Share & care july 2012

Share

&

Care

Electronic Magazine from Sri Padhmam Consultancy & Training

E.mail : [email protected]

A V Manivannan

Principal Consultant & Trainer

Website : www.sripadhmam.com

“What a person’s mind can conceive & believe,

it can achieve…”1Share & Care - July 2012

2

Share & Care - July 2012

In Chennai :

Plot # 231, New # 12, 44th Street, 8th Sector, KK Nagar west,Chennai. 600 078

In Pondicherry:

No. 30, Thillai Nagar,Pondicherry. 605 004

1. Best performers2. Mini Sudoku3. TQM thoughts4. Earth quake management5. Interesting Q & A6. Voice of Client : Eicher

A V ManivannanPrincipal Consultant & Trainer

Sri Padhmam Consultancy & TrainingChennai & Pondicherry

Website : www.sripadhmam.comCell : 94428 92185

Contents for the month


Leo Fasteners – Pondicherry

Stat

isti

cal t

oo

ls f

or

Stru

ctu

red

An

alys

is

Mr. G Srinivasan

Mr. S VettrivelMr. S Shanmugavelu

Mr. J Arivazhagan

BEST PERFORMERS

Wheels India ( TVS ), Sriperrumpudur

ISO

14

00

1:2

00

4

Trai

nin

g P

rogr

am Mr. H Selvaperumal

Mr. S Thirunavukarasu

Mr. S Rajkumar

Mr. J Kannan

Mr. V Senthilkumar

Mr. N Senguttuvan

Mr. M Suresh

Mr. M Nithyanandham


Sanmina – SCI, Oragadam

Pro

cess

FM

EA

wo

rksh

op

Mr. J Sivasankaran

Mr. R JayasinghMr. V S Venkataramanan

Mr. M Yuvaraj

BEST PERFORMERS

CRI Pumps, Coimbatore

Mr. G Rajagopalan

Mr. N Lakshmanan

Mr. C Parthiban

Mr. S Alageswaran

Mr. M Arunkumar

Mr. P Selvaraj

Ms. J Menaka

Pro

cess

FM

EA

wo

rksh

op


Leyland – DEEREE, ChennaiP

rob

lem

So

lvin

g to

ols

wo

rksh

op

Mr. S Tamilselvan

Mr. S Anada Kannan

Mr. R Ashokkumar Mr. B Imran

sudoku

f c v

f f y

A c

l n M a

1. It is derived from Plan Vs Achievement

Please visit our website www.sripadhmam.comfor right answers

2. It is Doing more & more with Less & less

3. Intended to take care of the Employees during illness

4. Who did the Hawthorne studies based on HR

n m tl

6

5. Job related action

2


http://www.sripadhmam.com/

7


A ready reckoner for Home Dwellers

An Earthquake

Preparedness Guide

National Disaster Management Division

Ministry of Home Affairs

North Block, New Delhi, India

Are your Interested to know –

• What is earth Quake ?• Where are you placed ?• Emergency Preparedness measures ?

Courtesy : Mr. S Deivanayagam, Safety Manager, ELGI equipments, Coimbatore

Free down load

From our website

www.sripadhmam.com

In English & Hindi

Total Quality Management( T Q M )

Share & Care - July 2012 8

As viewed by Mr. S M Sastry

Dr. Deming

TQM thoughts

9


“Total quality management” – Very often this very expression itself is treated as a subject only, to

be taught in class room. `Actually, this should be treated as “a way of life” by the people in

industries. However, the college students who take assignments in industries at a later stage, after

taking their respective degrees would do well to get an introduction to the concept of quality and

“total quality management”.

Quite long time back (about 40 years back), the industries used to have huge “ inspection

departments” which disappeared now in to oblivion. These departments would organize

elaborate inspection activities in order to ensure “right” components would be used in the sub-

assemblies or final products. The components which are not usable (normally called –“rejected”)

are quarantined, reworked’ re-inspected and used or scrapped as the case may be.

T M

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• This process usually ends up in huge loss of material, effort, time, delays in production and

unending disputes between the suppliers and the companies.

• This used to happen as the activities were completely compartmentalized. People used to take a

stand –“I have done my job.

• Quality !!! it is none of my business”

• So, as a result, the Indian consumer had to be content with the products produced with out-dated

technology and methods.

• The customers used to bear the complete losses due to inefficiency and wastage in the

manufacturing process.

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However, when the Indian markets were opened to international producers and manufacturers,

the Indian consumer was exposed to a new world of better products, and better quality and

products produced under better systems.

This realization on the part of the Indian consumer made the Indian manufacturers to sit up and

to think of new ways and new concepts to satisfy the new aspirations and needs of the Indian

consumers. As a result, several new and better concepts, tools and management systems found

their way in to Indian industries.

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Some of the concepts are –

• TPM (Total Productive Maintenance ),

• TQM (Total quality management),

And some of the tools are -

• SPC (Statistical process control),

• SQC (Statistical quality control) &

• “6 Sigma” etc.

Also, there are improved management systems called ISO 9001 , TS 16949 which lay down the

procedures to institute and ensure the required systems.

These systems will make sure that the features and requirements of a product for a customer are

built in to the process it-self with minimum auditing. (In olden days this auditing was referred to

as “inspection”. )

Views will follow……….

13


Interesting

AA V Manivannan

14


What way control charts are used during variable GR&R study ? What is the acceptance criteria for Chart and UCL and LCL X bar ?

AMr. S VaikundaRamu, Wheels India – TVS, Chennai

On M S A

Good one !

In Variable G R&R study, we need to homogenize the lot. This homogenization is done based on the formula, R double bar / D 4.

Result of this need to be compared with all the R bar values. If something is exceeding – that has to be removed from the lot and calculations to be repeated.

This homogenization shall be done directly as calculations only. There is no need for a Control chart for this study.

Whereas, for the Stability check ( Variable gages study ), there is a need for the Control charts to find out the presence of any Special causes.

Control charts rules ( all Non-random pattern rules ) are quite applicable for this study too and that shall be treated as ‘acceptance criteria’.

In a nut shell, Variable G R&R study need not call for any control chart application, but for the Stability check – control charts are needed.

15


During Design FMEA analysis, Block diagrams are required for the Components also ?

AMr. Ruthrakoti, Mitsuba Sical, Chennai

On Design FMEA

No need.

The very purpose of a Block diagram, during the Design FMEA analysis is to define the scope of the Design team.

The products so designed are suppose to perform in different places, interacting with other systems and different environmental conditions.

The design team must know the same and document in the form of a Boundary diagram / block diagram – defining the product’s ( ie., System’s ) scope of functioning.

While doing so, the linkages to other systems and sub-systems are also captured. All these are needed for the systems only, not needed for sub-system level and the components.

16


Will One Potential failure mode could happen due to many causes related to Process ?

AMr. Ramkumar S, FLS Midth, Chennai

On Process FMEA

Yes ! Quite possible !

Speed

Feed

Finish on aShaft Temp

Platingthickness

PlatingFinish

2 process Ch -- one product ch 1 process Ch -- two product ch

Please note, in case 2 we have 2 requirements ( viz. Plating thickness & Plating finish ).Both are Product parameters, in turn they have their potential failure modes too.

Temperature is one potential cause, contributes to different Failure modes.

Please see Case 1, where in TWO process parameters ( Viz. Speed & Feed ) are determining ONE productParameter ( Viz . Finish on the shaft ). Naturally for the potential failure mode Poor finish on the Shaft, 2 potential causes will contribute.

We may get more inputs on this, from the APQP & Control Plan methodology –Edition 2

Case 1 Case 2

17


Harnessing the competencies of our employees is a vital organizational

development initiative at our organization and we express our sincere thanks to

Mr.A V Manivannan for his good support in this endeavor.

He is associated for long with our organization regarding development of number of

critical competencies like PFMEA, DFMEA, APQP, PPAP & SPC. I must mention

the deep involvement and earnest effort of Mr.A V Manivannan to make each of the

training program a success.

His training programs are highly interactive which involves each and every

participant. In fact the feedback received from his programs are benchmark

for other programs conducted in our organization.

I have personally observed in his training sessions that all the participants interact

and share their experience and the concepts get fortified by his thorough subject

knowledge and expertise.

I must mention that the training programs conducted by him are not just formal

training sessions but he drives those programs wholeheartedly to bring

improvements in our processes and systems through the participants.

We sincerely appreciate his contribution and look forward to fruitful association for

years to come.

P S Basu, Head of Training,

Eicher Tractors, Bhopal, Madhya Pradesh

E mail : [email protected]

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Business

Share & care july 2012