tqm seminar

8/10/2019 Tqm Seminar

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TOTAL QUALITY MANAGEMENT

SEMINAR

BY-

SHOUTIK CHAKRABARTI ID-091020024

APURVA GHUTUKADE ID-091021064


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OUTLINE

INTRODUCTION AND DETAILS OF THE MAIN & COLLABORATINGCOMPANIES AND THE PRODCUT TO BE MANUFACTURED

PROFILES AND THE PROBLEMS PLAGUING THE FOUR COLLABORATORS

PROFILE AND PROBLEMS PLAGUING THE FIFTH COMPANY WHICH WILLWORK WITH THESE FOUR COMPANIES TO MAKE THE FINAL PRODUCT.

SOME BASIC SOLUTIONS TO THE PROBLEMS FACED BY THE FIVECOMPANIES


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INTRODUCTION

Product to be manufactured- A hybrid car(parallel)

COMPANY PROFILETASKS ASSIGNED &

PRODUCTS PRODUCED

HYBRIDENERGY LTD. MAIN COMPANYENGINE MANUFACTURING,

ASSEMBLY

ACCUCONSULTING INC. CONSULTANTCONSULTANCY AND

CONTINUOUS ASSISTANCE

MARKTECH LOGISTICS CORP. MARKETING & LOGISTICS

PROMOTION OF PRODUCT,

SUPPLY CHAIN

MANAGEMENT

BLAZETRICAL LTD.ELECTRICALS &

ELECTRONICS

MOTORS, ELECTRONIC

CIRCUITRY

MAXDESIGN LTD. MECHANICAL COMPONENTSCHASSIS, TRANSMISSION,

GLASS PANELS


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Auto industry trends


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Auto industry challenges

Global Warming

Air Pollution

Rising fuel prices

Declining fuel reserves


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AUTO INDUSTRY CHALLENGES


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WORKING PRINCIPLE


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WHY HYBRID CARS

Fuel efficient Ultra low emissions

Reduced Noise

Better Performance

Financial Benefits Rated as highly reliable cars by J.D. Powers and consumer reports

Customer satisfaction rate among buyers of hybrid vehicles is 80 to 90

percent according to J.D. Power, and Polk Automotive data


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WHOS M KING HYBRIDS TOD Y

Prius

Camry

Malibu

Silverado

& Sierra

Accord

Civic

RX400 hSUV

Escape


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Current

Market Scenario

Toyotahas an edge at the moment.

Honda, now in its second generation of hybrids, is improving in leaps

and bounds, but Toyota has expanded the technology into the luxury

car sector via Lexus.

When comparing the Prius to the current Civic Hybrid, Toyota's

technology is a bit more refined. Both have a similar function but theToyota, because it's had a head-start, has a more seamless transition

between the petrol and the electric motors.

Camry hybrid car has helped Toyota to win a Green Innovation Award

in 2011.


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projected co2 reduction


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UNTAPPED MARKET

Money doesn't grow on trees, but it does grow from something

else greenHYBRID VEHICLES


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WORKING PRINCIPLE


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WORKING PRINCIPLE

Gasoline-electric hybrid cars contain the following parts: Gasoline engine- The hybrid car has a gasoline engine much like the one

you will find on most cars. However, the engine on a hybrid is smaller and

uses advanced technologies to reduce emissions and increase efficiency.

Fuel tank- The fuel tank in a hybrid is the energy storage device for the

gasoline engine. Gasoline has a much higher energy density thanbatteries do. For example, it takes about 1,000 pounds of batteries to

store as much energy as 1 gallon (7 pounds) of gasoline.

Electric motor- The electric motor on a hybrid car is very sophisticated.

Advanced electronics allow it to act as a motor as well as a generator. For

example, when it needs to, it can draw energy from the batteries toaccelerate the car. But acting as a generator, it can slow the car down and

return energy to the batteries.

Generator- The generator is similar to an electric motor, but it acts only

to produce electrical power. It is used mostly on series hybrids


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WORKING PRINCIPLE

Batteries- The batteries in a hybrid car are the energy storage device for the

electric motor. Unlike the gasoline in the fuel tank, which can only power the

gasoline engine, the electric motor on a hybrid car can put energy into the

batteries as well as draw energy from them.

Transmission - The transmission on a hybrid car performs the same basic

function as the transmission on a conventional car. Some hybrids, like the

Honda Insight, have conventional transmissions. Others, like the Toyota Prius,have radically different ones, which we'll talk about later.


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GETTING TO THE PROFILES

The product would need the following things to be successful :

Initial thorough market survey{which has already been carried out}

Assistance of third-party consultants

Good promotion of the product

Reliable supply chain

Good quality vendors supplying all the necessary parts

As mentioned earlier, we will have four major associates providing

services such as consulting, marketing, supply chains, parts, spares etc.


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CONSULTANT

Third party consultants are approached to examine the viability of the project

and how to go about the whole thing right from how to go about

manufacturing the product to what types of works to outsource and finally the

channels of distribution.


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CONSULTANT

The consultancy firm is ACCUCONSULTING INC.

Some of the suggestions offered by them are:

Establish concrete short term goals as such projects usually get lost in

the maze of long term goals and commitments

Ensure willing venture capitalist. Capital is of the essence

Hire a marketing agency

Hire a logistics agency

Try using best quality material and implement various green measures

such as Green PLM in order to obtain licenses soon and also to establishoneself as the best in the business

Lay down very strict guidelines for the vendors. Include them in the

quality control process as well


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Managing

Director

ClientPartner 1

AssociateDirector

ClientManager

SeniorConsultants

Associate

Consultants

AssociateDirector

ClientManager

SeniorConsultants

Associate

Consultants

ClientPartner 2

AssociateDirector

ClientManager

SeniorConsultants

Associate

Consultants

AssociateDirector

ClientManager

SeniorConsultants

Associate

Consultants

ORGANISATIONAL STRUCTURE


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CONSULTANT

Problems faced by the consulting firm:

Poor channels of communication internally and externally

Late delivery of reports and suggestions

Poor soft skills of some of the junior level consultants

Arrogance on the part of the senior level consultants

Poor risk analysis at times

Very high expenses on the employees which in turn raises their

companysconsultancy fees.


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MARKETING LOGISTICS


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MARKETING LOGISTICS

Enough stress cannot be laid on the importance of a good marketing strategy

and on the availability of good quality supply chains. Our company co-

ordinates with one company which provides both marketing expertise as well

as logistics support


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C.E.O.

PRESIDENT(LOG)

AssociateDirector

ClientManager

Logistics Exec

AssociateDirector

ClientManager

Logistics Exec

PRESIDENT(MAR)

AssociateDirector

ClientManager

MarketingExec

AssociateDirector

ClientManager

MarketingExec



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MARKETING LOGISTICS

The marketing and logistics firm chosen is MARKTECH LOGISTICS CORP.

Some of the problems plaguing this company are:

Slightly laid back attitude while promoting the product especially in

sections of the society they feel will not buy this product

Lack of consistency in brochures distributed amongst various potentialclients such as the common people and corporate houses

Less focus on online promotion of the product

Lack of enough skilled personnel for loading and unloading goods from

their trucks

Many cases of defective products reaching our company


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ELECTRICALS ELECTRONICS

For the hybrid car, electrical components are very important. They

range from the motor, batteries to the various circuitry involved.


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C.E.O.

PRESIDENT(ELECTRICALS)

AssociateDirector

ClientManager

Exec

AssociateDirector

ClientManager

Exec

PRESIDENT(ELECTRONICS)

AssociateDirector

ClientManager

Exec

AssociateDirector

ClientManager

Exec



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ELECTRICALS ELECTRONICS

The firm chosen for electricals and electronics is BLAZETRICAL LTD.

Some of the problems plaguing this company are:

Non compliance of ISO standards while making motors in spite of repeated

requestsWay too many defects in electronic circuits

Poor shelf life of batteries

Delay in response to orders

Poor communication internally and externally


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MECHANICAL COMPONENTS


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No chassis, no body = No vehicle!No vehicle would function without the basic components such as the

transmission system.

Hence finding the right vendor for such crucial components is important.

The company approached is MAXDESGIN LTD.

MAXDESIGN LTD. has been entrusted with the responsibilities of

manufacturing the following :

Chassis

BodyDrivetrain/transmission

Glass panels

Seats

Entire interiors


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C.E.O.

PRESIDENT(TRANS)

AssociateDirector

ClientManager

Exec

AssociateDirector

ClientManager

Exec

PRESIDENT(ACCESSORIES)

AssociateDirector

ClientManager

Exec

AssociateDirector

ClientManager

Exec



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We see that MAXDESIGN LTD. Is a very crucial associate as it has been

handed over a number of tasks and hence it is imperative that it meet the

highest quality standards in every single aspect.

Some of the problems plaguing them are:

Many cases of cracks on the body of the carPoorly finished gear boxes , inaccurately machined and lack of proper fit

Noisy gear boxes

Short shelf life of clutch plates

Chassis unable to withstand slightly rough terrain

Glass panels not toughened enoughPoor quality material used for interiors


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HYBRID CAR MANUFACTURER

The company which will co-ordinate with the previously mentioned four

companies and some other companies and small vendors is HYBRIDENERGY

LTD. This is a start up founded by us and it is our desire to break into the

field of hybrid vehicles. It has been already explained that this is a lucrative

field.

The company will perform the following tasks:

Manufacture the C.I. engine

Assemble the whole car

Co-ordinate with its four most valued associates and a host of other

suppliers and vendorsImplement quality control measures itself and also assist its vendors

implement quality control measures as well

Some of the other suppliers would include those needed for the wheels,

various lubricants, oils, nuts and screws and small peripherals.


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PARTNERS 1 & 2

PRESIDENT(HR)

AssociateDirector

Exec

Engineers

AssociateDirector

Exec

Workers

PRESIDENT(OPS)

AssociateDirector

Exec

Engineers

AssociateDirector

Exec

Workers



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HYBRID CAR MANUFACTURER

With such big names in the field of hybrid cars, it is imperative for us to

provide good quality cars at affordable prices. The dilemma of every

manufacturer! Hence we are constantly working towards trying to improve

ourselves

Some of the problems plaguing HYBRIDENERGY LTD. are:

Shortage of skilled laborShortage of personnel to oversee the day to day operations

Many defects in the engines produced

Low productivity

Poor co-ordination with the numerous vendors

Not yet obtained all green certificationswithout which we cannot charge our customers a

premium for our products

Lack of enough quality checks for the incoming goods

Not enough training programs

Lack of good quality after sale service


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INTEGRATED WORKING

HYBRIDENERGYLTD.

MARKTECHLOGISTICS

CORP.

BLAZETRICALLTD.

MAXDESIGNLTD.

OTHERVENDORS

ACCUCONSULTING INC.


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Having seen the problems plaguing each of the five companies, lets

look at some of the quality control measures already accepted by

the industry and which we plan to implement as well.


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Prepare Future StateSolution draft

Identify Action Plan

Implementation ofFuture State Solutionand Measure Impact

Collect & Analyze Datafor Benchmark Item

Conduct Internalinterviews & Surveys

Conduct Reverse

Engineering

Identify What toBenchmark

Obtain top managementsupport

Identify BenchmarkingMetric

Develop the DataCollection Plan

Plan Do

CheckAct

Benchmarking


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Quality Control Measures


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Kaizen


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Strategic action plan


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Future scope ??

Hybridenergy Ltd aims to provide the best services to consumers by

quantifying gaps between the benchmarker's performance and

world-class performance and by adopting the best in class practices

through commitment to quality and sustainability.

Overseas markets


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