INTRODUCTION AND OBJECTIVES:

Total Quality Management (TQM) is a set of management practices throughout an organization, used to ensure the organization consistently meets or exceeds customer requirements. Two cornerstones of TQM are the monitoring and/or measurement of a process and the ability to maintain control of that process.  The feedback from a process will enable a company to continuously improve on areas that are lacking when warranted.  The objective of this assignment is to incorporate two methods that can be utilized as a means of attaining the goal of TQM.  Radio Frequency Identification (RFID) is a system used to store and manage data for specific products/processes. In Part 1 of this assignment, RFID’s will be incorporated into Virtual TQM production processes to illustrate it’s effectiveness at monitoring processes and assisting in supply chain management.  RFID’s effects on traceability will be assessed as well as their impact on CORA requirements analysis and PFRA risk analsysis.  The secondary objective of this assignment will be to conduct a quality audit of Virtual TQM’s ability to control the processes and TQM methodology discussed over the course of this semester.  This assignment is intended to illustrate how each of the aforementioned tools (RFID’s & Quality Audits) can be applied to the methodologies discussed in Assignments 1-4 to enhance Virtual TQM’s approach to Total Quality Management. 

The various tools applied to Virtual TQM’s quality driven system illustrates their eagerness to embrace new quality techniques and to show their ability to integrate them into there packaging facility. The methodologies described over the course semester has shown Virtual TQMs quality conscious approach to manufacturing.  This mindset will be used to entice potential clients and will culminate with a press release intended on attracting clients to utilize their facility to package and ultimately coordinate the distribution of their products.

METHODOLOGIES APPLIED:

Radio Frequency Identification is fast becoming a superior management tool for supply chain systems.  The RFID system has limitless capabilities within the distribution, receiving and ordering functions common to supply chain management.  It can also be utilized as a marketing tool to track customer base.  There are essentially two parts to the RFID system.  Tags which can be active, meaning they are powered and can store much more memory than that of their counterpart, the passive tag.  Passive tags lie in a dormant state until activated by a signal sent by a reader.  For Virtual TQM’s purposes, passive tags would play a greater role in that the could be printed into labels to be introduced to packaging lines to coordinate the process of various products from collaborative companies such as Crayola Products, Endless Games and Uncle Rez Games.  In conjunction with the visual inspection systems supplied by GE Fanuc, the tags will ensure that product from the collaborative companies is correctly packaged and not introduced into product lines where it does not belong.  Further more bulk palletized product can be identified by using the RFID’s to gurrantee the shipment to the correct recipient. 

A quality audit will be performed as well to give an overall assessement of Virtual TQM’s packaging facility and where it may need improvement.  Areas of concern that are identified will be addressed by making corrective reccommendations.

MAIN BODY OF THE PROJECT:

Radio Frequency Identification (RFID)

RFID’s are a groundbreaking technology with limitless applications.  A relatively new concept, RFID systems are having a greater influence on quality systems and Total Quality Management.  RFID's will be incorporated into virtual TQM's packaging process as a means to efficiently monitor and coordinate the manufacturing of mutliple products for the various partner groups. 

Traceability will be of utmost importance as multiple products will be entering and leaving the facility.  Coordiation and planning of various production lines will be more efficient by using the tags for identification of components to be packaged, packaged product and finally bulk palletized product for shipment.  The use of RFIDs will allow Virtual TQM to coordinate with increased traceability the receipt of materials, processing and subsequent distribution of product.  The CIMpgr models described in Assignment 1 have been reworked to incorporate RFIDs as an important resource that will aid in supply chain managment.  The will assist in segragating products from the partner  companies and ensure our clients product ultimately gets delivered to the correct retailers.  

The introduction of RFID's will also alleviate problematic areas observed in the CORA requirements analysis.  The introduction into the CORA spreadsheet shows the Virtual TQM is far superior in terms of meeting the requirements of our clients.  By observing the CORA analysis spreadsheet we can plainly see that RFID's as well as other identification systems (GE Fanuc) play an importantly role in the process and therefore deserve a high absolute importance rating.  Upon further review we can see that Virtual TQMs highly automated packaging results in a higher customer and product rating overall.  The RFID and other such automation components contribute greatly to the success of the process and result in increased customer satisfaction. 

Updated CORA Spreadsheet

https://wnordling.tripod.com/sitebuildercontent/Rework_CORA_bill_nordling.xls

Finally, with the introduction of RFIDs, Virtual TQM will undoubtedly reduce risks associated with packaging multiple products from the partner groups.  Readers will allow us to effectively monitor each individual package with 100% inspection without the worries of slowing down production.  The use of the RFID systems will also allow the prompt ordering of materials and shipment of finished product.  The Process Failure Risk Analsysis shows that the introduction of the RFIDs will lower the higher risks associated with human inspection of items as it will now be auotmated utilizing the readers and vision systems from GE Fanuc.  This will drastically cut down on  time wasted for inspection and reworks.  In addition the inspection time was drastically reduced as well as processing costs.  The accumulated risk priority numbers were reduced overwhelmingly thus ensuring a more effecient operation system.

Reworked PFRA Spreadsheet

 https://wnordling.tripod.com/Reworked_PFRA.xls

Total Quality Management Audit:

This audit was a conducted internally to assess Virtual TQM’s total quality management system.  The audit captured inspection systems comprised of GE Fanuc Automations along with newly introduced RFID systems in support of quality attributes associated with various products packaged for our clients including Crayola Products, Endless Games and Uncle Rez Games.  By simply integrating RFID into our processess we can see a dramatic improvement.  Incoming materials variability is kept to a minimum which inherently reduces variability on the packaging lines and consequently lowers the risk.  The automated systems are much more reliable than human inspection.  We can continuously monitor the flow of materials and have a firmer grasp on the supply chain.  An audit can identify weak areas that need improvement.  Initial setbacks due to incorporation of new technolgies are only temporary, but the long term rewards are well worth the effort.

As part of a continuing effort to improve quality control and to embrace the total quality management methodology, an audit of Virtual TQM was conducted.  The audit is based on many variables that comprise our quality system with emphasis on the following: 

PURCHASE CONTROLS:

Virtual TQM supplies a fully integrated packaging service to their clients.  Along with requirements specified by their clients they use state of the art monitoring controls utilizing RFID systems and GE Fanuc vision inspection systems.  Purchasing and usage of materials will be effectively tracked by use of RFID to minimize downtime and stock outs.  In addition incoming shipments from partner groups (clients) will be carfully monitored to ensure packaging materials are readily available.  By using RFIDs, Virtual TQM can automate the purchasing of materials by continuously monitoring inventory and generated waste.

AUDITS:

Virtual TQM supplies a fully integrated packaging service to their clients.  Virtual TQM works closely with clients and suppliers to ensure a synchronous operating system.  Audits are conducted periodically on suppliers to ensure they can meet our demands and that they also adhere to our guidelines.  We will also audit our clients to ensure incoming components that are to be packaged on our site do not jeopordize product and/or materials of our other clients. 

INCOMING INVENTORY INSPECTIONS:

All lots of incoming materials are inspected for compliance to in house specifications and compared against vendors COA.  Virtual TQM will work closely will supplying vendors to achieve this.  To showcase our clients product we must display it in a quality package. 

NON-CONFORMANCES:

Incoming materials that do not conform to in house acceptance standards are returned to the vendor.  Virtual TQM prides itself on quality and will not accept materials that do not meet the predetermined acceptance criteria.  In-process non-conformances shall meet a certain level of quality prior to packaging and may include materials from clients.  Virtual TQM will not package products that do not meet the predetermined acceptance criteria.  It is the responsibility of the client to supply Virtual TQM with a defect free product.  Finished product non-conformances will be dealt with by in house quality assessment.  Where warranted materials can be repackaged if a non-confomity is isolated to the packaging materials and not the contents within.  Finished product will be assessed by conformance to predetermined acceptable quality levels. 

TRACEABILITY:

Virtual TQM utilizes a passive RFID systems approach for individually packaged product.  The passive RFIDs allow for quick identification on our high speed packaging lines.  Bulk containers contain an active RFID for bulk palletized product.  This allows for constant identification on site.  The active RFID will remain with the palletized product until broken down by distributors or retailers.  The RFID system will enable our company to effectively monitor and control and incoming and outgoing parts.  In addition we can use RFIDs to assist in monitoring product once on the market to help our clients with identifying their target demographic to maximize their marketing approach.

CONTROLS OF PRODUCTION DOCUMENTS:

Production documents will be archived on a lot by lot basis in an electronic data base.  This will ensure easy recall for machine settings, processing parameters and retrieval of historical data if necessary.  They will be reviewed at the completion of each lot by a qualified representative of the quality department.  The files will have limited access to prevent loss of proprietary information.

CONTROLS OF PRODUCTION EQUIPMENT:

Packaging lines shall be calibrated and in a qualified state at the time of use.  A performance based validation will be performed on a product by product basis regardless of packaging complexity.  A performance qualification will be performed whenever a new product is introduced the packaging line.  Equivalency between packaging lines must be established prior to transferring products to alternate packaging lines.   Preventive maintenance shall be conducted quarterly.  Relaxed qualification may be performed if replacement parts are like for like machine parts.  All equipement is to be operated by qualified staff.  A training log will be kept to ensure that all operations of processing equipment are conducted by an indvidual that has been formerly trained.

PRODUCT RELEASE:

Quality Assurance will ultimately decide final product release.  All non-conformances must be investigated and closed prior to release.  All rejected and/or reworked product must be accounted for and justifed if it is to be released.  An overall product reconciliation and yield will be assessed prior to release for specific lots. Partial lot release may be warranted if a root cause can be identified as to what caused the defective portion of a lot.  Client will be notified of specifics as to why certain lots of their product cannot be released.   

CAPA OR PAR/CAR:

The CAPA system manages the review, analysis and reporting of manufacturing and quality input data, in order to facilitate decisions leading to continuous quality improvements of manufacturing and quality system processes at the Virtual TQM packaging facility.  Corrective and/or Preventive actions should be completed in a timely manner with specified due dates.  The work description of both shall be accurately documented for future recall.

PRODUCT REALIZATION:

The quality of any product or service is dictated by customer requirements.  Virtual-TQM utilizes CORA (Component Oriented Requirements Analysis) in an effort to identify  and assign various levels of importance pertaining to customer needs and wants.  This approach enables Virtual-TQM to satisfy these customer requirements and ultimately allows us to work with the customer to determine if they have a viable product.  Our expertise allows us to make suggestions on packaging configuration that may contribute to better marketing of their product. 

CUSTOMER SERVICE:

Virtual TQM prides itself on customer service.  The client as well as the consumer count on Virtual TQM to deliver the product in an attractive package.  A 24 hour customer service call center is available to the consumers for questions related to the product.  Our partner groups, upon request can be granted 24 hour access to databases archiving data associated with their product via the internet.  In addition we can provide a realtime account of the packaging lines as well as to our inventories and what stage of packaging their product currently resides. 

CUSTOMER SATISFACTION:

The ultimate goal of Virtual TQM is to provide a service that satisfies our clients.  Customer satisfaction is measure by utilizing the aformentioned CORA techniques.  Through continuous improvement in our processes we inhernently increase our quality systems and ultimately customer satisfaction.   By minimizing complaints and recalls our customer has our assurance that we can help them produce and market a quality product and to maintain their customer base. 

RECALLS:

Safety is paramount at Virtual TQM.  As most of the recipients of the product we package are young children we take the most conservative approach when recalling a product.  We work close with our clients and suppliers and have full disclosure on products that may be harmful to the consumer. Our detailed supply chain management systems utilize active RFID’s that serve a dual purpose function.  They identify lot, manufacture date and other pertinent information in addition to acting as a GPS tracking system.  We can track product that is questionable and perform full recall by notifying our distributors.  Our patented passive RFID is applied to each packaged box and upon recall will prompt distributor and retail outlet readers to disallow purchase.  In the event of a recall a public announcement will be made with coordination of our clients. 

CONTINUOUS IMPROVEMENT:

By utilizing the methods that have been discussed in all of the assignment Virtual TQM will continuously strive for perfection.  Working closely with our clients and constantly analysis our processes we can effectively correct problematic areas.  These areas, once identified can be corrected and preveted by applying new technologies such as the RFID and Vision inspection systems.  New standardized procedures can be incoporated into our quality system to ensure these issues do not arise again or at the least be kept to a minimum.

ECO-FRIENDLINESS AND CARBON FOOTPRINT AUDIT:

Virtual TQM will utilize whenever possible recycled materials.  Packaging, both individual and bulk packaging configurations will utilize recycled corrugated cardboard.  Virtual TQM also maximizes output by reducing defective finished product through reworking of product.  Waste is kept to a minimum and our packaging materials are  fully recyclable. 

PRESS RELEASE:

Virutual TQM provides industry leaders such as Crayola, Endless Games, Uncle Rez Games to name a few, with various packaging configurations for gaming products.  Our services are quality driven to ensure that our clients product is delivered in an attractive package.  Our quality priciples are driven by ISO 9001:2000 standards as follows:

We utilize various techniques that focus on our clients requiements.  We utilize CORA to as a tool to better understand what it is that our clients expect of us and the appropriate measures we can take to meet them.  Our approach to total quality managment is embraced by our entire company here at Virtual TQM.   The total quality managment approach is demanded by our managment and enforced upon all with whom we collaborate with.  Our strict adherence to these principles allows us to be at the forefront of our industry.   Our highly skilled staff ensures that our company can provide the ultimate in quality services.  Our quality is instilled throughout the company and not left solely on the shoulders of a quality group.  Our approach to designing processess is carefully orchestrated by using modeling techniques such as CIMpgr.   Our systematic approach to management accounts for all aspects of the company and determies how each impacts one another.  By synchronizing our organization we can consolidate our collective efforts to meet our customers needs.  By fully understanding our operating systems we can continually improve upon them and subsequently provide a higher quality product for our clients.  The continuous monitoring of all operations within our facility gives real time feedback that enables us to pint point potential issues before they occur.  We can accurately assess our systems through our analysis and firm understanding our our sytems as well as clients products.  Close collaboration with our clients and suppliers allows our network to grow, that will benefit all the parties involved.

SUMMARY:

Virtual TQM has incorporated yet another quality tool to better their company.  This assignment shows how the utilization of RFID and Audits can improve upon an already quality based system.  This form of continuous improvement shows that by applying not only these techniques, but those of the other assignments can continually mold the Total Quality Management system.  The auditing of the system in addtion to the various tools for analysis such as CORA and PFRA shows the faults of the system and allows us to correct them.  The improvement of this system ultimately yields a more efficient quality conscious company and greater customer satisfaction.