quality Management (TQM)• TQM CONCEPTSTQM CONCEPTS• TQM Beliefs.TQM Beliefs. • TQM Guru’s Guru’s • The Evolution of TQM.TQM.• TQM Principles.Principles.• TQM ConstructsTQM Constructs.• TQM Organization.TQM Organization.• Benefits of TQM. • TQM Tools. • TQM Phases

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