Website : of Experiments ( DoE t Shainin ... to determine the condition of the product from a quality ... for the study must include the entire process

& Care

“This e-magazine is for FREE Circulation only”

Sri Padhmam Consultancy & Training “What a Person’s mind can conceive & believe,

it can achieve !”

Mobile : 094428 92185 e-mail : [email protected]

Website : www.sripadhmam.com

1

Quality month November ( 2016 ) Special !

Toppers !

Royal Enfield, Chennai

TQM & 6S Work Place Management

Coordinated by

Mr. T Ramalingam & team

Sri Padhmam Share & Care E- Magazine Nov 2016 094428 92185 [email protected]

2

Toppers !

Wheels India ( TVS ), Chennai

ISO 14001-2015

Environmental Management System ( EMS )

Coordinated by

Mr. K Saravanan


3

Toppers !

Poclain Hydraulics, Pondicherry

8D Methodology ( Aligned to QRQC ) for the Suppliers

Coordinated by

Mr. G Prabu & Team


4

Toppers !

Brakes India ( TVS ), Chennai

Design of Experiments ( DoE – Shainin techniques )

Coordinated by

Mr. Lakshminarasinhan & Team


5

Toppers !

Public Program in Chennai

Measurement Systems Analysis ( MSA )

Coordinated by

Mr. G Moorthy & Team


6


7

Deep dive in to

the Core tools of Automobiles

5


Deep

div

e in

to

the

C

ore

to

ols

of

Au

tom

ob

ile

s

1. Pro ess FMEA will e do e duri g APQP …..

a) Phase 2 b) Phase 1 c) Phase 3 d) All of them

2. In the 4th editio of FMEA…..

a) Requirements are eliminated b) Requirements column is separated

3. MSA & SPC studies are do e as a part of APQP duri g ……

a) Phase 2 b) Phase 4 c) Phase 5 d) Phase 1 itself e) None of them

4. Non-ra do patter s i the SPC are …..

a) Trends b) Runs c) Both a & b d) None of them

5. Chara teristi s Matri is losel li ked to …..

a) Design FMEA b) PPAP documentation c) MSA studies d) None of them

5 Part # 5

Right Answers

in the Next month

Share & Care


Cost of Quality : A Detailed look ! 2


Appraisal Costs.

Appraisal costs are those costs associated with measuring, evaluating, or auditing products,

components, and purchased materials to ensure conformance to the standards that have been

imposed.

These costs are incurred to determine the condition of the product from a quality viewpoint and

ensure that it conforms to specifications.

The major subcategories are….

Inspection and test of incoming material : Costs associated with the inspection and testing of all

material.

This subcategory includes receiving inspection and test; inspection, test, and evaluation at the

vendor’s facility and a periodic audit of the quality-assurance system.

This could also include intra-plant vendors.

Quality Costs : A detailed Look


Product inspection and test : The cost of checking the conformance of the product throughout its

various stages of manufacturing, including final acceptance testing, packing and shipping checks, and

any test done at the customer’s facilities prior to turning the product over to the customer.

This also includes life testing, environmental testing, and reliability testing.

Materials and services consumed :The cost of material and products consumed in a destructive test or

devalued by reliability tests.

Maintaining accuracy of test equipment : The cost of operating a system that keeps the measuring

instruments and equipment in calibration.

Will Co ti ue …

Quality Costs : A detailed Look


Habit of reading books is a proven source of inspiration !

From now, some of our circle members are sharing the

book(s), which has inspired them so far !

I find Dr. C V as a highly knowledgeable person with humbleness ! We met in Bangalore way back 2009 and till date the relationship

continues ! Very difficult to find another person like him, in terms of Grooming the Sub-ordinates !

13 Sri Padhmam Share & Care E- Magazine Nov 2016 094428 92185 [email protected]

# Title of the Book Author Points of Inspiration

1 To Kill a Mocking Bird Harper Lee A sweet book made into a great movie.

2 I a OK . You’re OK Thomas Harris It introduces one to TA (Transaction

Analysis) which is a great concept to

understand interactions/relationships

3 The Fifth Discipline Peter Singe Introduces the concept of Systems

thinking which will be a valuable

learning.

Books provide us

lot of lights

to lead our life more

Successful &

Meaningful too !

Top 3 books : My Choice !


Statistical tools : A Close look !

We are offering many Statistics based Workshops such as Statistical process control, Six Sigma awareness, Control Charts, Capability studies and Design of Experiments ( Shainin ). This exercise will help those who had undergone the above mentioned programs by us !

Special Exercise for the Practitioners of Statistics !


# Statistical Tool Focus Point

Please select the best Option & Circle

Option A

Option B Option C

1 Likert Scale

Acceptance Criteria

1 : 10 1 : 2 1 : 5

2 Cause & Effect Diagram

Out puts

Possible Causes Root - Causes Probable Causes

3 Component Search

Key Activity

Swapping of parts Replacing of parts Re-working of parts

4 Cp & Cpk Studies Process Conditions Do not change Must Change Keep the Routine

practices

5

B vs C Purpose To optimize the Results To Validate the

proposed Changes To validate the

present process

6

False alarm Calculations

Acceptance Criteria 2 % Maximum 5 % Maximum 5 % Minimum

Statistical Tools : A Close look I

Right answers will be given in the next month e-magazine !


Interesting Questions &

Answers !

We come across lot of Interesting

Questions in different modes and

happy to share them along with

our answers to you !


Mr. P Vijay Kumar

Dynamic Stampings, Chennai

Event During S P C Workshop

How to perform Cp & Cpk

Studies for the Pressed

Parts ?

Please understand, that processes such as Pressing, Sintering may provide a very good Cp but NOT Cpk. This is primarily because of the basic design of the Tooling. Generally, in the very beginning of life of the tool, the Cpk may not be meeting the norms of 1.33 ( or 1.67 as the case may be ) Whereas, in the mid of tool’s life, the Cpk may become very good and again may come down. Hence, we shall estimate only the Cp but not Cpk. I

nte

rest

ing

Q &

A


Mr. Sri Ranga Boopathy & Team

Chola Pumps, Coimbatore

Event During Process FMEA Hand-holding

Is it right to consider FMEA

as a Control Method ?

We may consider FMEA ( both Process Design ) as a tool to arrive at new Control methods ! FMEA is an approach, which will help us to know the strength of Current Control methods and also to decide the new Control methods ( as Recommended actions ).

Inte

rest

ing

Q &

A


Mr. S Balaji

Brakes India ( TVS ), SEZ, Chennai

Event Through e-mail on M S A – Stability Check

While conducting the “Stability check” in MSA, should we use the Tolerance Range or the Process Range ?

What must be the study frequency ?

As per the MSA 4th edition guidelines, we must use the Process Range

( Six sigma range ) for all the MSA studies.

Stability check must also cover the entire process range, including

the Nominal ( say X double bar …. Process average ) values also.

The periodicity shall be determined based upon the Special cause

influences in the Inspection process ( now, it is the Stability check

process ).

The samples selected for the study must include the entire process

range !

Inte

rest

ing

Q &

A


Mr. Munendra Singh

Sri Ram Fibres, Chennai

Event During S P C workshop

During Homogenization,

how many data points

shall be removed

maximum ?

As a thumb rule, 20 % of the data points ( X bar & R together )

shall be removed as a maximum.

If the need is to remove more and more data points, it is an

indication, that the process is having lot of Special cause

variations and hence, Controlling Statistically is not a right

option.

It is 20 % of the data points, but NOT 20 data points !

Inte

rest

ing

Q &

A


Team Building Program Feed-back

from the Delegates of TGI Packaging, Chennai

• I have learned so much of

my self !

• I’m really impressed by your

way of expressing to deliver the

messages !

• In my life, you’re an

unforgettable person sir !

Sri Padhmam Develops the Employees. In turn, they develop the Organization !

Satyam Grand Resort, Chennai

Sri Padhmam Consultancy & Training 094428 92185 www.sripadhmam.com [email protected]

22

Added service from Sri Padhmam from now onwards ….. Audit service

Systems Audit

Process Audit

Systems Audit

Systems Audit

Sri Padhmam

shall support you through

Audits

on

Sri Padhmam www.sripadhmam.com 094428 92185 [email protected]

24

How to conduct the Management Review Meetings

( MRMs ) effectively ?

For dow loadi g, please li k ….

www.sripadhmam.com

How to compute the Cpk for the Non-normal Distributions ( Skewed distributions ) ?

Both are now available in our website !

Sri Padhmam www.sripadhmam.com 094428 92185 [email protected]

http://www.sripadhmam.com/

Documents

Website : of Experiments ( DoE t Shainin ... to determine the condition of the product from a quality ... for the study must include the entire process