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TOTAL QUALITY MANAGEMENT

M.SENTHIL KUMAR, AP/CSEIII CSEVI EVEN SEM (2015-16)GE6757 - TOTAL QUALITY MANAGEMENT(Regulation 2013)

Subject Name:TOTAL QUALITY MANAGEMENTSubject Code:GE6757Unit No:3Year:IIIBranch:CSEFaculty Name:M.SENTHIL KUMARTopic No.Topic NameSources*Mode of teachingReal life / Real time ApplicationsCumulative PeriodChapter NoPage No17.1The Seven Traditional Tools of Quality(Check sheet, Pareto Chart, Flow chart, Cause & Effect Diagram)W1---PPTMercedes Benz1317.2The Seven Traditional Tools of Quality(Histogram, Scatter Diagram, Control Chart)W1---PPT1418.1New Management Tools (Affinity diagram, Inter-relationship diagram, Tree diagram, Matrix Diagram)T1443PPTFord Customer care15

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18.2New Management Tools (Prioritization matrices, PDPC, Arrow Diagram)T1443PPTFord Customer care1619.1Six Sigma Concepts & Methodology T1147VIDEOToyota and Honda1719.2Six Sigma Applications to manufacturingT1149VIDEOToyota and Honda1820Service Sector including ITT1223BBIBMs - Service1921.1Bench marking Reason to bench markT1207PPTBell Telephone Laboratories2021.2Bench marking Benchmarking processT1207PPT2122.1FMEA StagesT1377BBIBMs Customer Relationship2222.2FMEA TypesT1385BB23

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TQM TOOLS & TECHNIQUES

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TQM by ... M.Senthil Kumar

Check sheet is a Form/Document used to collect data in real time at the location where the data is generated.Central tool for Quality Assurance programs.Specially useful for operational procedures. Could be derived from the flowchart and fishbone diagrams.

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A Pareto Chart is a type of chart that contains both bars and line graph, where individual values are represented in descending order by bars and the cumulative total represented by the line graph.A graph to identify and plot problems /defects in descending order of frequency.Principle of Pareto chart is: 80% of problems stem from 20% of the various causes.8 homePareto chart

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Flow ChartTQM by ... M.Senthil Kumar10

A Flow Chart is a type of diagram that represents an algorithm, workflow (or) process, showing the steps as boxes of various kinds and their order by connecting them with arrows.A Pictorial representation of describing a process used to plan stages of a project or program.home

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TQM by ... M.Senthil KumarAlso known as ISHIKAWA diagram and Fishbone diagram.A diagram showing the cause of a certain event. (i.e.) used to identify potential factors causing an overall effect, also used to see all possible causes of a result and hopefully find the root causes of imperfection.It is called as fish-bone diagram because its shape is similar to side view of a fish skeleton.

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TQM by ... M.Senthil Kumar14It is a graphic summary of variation in a set of data and an estimate estimate of theprobability distributionof a continuous variable(quantitative variable).A One uses thegraph to show frequency distributions. It looks very much like a bar chart.Sometimes it is said to be derived from theAncient Greek(histos) "anything set upright and(gramma) "drawing, record, writing". It is also said thatKarl Pearson, who introduced the term in 1891, derived the name from "historical diagram".

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A scatter diagram is effectively a line graph with no line - i.e. the point intersections between the two data sets are plotted but no attempt is made to physically draw a line.A type ofmathematical diagramusingCartesian coordinatesto display values for typically twovariablesfor a set of data.Sometimes it is called as scatter plot or scatter graph.TQM by ... M.Senthil Kumar16 homeScatter Diagram

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Also called Shewhart charts or process-behavior charts, instatistical process controlare tools used to determine if a manufacturing orbusiness processis in a state ofstatistical control.The control chart is a graph used to study how a process changes over time. Data are plotted in time order. A control chart always has a central line for the average, an upper line for the upper control limit and a lower line for the lower control limit.TQM by ... M.Senthil Kumar18 homeControl Chart

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Seven New Management Tools home

Affinity DiagramAlso Called as affinity chart, KJ method Variation, thematic analysis.An Affinity Diagram is a special type of brainstorming process that is used for organizing large groups of information into meaningful categories. It helps us to clarify and make sense of a large or complex problem .

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TQM by ... M.Senthil Kumar23ProcessRecord each idea on cards or notes Look for ideas that seem to be related Sort cards into groups until all cards have been used. Tour to OotyEnough AmountCelebration at OotyNew Year Celebration in SSCE home

Inter-Relationship DiagraphShows causeandeffect relationships. The process of creating a relations diagram helps a group analyze the natural links between different aspects of a complex situation.Also called Network diagram or relations diagram.

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TQM by ... M.Senthil Kumar25 homeExample of Inter-relations diagram for identifying the potential causes of late delivery:Poor scheduling practices (6 outgoing arrows), Late order from customer (5 outgoing arrows), and Equipment breakdown (3 outgoing arrows).

Tree Diagram

TQM by ... M.Senthil Kumar26 homeAlso called systematic diagram, tree analysis, analytical tree, hierarchy diagram.Used to break down broad categories into finer and finer levels of detail.It can map levels of detail of tasks that are required to accomplish a goal or task.

TQM by ... M.Senthil Kumar27ProcessDevelop a statement of the goal.Ask a question that will lead you to the next level of detail. Brainstorm all possible answers. Write each idea in a line below. Show links between the tiers with arrows. Do a necessary and sufficient check. Are all the items at this level necessary for the one on the level above? Each of the new idea statements now becomes the subject: a goal, objective or problem statement. Continue to turn each new idea into a subject statement and ask the question, till you reach a root cause.Do a necessary and sufficient check of the entire diagram. Are all the items necessary for the objective? home

TQM by ... M.Senthil Kumar28 homeGoal/Objective is to eat ice-cream with toppingsStatement of the goalSubject of the Goal

Matrix DiagramThis tool shows the relationship between items. At each intersection a relationship is either absent or present. It then gives information about the relationship, such as its strength, the roles played by various individuals or measurements.Shows the relationship between two, three or four groups of information. The most common type in matrix diagram for using 7 management tools in planning is L-Shaped matrix.L-shaped matrix is for 2-variables.TQM by ... M.Senthil Kumar29 home

L-shaped2 groupsAB (or AA)T-shaped3 groupsBAC but not BCY-shaped3 groupsABCAC-shaped3 groupsAll three simultaneously (3-D)X-shaped4 groupsABCDA but not ACor BDRoof-shaped1 groupA A when also AB in L or T

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Six Different shaped Matrices are: home

Customer ACustomer BCustomer CRequirement 1Requirement 2Requirement 3

Example for L-Shaped matrixTQM by ... M.Senthil Kumar31 home

Prioritization MatricesTQM by ... M.Senthil Kumar32This tool is used to prioritize items and describe them in terms of weighted criteria. It uses a combination of tree and matrix diagramming techniques to do a pair-wise evaluation of items and to narrow down options to the most desired or most effective. This tools prioritize issues, tasks, characteristics based on weighted criteria using a combination of tree and matrix diagram techniques. Once prioritized, effective decisions can be made.

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YearSingle arrearTwo ArrearThree ArrearTotalIV CSE18101240III CSE86418II CSE64212

Result analysis for the Dept of CSETQM by ... M.Senthil Kumar33 home

PDPC Process Decision Program ChartTQM by ... M.Senthil Kumar34A useful way of planning is to break down tasks into a hierarchy, using a Tree Diagram. The PDPC extends the tree diagram a couple of levels to identify risks and countermeasures for the bottom level tasks.Different shaped boxes are used to highlight risks and identify possible countermeasures.The PDPC is similar to the Failure Modes and Effects Analysis (FMEA) in that both identify risks, consequences of failure, and contingency actions; the FMEA also rates relative risk levels for each potential failure point.identifying what can go wrong (failure mode or risks) consequences of that failure (effect or consequence) possible countermeasures (risk mitigation action plan) home

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Activity Network DiagramTQM by ... M.Senthil Kumar36Also called as Arrow diagram, network diagram, activity chart, node diagram, CPM (critical path method) chart.This tool is used to plan the appropriate sequence or schedule for a set of tasks and related subtasks. It is used when subtasks must occur in parallel.Shows the required order of tasks in a project or process, the best schedule for the entire project, and potential scheduling and resource proTwo TypesArrow on Node.Arrow on Arrow. home

TQM by ... M.Senthil Kumar37 homeEg: showing the project turn-over in an organization

TQM by ... M.Senthil Kumar38Set of techniques and tools for continuous process improvement.Statistically oriented approach to process improvement, designed to reach a quality level of less than 3.4 Defects Per Million Opportunities (DPMO) for Critical-To-Quality (CTQ) characteristics in a manufacturing or service process. Data-driven approach and methodology for eliminating defects (driving towardsixstandard deviations between the mean and the nearest specification limit) in any process from manufacturing to transactional and from product to service. homeSIX SIGMA ()

TQM by ... M.Senthil Kumar39What is Six Sigma?Types of Six SigmaLean Six Sigma.

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