Manufacturing Quality

Presented ByDeepa Chauhan

Introduction-Manufacturing

It involves making products from raw material by various processes or operations. It is complex activity, involving people who have wide variety machinery, equipment and feeling with various levels of automation, including computer, robots and material handling equipment with a range of knowledge, skills.

Method of Manufacturing Method of manufacturing have changed from the rigid, push-

oriented production principles of the early 20th century to more flexible, pull principles.

Assembly line manufactures used to push mass production ahead based on estimates of future demand.

The modern manufacturing method have three main considerations:-

1. Waste reduction is done by following several techniques:a) Just-in-time manufactures:- suppliers to keep process moving

and scheduled at factory place just in time for them used in production.

b) An automatic request for new suppliers when supplies are running low. these alerts are called kanban. These are computerized.

c) Just -in-sequences:- supplies arrive at the factory at exact moment with in the manufacturing sequence. Give a standstill if supplies few minute late.

d) Total productive maintenance:- avoid stopping production. Some factoring wait until the repair minor issues with their machines at the end of the day.

a) Quick response manufacturing:- customer request for a product and the final delivery for a that product as brief as possible.

b) Cellular manufacturing:- separates the factory floor in to different section and machines are placed in a order so that material flow naturally towards the competition of a product.

c) Single-minute exchange of Die:- is reduce waste time. Even between projects smed focuses on changing the factory premises from working on an old product to new product as quickly as possible.

2. Quality of a product has to be maintained:- a manufacturing process is given a sigma rating based on the percentage of its product yield being defect free.

A one sigma rating designates a process with a yields of 31% and six sigma rating is a processes which is nearly perfect that 99.99% defect free. Thus, every company wants six sigma for all manufacturing process to find out and remove defects.

define, measure, analyze, design, verify(DMADV):- it is a methodology to analyzing of customer demand ,manufacturers plan ahead and try to design ways to avoid defects in first place.

Critical to quality and quality function:- deployment are two concept try to pinpoint the element of a product that are most important to the customers and translate those needs in to manufacturing strategy that focuses on getting the critical elements exactly right.

. suppliers, inputs, process, outputs customers(SIPOC) is followed to allow manufacturers to trace the life cycle of their products from suppliers to customer and identify problem areas.

3. Accelerate production:- production is accelerated to make sure products are made available and demand is met.CAM and CAD should be adapted. Cad is used for design of production process and Cam is guide parts through those process with robots and computer controlled Machine.

CIM creates a network of computers that observe and operate the manufacturing process. Computer can monitor every step of production for defects and change the actions of machine almost immediately leading to flexibility.

Finally , the three major goals of reducing cost, maintaining quality, and accelerating production are achieved through combined efforts of lean manufacturing theories, six sigma methodologies, and flexible processes.

Steps for quality manufacturing Improving quality manufacturing processes leads to

decreased waste, better quality products, and an overall improvement in customer satisfaction.

To ensure the following steps are completed and taken from beginning to end:

1. Actual process:- name process, and its purchase, its starting ending points, inputs and outputs and overall requirements, and customer and suppliers who will be affected by this process.

2. Areas of improvement:-take a random sampling. It make sure disintegration of parts and loose fastness and so forth.

3. Solution for the problems- consult with specialist and brainstorming, feedback

4. Detailed solution:- budget5. Put plan into action – involve everyone from highest level

to lower level.6. Evaluate-improvement process as a whole .

Inspection and control of productThe quality appraisal may take

the form of physical inspection of entire product or a small part of it. the inspection of a small portion, is termed as ‘sampling inspection’.

1. 100% inspection2. Sampling inspection3. Sampling plan

Quality in salesPurchasing decisions are based on the price and the

quality of a product .it would be first consideration otherwise sale of a product may suffer if priced too high. Even though quality of a product is good quality.

The quality reputation of a company is a great asset which makes selling very much easier and also help in growth and diversification.

If every one in the company make it his business to please the customer then quality image become longer.

Methods of establishing a quality reputation are:Sold only those product which can fully meet

customer expectation.Prompt and courteous adjustment of warranty

claims, in case of product fail.Effective after sale service.

After-sales serviceThe reliability and maintainability are important

quality parameters. effective after sales service is an essential element in ensuring reliability and maintainability.

It not only cover maintenance and service facilities, but also all post-sale efforts to ensuring maximum customer satisfaction.

Important aspects of after sale service are:-i. Customer educationii. Maintenance and repairs service whenever

needediii. Importance to customer complaints

Repairs facilities are set up by the servicing and repair centers managed by the company.

It may provide license to other repair agencies to provide those services on its behalf.

GuaranteeThe guarantee of quality is for benefit of

the customer, if the product purchased turns out to be defective.

It is an undertaking by the selling company that it will replace the product free of cost or refund the money.

It include terms and conditions that should be clear and unambiguous.

i. Validity periodii. Manufactures liabilityiii. Guarantee claims procedureiv. Guarantee invalidation condition

Analysis of claimsThe investigation of complaints involves

thorough technical knowledge of the product.

Guarantee claims may be investigated by the quality control department if decided

Time should not be longer because it makes further annoyance to the customer.

Minor claims being settled by service centre and major by the company itself.

The advisor can play with the design feature but quality of conformance must be based on faith .

Design , production and distribution aim to service the satisfaction of the customer needs.

Feedback play vital part in building quality of a product. It should be continuous in the organization