GUIDE TO TOTAL QUALITY MANAGEMENT (IE673-852)

Assignment 1: TQM Process / System Modeling Method

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Assignment 1: TQM Process / System Modeling Method
Assignment 2: Component Oriented TQM Process Related Requirements Analysis
Assignment 3: Process Improvement and Process Control Analysis
Assignment 4: Process Failure Risk Analysis
Assignment 5: TQM Audit & System Improvement using RFID / TQM methods:
Assignment 0: Executive Summary
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Total Quality Management: IE 673, Spring 2008
Assignment #1
Author: William V. Nordling
February 22, 2008
eLearning Pack ID: 673-Spring 2008-61-12

CONTENTS:

·         Introduction  and Objectives

·         Applied Methodologies

·         Main Body of the Project

·         Summary

·         Data Dictionary

·         Further work needed

·         Reference

INTRODUCTION AND OBJECTIVES:

Virtual-TQM was founded as part of a class project for a graduate course (IE673) offered at the New Jersey Institute of Technology.  It is a virtual company that will utilize PC based automated manufacturing systems to aid in maximizing productivity.  Virtual TQM will act as a third party contracted company that will collaborate with the following companies to develop and market new and exciting games for entertainment purposes.

·         Crayola Products

·         Endless Games

·         Uncle Rez Games

·         GE Fanuc Automation

The overall objective of this project is to illustrate a TQM process model with an emphasis of the conception to market process needed to manufacture various games and crafts used for entertainment purposes.  The virtual company will manufacture various board games and crafts for three front runners in the gaming/craft industry utilizing state of the art automated processing CNC’s.

APPLIED METHODOLOGIES:

As part of this project CIM (Computer Integrated Manufacturing) will be utilized to model the design and manufacuturing process to enhance the quality of the various games and crafts marketed by the aformentioned companies.  The CIMpgr methodology will be used as a model throughout the entire life cycle from product inception to distribution and customer feedback.  CIMpgr is a graphical method for modeling a system and uses a set of diagrams that illustrate the relationships between the variables associated with the production of the product along with their functions. The CIMpgr approach will address the individual component processes/objects and identify the inputs, outputs, resources, and controls. This approach will aid in improving processing time, reducing failure rate, increasing robustness, reducing cost which will ultimately result in customer satisfaction.

MAIN BODY OF THE PROJECT:

Utilizing the CIMpgr approach, continuous improvements to the process can be attained. This will ensure that every step throughout the process is addressed and meets the customers needs.  The model will lend itself to the monitoring and tracebility of Quality with respect to the product. The automated systems that will be incorporated will minimize variability in the end product and maximize the productivity.  The model will allow for lower costs, shorter processing times and improved and consistent results which ultimately will result in a satisfied customer.   

First Layer of Process Model (A0)
By observation we can see that customer requirments will be driven by the packaging configurations of their respective product and ranks highest on the priority gauge.  To a lesser extent will be in house expertise.  The packaging lines are highly automate and have the latest inspection systems which will ensure that quality product is introduced to the market.  Data will be collected as various prodcuts are introduced and knowledge is gained.  This data will enhance Virtual TQM's understanding of the packaging configurations allowing us to streamline processes and reduce changeover time if like line set up will be utilized for similar packaging configurations.  The ultimate goal with the highest priority of course is customer/client satisfaction.
 

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Second Layer of Process Model (A1, A2, A3, A4)

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Third Layer of Process Model (A3.1, A3.2)

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CASE VIDEO FILE ANALYSIS:

As part of this exercise, two full length video files were viewed to determine how each company approaches their respective quality assessment.  The following contains a summary of each companies approach to the quality assessments.

 

Bentley Quality:

 

Bentley specializes in automobiles with an high degree of quality and craftsmanship built into there designs.  Bentley’s goal, or the “Essence of Bentley” is to deliver a car that portrays style & design, power & performance and a high degree of cache & sex appeal.  These attributes aren’t necessarily needed for the car to operate correctly yet is incorporated into the design base on customer feedback and wants.  The company maintains a customer base by designing cars that are extremely pricey due to the quality that is built into them.  Most purchasers of a Bentley are selfmade and purchase the car as a means to flaunt their financial status and success.  Bentley acknowledges this and therefore designs there automobiles with customer satisfaction in mind.  Bentley uses materials that the purchaser associates with a quality product and the construction shows a high degree of craftsmanship.  They utilize materials such as wood, leather and metal to accomplish this.  They construct their automobiles with extreme detail and ensure that each automobile is pieced together with tight tolerances.  To a purchaser, they want to see this high level of detail that comes with the high price tag. They incoporate all standard safety features along with more modern conveniences such as GPS and elaborate sound systems.  All this is tied into a classic yet timeless look and feel.  As previously mentioned Bentley relishes in the detail and level of their craftsmanship and is unmatched in their eyes.  Skilled fabricators are trained to perform the assembly of each automobile with each having years of experience.  From the instrumentation panels to the hand stiched seats the level quality is superb and shows no variability.  The tolerances and marriage of parts ensure that the appearance showcases a quality product.  Comfort and control is also a major part of each of the automobiles.  A large wheel base ensures adequate space is provided to the driver as well as passengers.  The enlarged rear seating also targets the passengers and allows them to enjoy the overall quality of the cars design as well.  Bentley is regarded as the upper echelon in the automobile industry and rely on their customer base to dictate the level of quality built into their product.  They educate and recruit the best up and coming designers.  Younger designers from around the world bring their contemporary influence to interject new and creative ideas, thus enabling the company to keep up with the latest innovations.

 

COGNEX-VISION:

 

Cognex vision systems are primarily for the inspection of product for defects.  This is an online system that can be used with continuous production lines.  The systems are multifunctional in that can be used for dimensional gauging, defect inspection, robot guidance and identification.  The dimensional gauging capabilities of the systems can be used for measuring distances and/or tolerances with respect to reference points.  It can read edges by viewing contrasting patterns and thus define shapes.   Defective parts can be identified by programming the system prior to inspection with the correct acceptance criteria.  The systems can also be used for robot guidance for variables such as positioning, angle, scale and variation.  Products can be marked with code for identification puroposes.  A 2D data matrix code can yield information such as type of part and date of manufacture.   The systems can also generate statistically data from measurements.  The data can be analyzed online and spot trends that can identify potential trends that might result in an out of control system.  The system is internet based allowing for viewing from various locations.  While the product pass by the vision system it takes a static image with scan time being dependant on line speed and complexity of the item being scanned.  The vision system is much more efficient in identifying components that do not meet specifications.  All of the attributes of the Cognex vision system ensure that a quality product is being shipped to the consumer by elminating the potential for defective product making its way to market. 

SUMMARY:

Utilizing the CIMpgr approach, one can identify the resources needed to see the product through its lifecycle.  By defining the variables associated with the production of end product, key activities and responsibilities can be identified and monitored towards improvement.  The TQM process model will aid in addressing problematic areas that warrant correction.

FURTHER WORK NEEDED/PROPOSED:

Virtual-TQM will continue to build upon the foundation of Total Quality Management outlined herein.

REFERENCES:

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IE673-852 TOTAL QUALITY MANAGEMENT