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TOTAL TOTAL QUALITY QUALITY MANAGEMENT MANAGEMENT By: By: Zahid Hussain Zahid Hussain Quality Trainer Quality Trainer MS-Total Quality Management MS-Total Quality Management IRCA Lead Auditor ISO-9001-2000 IRCA Lead Auditor ISO-9001-2000 B.Sc Engineering (Chemical) B.Sc Engineering (Chemical) PCBA–UCP PCBA–UCP SESSION – 7- 8
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Page 1: Session 7 8 Juran Triology Taguchi Loss Function

TOTALTOTALQUALITYQUALITY

MANAGEMENTMANAGEMENT

By:By:Zahid HussainZahid Hussain

Quality TrainerQuality TrainerMS-Total Quality ManagementMS-Total Quality Management

IRCA Lead Auditor ISO-9001-2000IRCA Lead Auditor ISO-9001-2000 B.Sc Engineering (Chemical)B.Sc Engineering (Chemical)

PCBA–UCP PCBA–UCP

SESSION – 7-8

Page 2: Session 7 8 Juran Triology Taguchi Loss Function

Dr. Edward W. Deming

(Management Philosophy and Systems) (1900-1993) The Statistician USADr. Joseph M.

Juran (Quality Trilogy)

(1904-2008 -103 years age)- USA- industrial engineer

Dr. Philip Crosby Zero defects and Cost of quality) (1926 -2001) Age 75) USA.

Dr. Kaoru Ishikawa Simple tools, QCC, Company-wide quality) (1915-1989) Age-74, Japan, Mechanical Engineer

Dr. Genichi Taguchi (Loss Function), 1924- 1989 65 years, Japan, Textile Engineer

Q in Descon Chemicals

Leaders in Quality Leaders in Quality RevolutionRevolution

Page 3: Session 7 8 Juran Triology Taguchi Loss Function

Dr. Genichi TaguchiDr. Genichi Taguchi

Mechanical Engineer – Won Deming award -4 timesMechanical Engineer – Won Deming award -4 times Taguchi methods emphasize Taguchi methods emphasize consistency of consistency of

performance and reduced variationperformance and reduced variation, (Cost, , (Cost, target & Variation)target & Variation)

Quality Loss function (deviation from target is a Quality Loss function (deviation from target is a loss )loss )

Parameter design which is an application of Design Parameter design which is an application of Design of Experiments (DOE).of Experiments (DOE).

Taguchi Definition of Quality:Taguchi Definition of Quality:– Stresses on Stresses on engineering approachengineering approach to Quality to Quality– Produce with Produce with minimum variationminimum variation to target goals to target goals– Focus on DesignFocus on Design for Quality for Quality– Quality is Quality is Loss function. Loss function.

The application of scientific and mathematical principles to practical ends such as the design, manufacture, and operation of efficient and economical structures, machines, processes, and systems

It is a structured and organized method used to determine the relationship between the different factors (XS) effecting a process and the output of process (Y).

Page 4: Session 7 8 Juran Triology Taguchi Loss Function

TAGUCHI LOSS FUNCTIONTAGUCHI LOSS FUNCTION

Upper Specificatio

n Limit

Lower Specificatio

n Limit

Goal Post View

No Loss Incurred

Loss Incurred

Loss Incurred

Traditional Loss Function

Page 5: Session 7 8 Juran Triology Taguchi Loss Function

TAGUCHI LOSS FUNCTIONTAGUCHI LOSS FUNCTION

Page 6: Session 7 8 Juran Triology Taguchi Loss Function

TAGUCHI LOSS FUNCTIONTAGUCHI LOSS FUNCTION Loss function; provides a process Loss function; provides a process

for computing the for computing the cost of cost of deviationdeviation from the target value. from the target value.

Taguchi’s view was that Taguchi’s view was that any any variation from the expected variation from the expected value was a loss. This places value was a loss. This places emphasis or emphasis or reducing process reducing process variationvariation, not merely accepting , not merely accepting it. it.

If If process variation can be process variation can be reducedreduced, then design tolerances , then design tolerances can be reduced. This increases can be reduced. This increases quality of manufacturing and quality of manufacturing and quality of the product. The quality of the product. The ultimate aim of Taguchi would be ultimate aim of Taguchi would be zero tolerance.zero tolerance.

Page 7: Session 7 8 Juran Triology Taguchi Loss Function

TAGUCHI LOSS FUNCTIONTAGUCHI LOSS FUNCTION

Page 8: Session 7 8 Juran Triology Taguchi Loss Function

TAGUCHI LOSS FUNCTIONTAGUCHI LOSS FUNCTION

– Quality is Loss functionQuality is Loss function. . Loss function Loss function measures qualitymeasures quality Loss function establishes a Loss function establishes a financial measurefinancial measure of of

the user the user dissatisfaction with product dissatisfaction with product performanceperformance as it deviate from a target value. as it deviate from a target value.

Product quality is influenced by uncontrolled Product quality is influenced by uncontrolled sources of variance i.e. sources of variance i.e. the noise factorsthe noise factors..

Concept of societal loss (failure to meet Concept of societal loss (failure to meet customer requirements and ideal performance, customer requirements and ideal performance, harmful side effects, toxic by product)harmful side effects, toxic by product)

Example of vinyl sheet thicknessExample of vinyl sheet thickness

Page 9: Session 7 8 Juran Triology Taguchi Loss Function

TAGUCHI LOSS FUNCTIONTAGUCHI LOSS FUNCTIONSony Corporation- An

Example

• Sony uses the Taguchi model in managing the television sets it produces.

• Quality characteristic=Color density of the televisions.

• Color density measured between Upper and lower tolerance level.

• The Taguchi model provides a good way to analyze the costs associated with variability, even within the limits.

Page 10: Session 7 8 Juran Triology Taguchi Loss Function

TAGUCHI LOSS FUNCTIONTAGUCHI LOSS FUNCTION

ActivityActivity Plant 1Plant 1 Plant 2Plant 2

Color density measured between UTL & LTL.

uniformly distributed televisions that fell between the specification limits.

normal distribution with an average near the set target.

Quality ControlQuality Control focusing on a defect rate rather than a variation from the target.

focusing variation from target rather than the defect rate

ShipmentShipment shipped at a zero defect rate, the specification limits allowed for too much variation

shipped at a zero defect rate, the limits were smaller and the quality was more consistent

Customer Customer ResponseResponse

Lower level of satisfactionwarranty expenses were high.

higher level of satisfactionwarranty expenses were lower.

Sony Corporation- An Example

Page 11: Session 7 8 Juran Triology Taguchi Loss Function

TAGUCHI LOSS FUNCTIONTAGUCHI LOSS FUNCTIONSony Corporation- An

Example

LTL LTLUTL UTLTarget Target

ConclusionIf companies want to remain competitive, they have to

provide quality productsprovide quality products. To accomplish this, a

company must focus on the reduction of variability of a product’s characteristics around a specific target value. The traditional approach is not enough. To remain a world competitor, a

company must consider the Taguchi QLF approach.

Page 12: Session 7 8 Juran Triology Taguchi Loss Function

Dr. Joseph M. JuranDr. Joseph M. Juran

““Fitness for Use”Fitness for Use” Seven Basic ways to improve Seven Basic ways to improve Renowned for his quality trilogy.Renowned for his quality trilogy.

– QUALITY TRILOGY:QUALITY TRILOGY: Quality Planning.Quality Planning. Quality Control.Quality Control. Quality ImprovementQuality Improvement

Page 13: Session 7 8 Juran Triology Taguchi Loss Function

Seven basic ways to Seven basic ways to ImproveImprove

Optimize resources Optimize resources (Process- optimize resources, (Process- optimize resources, Improve controls)Improve controls)

Reduce Errors. Reduce Errors. (Better Control Reduce and eliminate (Better Control Reduce and eliminate rework and wastes).rework and wastes).

Meet or exceed expectations of customerMeet or exceed expectations of customer Register abnormalities (Register abnormalities (find root cause , do find root cause , do

corrective action, document for future)corrective action, document for future) Use technical tools Use technical tools (like statistical process (like statistical process

Control, benchmarking etc)Control, benchmarking etc) Education and training.Education and training. Make the Process safer.Make the Process safer.

Page 14: Session 7 8 Juran Triology Taguchi Loss Function

Approaches towards Approaches towards Continuous ImprovementsContinuous Improvements

Juran’s TrilogyJuran’s Trilogy Shewhart’s Plan-Do-Study-Act CycleShewhart’s Plan-Do-Study-Act Cycle Kaizen (Change +Good)Kaizen (Change +Good) Reengineering Reengineering (Rethinking , Redesign of business processes to (Rethinking , Redesign of business processes to

achieve dramatic improvements)achieve dramatic improvements)

Six Sigma Six Sigma (Tool used to measure process capability) (Tool used to measure process capability)

Page 15: Session 7 8 Juran Triology Taguchi Loss Function

JURAN’S TRILOGYJURAN’S TRILOGYQuality Planning.Quality Planning. Determination

of External Customers

Needs of External Customers

Development Of Product Or Services

Features

Development Of The

Process

Transferring Plans to

Operations.

Quality Control.Quality Control.

DeterminationOf Items

Set Goals Measurement

Of Actual Performance

Comparison Of actual with

Goals

Act on the differences.

Quality Improvement. Allocate Resources, People to Pursue Quality

Training

Page 16: Session 7 8 Juran Triology Taguchi Loss Function

Improvement Improvement StrategiesStrategies

Rep

air

Refi

nem

en

t

Ren

ovati

on

Rein

ven

tion

Page 17: Session 7 8 Juran Triology Taguchi Loss Function

Improvement Improvement StrategiesStrategies

Repair:

“Anything broken must be fixed so that it functions as designed.”

Strategies divided into two levels:

1. Temporary or Short- term measure (Correction)

2. Permanent measure (Corrective action)

Refinement: “Activities that continually improve a process that is

not broken.” Gradual change – face little resistance from

employees Refinement improves efficiency and effectiveness.

Page 18: Session 7 8 Juran Triology Taguchi Loss Function

Improvement Improvement StrategiesStrategies

Renovation:

“This Strategy results in major or breakthrough Improvement.”

It look different from original but same. (Hole drilling by hands and by drill machine)

Innovation & technological advancement are key factors in this approach. (Rechargeable drill machine same as hand drill)

Reinvention (Re-Engineering): “Reinvention begins by imagining that the current

approach can never satisfy customer requirements. ( Reinvention is done by understanding customer requirement, such as process of drilling hole by laser.)

Page 19: Session 7 8 Juran Triology Taguchi Loss Function

QUESTIONQUESTIONSS