Quality Management and Reliability

(MN5554)

Dr QingPing Yang

College of Engineering, Design and Physical Sciences

Brunel University London

Email: QingPing.Yang@brunel.ac.uk

Introduction

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 Why Quality is Important?

2009–2010 Toyota Vehicle Recalls

• From Nov 2009 to early 2010, Toyota recalled

more than 8 million cars and trucks worldwide in
several recall campaigns, and briefly halted
production and sales due to Unintended
Acceleration.

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Cost
• 6200 complaints, 89 deaths and 57 injuries (from 2000 to
May 2010 in the US).
• On 6 April 2010, the US government sought a record
penalty of US$16.375 million from Toyota for its delayed
response in notifying the National Highway Traffic Safety
Administration regarding the defective accelerator pedals.
• A total loss of US$2.47 billion across the country from the
entire incident, with additional US$2 billion from lost
output and sales worldwide.
• On February 24, 2010, Toyota CEO Akio Toyoda testified
before the House Committee on Oversight and Government
Reform.

Causes of Toyota Unintended Acceleration

• Floor mat
• Mechanical sticking of the
accelerator pedal
• Anti-lock brake software

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Samsung Galaxy Note 7 Recall
• 35 reports of battery failure (catching fire or
exploding while charging) since its US launch on
19th August 2016.
• On 2 September 2016, Samsung suspended sales
of the Galaxy Note 7 and announced a worldwide
product exchange program.
• Estimated to cost Samsung US$1 billion to
replace the over 2 million devices it had sold
before the recall and to cause Samsung to lose
nearly US$17 billion in revenue .
• Overheat and combust or explode due to faulty
battery design.

Quality Problems for Chinese Manufacturing

• Losing both lower and higher end markets
• Relatively low product quality
− According to reliable estimation, Chinese
manufacturing industries annually suffer from
direct economic loss of more than £17 billions due
to quality problems and indirect loss of more than
£100 billions due to impacts on other industries
and pollution treatments, etc.
• Safety problems (production, food, energy, etc)
• Environment problems (e.g. smogs, pollutions)

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Covid-19 Pandemic and Quality Management

• Quality management issues in:

− Origin and spread of the coronavirus (SARS-CoV-2)
− Prevention measures (hand washing, social distancing, restrictions and
lockdowns)
− Quality of testing kids, PPEs, diagnostics and treatments
− Uncertainty and disinformation
• As of 05 October 2021 (13:38 GMT), there have been
236,297,249 laboratory-confirmed cases of Covid-19 with
4,825,433 deaths.

Why Quality is Important?

• Definition of Manufacturing
− The process of converting raw materials,
components, or parts into finished goods that meet a
customer's expectations or specifications.

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Priority Process Technologies
– quotes from the consultation (1/2)

Priority Process Technologies

– quotes from the consultation (2/2)

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 Industrie 1.0 to Industrie 4.0

Industrie 4.0 as Part of a Smart, Networked World

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 “The 20th century has been the Century of
Productivity, but the 21st century will be the
Century of Quality”.

Joseph Juran

Main Aims

• To provide an in-depth understanding of the principles of

modern quality assurance which underpin the discipline and
their applications in engineering, manufacturing and
enterprise.

• To provide a professional-level working knowledge of the

advanced techniques of reliability engineering and an ability
to apply them to improving the maintenance, the
maintainability and the safety of existing and proposed plant
in their workplace.

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Learning Outcomes
At the end of this module, students will be able:
• To gain in-depth knowledge of various quality management principles,
approaches and philosophies (K).

• To organise the collection of plant data and undertake an analysis of it, which
will facilitate the diagnosis of reliability problems and their effective elimination
(K).

• To select and apply the most appropriate of the currently available techniques
for reliability assessment (K).

• To be able to analyse real quality problems and apply suitable techniques to

improve quality (C).

• To demonstrate an in-depth appreciation of the contribution of quality

management techniques to competitiveness of a manufacturing enterprise (S).

Main Topics (Part A)

Quality Management:

• Introduction; Brief history of QA;

• Definition of quality and the views of the Gurus;
• ISO 9000 quality management systems;
• Problem solving and quality tools;
• FMEA;
• Statistical process control; Six sigma;
• Significance testing; Taguchi methods.

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Main Topics (Part B)
Reliability:

• Decision analysis; Fault-tree analysis;

• Reliability of items; Weibull analysis;
• Reliability of systems;
• Failure mode and criticality analysis;
• Review of other advanced techniques for reliability
analysis: Event tree, Markov and simulation techniques.

Assessment

• Examination (QM) 50%

(2 hours)

• Assignment (Reliability ) 50%

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Reading List
0. Handouts/lecture materials (available on the BBL)
• Lecture slides
• Exercises

1. ESSENTIAL READING
• Lecture Notes (available on the BBL)

2. RECOMMENDED READING
• Oakland J S, 2003, ‘Total quality management’, London: Butterworths.
HD62.15.O352 2003.
• Patrick D.T. O'Connor with David Newton, Richard Bromley, 2002, ‘Practical
Reliability Engineering’, 4th Edition, revised, Wiley. TS173.O36 2002.
• Slack N, Chambers S, and Johnston R, 2004, ‘Operations Management’ 4th
Edition, Pearson Education. TS155.S63 2004.
• SMMT, 2003, ‘Failure modes and effects analysis’.
• Bentley, J. P., 1999, ‘An Introduction to Reliability and Quality Engineering’,
2nd Edition, Addison Wesley. TS173.B46 1999.

Lecture Schedule (2021/22)

Week Date Session
Introduction;
3 06/10/21
History of quality management; Concept of quality; Quality gurus;
4 13/10/21 Initial data analysis

5 20/10/21 ISO 9000; Problem solving tools 1; Problem solving tools 2

6 27/10/21 Measuring the Reliability of Items

7 03/11/21 SPC

8 10/11/21 Weibull Analysis of Lifetime Data (1)

9 17/11/21 Six sigma; FMEA

10 25/11/21 Weibull Analysis of Lifetime Data (2)

11 02/12/21 Significance testing; ANOVA

12 09/12/21 Reliability of Systems

13 16/12/21 Loss function, Taguchi methods

Time: 2-5:00pm Wednesdays Venue: LECT C (SD 80) / Online over Teams

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