Welcome and today's lecture in introduction to manufacturing, today's topic is quality manufacturing.
I know when we think about manufacturing usually quality isn't the first thing
that comes to mind, but honestly it should be whether you're a CEO or are you the
person that is working on actually doing maintenance on the piece
of equipment quality should be actually at the at the forefront of what we're
doing or what we're thinking when it comes to manufacturing you have to remember that
manufacturing business are in business for one thing and that is to make money in order
to make money there to provide a very high quality product to do that
and it takes everybody throughout the whole organization to make that
happen so today we can go into days and days and days of talking
about quality today we're just going to really focus on generic terms trying
to let you understand what quality is why is it important
and give you a good background on quality and manufacturing so right off the bat
quality is the totality of features characteristics of
the product that bears on its ability to satisfy given needs that's as per ASQC
which is American Association of Quality Control and/or ANSI
just look at that real quick and of course I like the very end satisfy given
need usually to a set specification what is somebody saying that they want
and how well does it particularly meet so just like say your mouse on
your computer there somebody built that to a certain need, was it to a specification
to a standard, was it just kind of thrown together haphazardly and said ok here we go
this is a product that I do want to send out. I do like what Edwards Deming has a
say, he says the customer's definition of quality
is the only one that matters. So what that means is any given time that quality
could be adjusted one way or another depending on what the customer feels, so
I think every part that somebody sales you have folks who think it's the quality of say
your mouse on your computer here you know I look at it, I may want a much higher quality
or somebody else is comfortable much lesser quality so you really have to
understand if you're a manufacturer, someone who's concerned with quality you have to find a
fine line in there of where it's at but keep in mind that quality is not
perfecting and fine-tune the part at the end of the stage of manufacture. You're
not at the last minute
going to clean it up, put some nice lines on it and do whatever you need to do to make
it look right to give it and say hey it's high quality but high quality is actually
built into the product from every stage, from conception to the specification
phase, to the design phase, through prototyping if that's what you're going
to be doing, definitely testing and then all the way through the manufacturing
stage and out the door to the final customer, because if you don't do that
then you're going to end up having the higher costs that is associated with that higher
manufacturing costs or the cost of quality and cost of quality is how much
money is spent to build a quality product and when doing that you should consider
the cost of not creating a product that meets certain quality specifications so
you know any time that I build a product is not done to specification I have
to do rework, I have to redo testing, I have to redo assembly again,
maybe redo my tools. All those things affect how much it goes into quality if
I would have built in quality from the get go, from day one
quality built in, my cost is going to be much less. So you can look at it as cost
of quality is any cost that would not have been expended if the quality was
perfect from the get go so if through every stage of my process of manufacturing I
consider quality I take a little time to make the little details work all the way
through the end,
not expending any more time, not expending any more money on resources, any
more money on labor that is what my cost to make this high quality
product cost that is cost of quality if I had to spend something extra. Total
quality costs are incurred by investing in prevention of nonperformance to requirements, maybe
it's making sure that certain tests are done periodically through the manufacturing
phase to ensure that I'm meeting my specifications to get a high quality product
out the door. Appraising a product or services for conformance and failing to
meet those requirements you're going to have some that do fail to
meet those and you have to understand how am I going to adjust and look at those to address that
situation but by building quality into your processes companies are able to
reduce the cost of quality. Making it, building the fine tuning in each step to
have a quality product as you proceed, you can reduce the cost of quality
everyone is going to contribute to that not just the person, the Ohio CEO, not
just the supervisor on the shift that's doing it, not even the guys that are
doing quality control, everybody including the guys that are doing
maintenance on equipment. That equipment has to be running to its optimal ability
at its tolerances that it's built for an order for it to be able to do this
so if a piece of equipment is not working very well it might be you
know causing the equipment or pieces of the product in your subassembly to
come out with not quite to your specification then you got a problem so
that's to make sure that everybody is involved with that to make sure the quality
is there, built in quality means taking a proactive approach to identify and
control errors
the goal is to eliminate any necessary rework and it's up to the person, that's up
to every individual in the system to say hey I'm not going to let it pass on, I
see the problem here whether it's my station that is causing it or
another station, I'm gonna stop it here we're going to fix it and we're
going to before it moves on to another. Last thing I want to do is get to the end of the day, I
knew from eight o'clock in the morning that I was producing an non-quality part and 10,000
pieces are being made, now the company has to step back
rework 10,000 pieces that I could have solved or stopped at 10 a.m. this
morning, so keep that in mind whether you're on the assembly line in
manufacturing or maybe in the maintenance side of it everybody is going to be a
part of that process. Individuals can do that by following your standard
operating procedures maintaining calibrated measurement equipement especially if you're
on a quality control team probably every so many parts you check you want to double
check you're measuring equipment make sure it still calibrated, make sure
it still reading what it's supposed to read and go on from there, so that is very
important for that. Built in error proofing and processes can also help
control the cost of quality, make sure that you're taking the
human element out of it, can I add different you know maybe a different
checks and balances in there to check for error proofing those are all things
that are important but it is important that when an error is found it may be
necessary for you or that individual to stop the process and use problem-solving
techniques to solve that problem. Typically you'll have a standard
operating procedure that'll tell you what to do when that case comes because
businesses manufacturers who want to save money they're going to have a
policy in place to do that but the effects of poor quality can be low
customer satisfaction,
low productivity, low morale of the workforce, rework which is going to be
very frustrating and people have to step back and do rework they're not being
productive and so chances are maybe their quality numbers or their
production numbers are down. Those are all things that can
also affect morale as well as cost, inspection cost, delay in shipping
you know we're supposed to have 10,000 units go out today but we can't because we're having
go back and rework those
because you know we didn't stop the process at eight o'clock this morning like we should
have so on and so forth
high inventory costs and definitely you know greater waste of material. A key
element of process design is determining the impact of critical factors. Critical
factors include aspects which presents serious dangers to human life,
human health, risk to the environment or maybe possible potential of
loss of large sums of money to manufacturer. Those maybe while they're
still manufacturing, maybe there at the end of the line so if I'm making a manufacturing
of an automobile and I know that this quality that I'm
building is not quite safe enough so that end of the day I can hurt future owners
my cars and drivers maybe the people in the passenger seat or the backseat.
Those are critical factors. I am endangering human life or human health
so those are things that you need to kind of know and a lot of times a human
error is a large factor in that, so you know looking at means to make you take
control or the reduced human interaction by allowing you know computers or
allowing certain types of the checks and balances in place to do that or
sometimes beneficial and definitely a factor to have for when it comes to quality
errors by humans can be a lack of technique or skill, a lot of times that the
manufacturing process maybe it's the fact of the process itself, it's hard
to train a human to do it, train a body. Maybe it's just the location of where
this facility is at you have a hard time finding skilled workforce. Happens a
lot so a lot of times that you know by humans or a labor force that's
unskilled sometimes will cause quality to be brought down, so either you can train
them, find a workforce training, work in more technology but a lot of times it's
just as simple as lack of skill but sometimes it's a lack of instant feedback
like I mentioned earlier you may go through 10,000 pieces before you
realize that there's a problem, so that lack of instant feedback as soon as that
first one of first non-conforming part moved through the assembly line, boom there you
go. Now you get 10,000 parts are out of conformance and lack of instant feedback
allowed that to happen. So maybe there's a way that we're using lasers and using some
type of quality control technique you know that you're able to try to get your
lack of or reduced that lack of instant feedback to a shorter time frame so maybe only one part,
two part, five part go through the line versus maybe 10,000 parts so and
of course even if you do have a skilled labor force a lot of times just the
labor inattentiveness is something that causes problems especially with quality and
you might have find ways to adjust, well how can I keep these employees little more in the
game, have been paying attention a little bit closer, maybe I need to rotate them out
more people in and out so that the attention spans of my employees
stay fresh or stay up to date while things are happening so sometimes
management needs to get involved and look at that too but when corrective actions when
things do happen you have corrective actions. Corrective actions are
taken to repair problem after it has occurred.
Remember it's a corrective action these actions may especially include assigned
responsibility for correcting the situation,
assess the importance of the problem, determine is a critical defect, a major
defect or a minor defect. Make sure that you know you identify the negative
elements resulting from defects, how many parts were damaged, how many parts were
affected. Identify the root cause, you don't identify that as soon as you turn the machine back on
or start the process back on your back to doing it again, right? Implement controls
necessary to reduce that occurrence and of course dispose of any bad product but
I think the thing that's most important, think we've all been in meetings in the
past where sat there for an hour or an hour and a half sometime
you walk out the meeting and go, well who's handling that number one topic well
I don't know nobody assigned the problem. Boom! The biggest thing to do
is to assign responsibility for the situation, if nobody's given that
responsibility then chances are nobody's out there working on it, so assign it to
somebody whether it's a supervisor, maybe it's you, maybe depending on what the defect
really is, maybe it's a maintenance person, maybe it's supervisor, maybe it's a CEO. I don't know,
depends on how big of a problem it is to reach out and solve the
problem but the biggest thing is to assign that responsibility to somebody
or team if not just somebody. You had corrective actions but then
you also have preventive actions. Preventive actions are taken to prevent
a problem before it occurs may include equipment maintenance, maybe the
evaluating of your vendor, well I have a vendor that makes a certain subpart
well they have been lately producing some higher than average defects or maybe you
need to go back and find another vendor maybe we just need to go and jack them up and
say hey you're not meeting specifications for me it's time for you
to get know you tighten up a little bit. Safety reviews any time that you're
not working in a safe environment housekeeping the big thing when it comes
to quality too. If you're not working a safe environment you're probably going to
be producing a very poor quality product. Personnel review maybe making quality
incentives your people who are putting it together, hey if we can reduce
our quality number by 10 percent we might be able to give you a one percent bonus at the end
or maybe this or that so sometimes it's as simple as hey we're going to buy a t-shirt
for everybody saying that we're quality, our quality numbers were up. Every
little thing like that works. It
helps build morale as well and then of course design improvement. If your design team can build
quality into their design from the get go
chances are your end product is going to have a high quality of craftsmanship at
the end because its built-in from the design. So today that is a brief
overview of quality. Everything we covered today should get you through your
exam. I wish you luck.