MANUFACTURING SYSTEM

Prepared by :
MUHAMMAD RAIHAN BIN DZULKEFLI NURUL SHAFIQAH BT MAT FAUZI NUR JANNAH BT KHOZARI

 The PDCA Cycle (Plan, Do, Check, Act) is also commonly known as the Demming wheel, named after W. Edwards Demming, a Quality Management pioneer

The cycle is a well known model for CPI, or continual process improvement.
It is also a basic foundation for the various iterative and spiral process models in IT project management.

The PDCA cycle involves four basic steps Plan, Do, Check and Act. These are:

Plan To identify and recognize a particular

problem, break it down into smaller, more manageable components, select one for improvement and outline the methods and solutions that can be taken to solve this problem / component. This phase also included establishing correct metrics through which we can measure concretely the factors cause the problem.

Do

Known as the prototyping phase in IT projects, this involves testing the proposed change on an experimental basis and / or on a small scale. Such caution is warranted; this minimizes the risk of disrupting regular processes, and allows management to test whether such changes will actually make a positive impact or not (without running the risk of reducing productivity or affecting profits).

Check An evaluation of the tests carried out

(i.e. the Do phase). Usually problems and their impact are measured by certain metrics (decided in the Plan phase), and this phase circles around measuring results in the Do phase versus benchmark results specified in the Plan phase. In project management terminology, this means evaluating key performance indicators in light of experimental changes in a practical setting.

Act An implementation of the proposed

changes in case the tests (Do phase) prove successful (established by the Check phase). This phase transforms the proposed changes into integrated practices within your regular business processes.

Project Planning and Implementing Tools :

PlanDoCheckAct Cycle
Description The plandocheckact cycle is a four-step model for carrying out change. Just as a circle has no end, the PDCA cycle should be repeated again and again for continuous improvement.

Plan-do-check-act cycle

When to Use Plan-Do-Check-Act

As a model for continuous improvement. When starting a new improvement project. When developing a new or improved design of a process, product or service. When defining a repetitive work process. When planning data collection and analysis in order to verify and prioritize problems or root causes. When implementing any change.

QUALITY ASSURANCE

Quality assurance is the process of verifying or determining whether products or services meet or exceed customer expectations. Quality assurance is a process-driven approach with specific steps to help define and attain goals. This process considers design, development, production, and service.

ZERO DEFECTS

What is it ?
Zero Defects, pioneered by Philip Crosby, is a business practice which aims to reduce and minimise the number of defects and errors in a process and to do things right the first time. The ultimate aim will be to reduce the level of defects to zero. However, this may not be possible and in practice and what it means is that everything possible will be done to eliminate the likelihood of errors or defects occurring. The overall effect of achieving zero defects is the maximisation of profitability. More recently the concept of zero defects has lead to the creation and development of six sigma pioneered by Motorola and now adopted worldwide by many other organisations.

How can it be used ?

The concept of zero defects can be practically utilised in any situation to improve quality and reduce cost. However it doesnt just happen, as the right conditions have to be established to allow this to take place.

A process, system or method of working has to be established which allows for the achievement of zero defects.
If this process and the associated conditions are not created then it will not be possible for anyone involved in the process to achieve the desired objective of zero defects. In such a process it will be possible to measure the cost of none conformance in terms of wasted materials and wasted time.

 Any process that is to be designed to include this concept must be clear on its customer expectations and desires. The ideal is to aim for a process and finished article that conforms to customer requirements and does not fall short of or exceed these requirements. For example, in recent years many financial organisations have made claims regarding how quickly they can process a home loan application. But what they may have failed to realise is that in spending a great deal of time and money reducing processing time they are exceeding customer requirements (even if they believe that they know them). In these cases they have exceeded the cost of conformance when it was not necessary to do so.

Advantages
1. Cost reduction caused by a decrease in waste. This waste could be both wasted materials and wasted time due to unnecessary rework 2. Cost reduction due to the fact that time is now being spent on only producing goods or services that are produced according to the requirements of consumers. 3. Building and delivering a finished article that conforms to consumer requirements at all times will result in increased customer satisfaction, improved customer retention and increased profitability. 4. Possible to measure the cost of quality

Disadvantages
1. A process can be over engineered by an organisation in its efforts to create zero defects.

2.

Whilst endeavouring to create a situation of zero defects increasing time and expense may be spent in an attempt to build the perfect process that delivers the perfect finished product, which in reality may not be possible.
For example, a consumer requirement may be a desire to buy a motor car that is 100% reliable, never rusts and maximises fuel consumption.

3.

4. However, in this instance, in practice, if an organisation doesnt have some kind of built in obsolescence it will have a more limited life.

QUALITY ASSURANCE INSPECTION

Quality control or quality assurance inspection is defined as the assessment of characteristics with respect to defined standards in order to assure quality to the customers for any industry of business.

Any quality monitoring inspection process consists of the following steps :

deciding the sample size Selection of sample Measuring or testing Examining Comparing with specifications Deciding on subsequent action

STATISTICAL PROCESS CONTROL :

Statistical Process Control (SPC) can be applied to software

development processes. A process has one or more outputs, as depicted in the figure below. These outputs, in turn, have measurable attributes. SPC is based on the idea that these attributes have two sources of variation: natural (also known as common) and assignable (also known as special) causes. If the observed variability of the attributes of a process is within the range of variability from natural causes, the process is said to be under statistical control. The practitioner of SPC tracks the variability of the process to be controlled. When that variability exceeds the range to be expected from natural causes, one then identifies and corrects assignable causes.

SPC is a powerful tool to optimize the amount of information needed for use in making management decisions. Statistical techniques provide an understanding of the business baselines, insights for process improvements, communication of value and results of processes, and active and visible involvement. SPC provides real time analysis to establish controllable process baselines; learn, set, and dynamically improve process capabilities; and focus business on areas needing improvement. SPC moves away from opinion-based decision making.

 These benefits of SPC cannot be obtained

immediately by all organizations.

SPC requires defined processes and a

discipline of following them.

It requires a climate in which personnel are

not punished when problems are detected, and strong management commitment.

Steps for implementing Statistical Process Control are:

Identify defined processes Identify measurable attributes of the

process Characterize natural variation of attributes Track process variation If the process is in control, continue to track If the process is not in control: - Identify assignable cause - Remove assignable cause - Return to Track process variation

How To Perform SPC :

Characteristics of Zero Defects :

For the based, make the product or services which

correct and good for the started Holds the principle to prevent disability not for defects rectity Relationship between employer and works with be more friendly Relationship between employer and workers will more open Company will be more care about their products to compleate in the market

The benefits of introducing a quality control circle program in the work place are many :
O Heightened quality awareness reveals faults in the system that might obstruct good practices. It improves the quality of your firm's products and services, thereby increasing the value of your brand, and securing your customers' confidence. The quality of customer relationship management can be further enhanced by using help desk software from the likes of

O The people who are part of the quality control circle will feel a sense of ownership for the project. Higher yields and lower rejection rates also result in enhanced job satisfaction for workers, which in turn drives them to contribute more. o A quality control circle program also brings about improved two-way communication between the staff and the management. O Finally, the financial benefits will certainly exceed the costs of implementing the program. A study revealed that some companies improved their savings ten fold!

Importance of QCC in a Particular Firm :

Quality improvement Reduce waste of product and time Reduce damage Improvement of workers skill To avoid duplicated and make it more sistematics

The End.. Thank you..