9/25/2015

Supplemental Tools,
Techniques, Methodologies
for Quality Management
By Prof. Jerome T. Alvarez

Concurrent Engineering
Use of teams in design and engineering activities.
Continuing product-development involvement and
responsibility from original concept thru sales.
Implies that all product or service development is
done concurrently through a comprehensive,
systematic approach.
Vs. Traditional: Serial Approach
CE Approach: teams attack all aspects of product or
service development simultaneously.
Most important concept of CE is that quality is
considered from the start of the design.

Traditional Process

Concurrent Engineering
The simultaneous performance of product design and
process design. Typically, concurrent engineering
involves the formation of cross-functional teams.
This allows engineers and managers of different
disciplines to work together simultaneously in
developing product and process design.
Foster, S. Thomas. Managing Quality: An Integrative Approach. Upper
Saddle River New Jersey: Prentice Hall, 2001.

Customer

Marketing

Engineering

Operations

Specifies
Need

Interprets
Need

Designs
Product

Produces
Product

Defines
Quality

Plans
Quality
Monitors
Quality
4

Product Design Miscommunications

As the customer want
it.
As Finance
can afford
1984-1994 T/Maker Co.

As Operations
can make it.

As Marketing
interpret it.

1984-1994 T/Maker Co.

As Engineering
designs it.

Concurrent Engineering
Concurrent engineering methodologies permit the
separate tasks of the product development process to
be carried out simultaneously rather than
sequentially.
Product design, testing, manufacturing and process
planning through logistics, for example, are done
side-by-side and interactively. Potential problems in
fabrication, assembly, support and quality are
identified and resolved early in the design process.
Izuchukwu, John. Architecture and Process :The Role of Integrated Systems in Concurrent Engineering.
Industrial Management Mar/Apr 1992: p. 19-23.

1984-1994 T/Maker Co.

1984-1994 T/Maker Co.

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Cellular Manufacturing (CM) Technology

Cellular Manufacturing organizes the entire
process for similar products into a group of
team members, includes all the necessary
equipment and is known as a "Cell".
The cells are arranged to easily facilitate all
operations. Parts are handed off from operation
to operation eliminating setups and unnecessary
costs between operations.
Merryman, Wes. Cellular Manufacturing.Online. Internet.
Available at http://www.ciras.iastate.edu/CIRASnews/cellular.html

CM Reduction Benefit
Production & Quality Control Cost - 80%
Setup Time - 69%
Throughput time - 70%
Overdue orders - 82%
Raw Materials Inventory - 42%
Finished Goods Inventory - 60%
Employees Output per unit time - 33%

Cellular Manufacturing (CM) Technology

Primary purpose:
Reduce cycle time
Reduce inventories

Other benefits include:

Elimination of waste by linking steps
Space reduction
Quality improvement
Labor cost reduction
Improved machine utilization
Product flow is more visible - easier control

FMS/ FMC
Flexible Manufacturing Systems
designed to produce a family of similar parts.

Flexible Manufacturing Cells (Work Cell

Concept)
involves placing different machines and
operators together in the same location to
complete all operations on a part.

Kok, Alvin Lim Hui. Time Based Manufacturing. Journal of Operations Management. 7 July 1999

Poka-yoke
Literally means mistake-proofing, making fail-safe.
Fool-proof devices
This consists of applying simple, low-cost mechanical and
electrical devices to help prevent human error in a process.
An approach for mistake-proofing processes using automatic
devices or methods to avoid simple human error.
Developed and refined by Shigeo Shingo, a Japanese
manufacturing engineer who developed the Toyota
Production System.
Focused on 2 aspects: prediction and detection.

Six Commonly used Poka-yoke devices:

Limit switches
Guide pins
Counters
Alarms or error detectors
Checklists
Color coding

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Poka-yokes
MMC/SD/SIM cards can only be inserted the right
way
Microwave ovens shut off automatically when door
is opened
Some coffeemakers shuts off drip when the
coffeepot is removed
Grocery carts does not roll down when moving up
Automatic doors have sensors that prevents door
from closing when there is a blockage

Check Lists:
Commonly confused with check sheets
Do not solve problems
Used as reminders of what to do & what not to do.
Example: Check List by Pilots before flying a plane.

Poka-yokes
Treadmills have a clip that attaches to the runner and
shuts down machine off if runner falls
At some restaurants, the trash can opening is too
small to block trays from being accidentally
discarded
Automatic transmission cars wont start unless in
Park or Neutral Mode
New cars (manual transmission) wont start without
first pressing on the clutch pedal

CPM-PERT
Critical Path Method-Program Evaluation & Review
Technique.
Special Type of Flowchart
Events, activity, & activity times are used.
Path requires the shortest length of time, Critical Path.
Total length of time for that path is the Critical Time.
Method to get from one event to another.

ea
rs
ne
ck
fe
et

Force Field Analysis

a technique that helps identify forces promoting or
hindering a certain cause of action or condition in
solving problems or making decisions.
Forces are anything that contribute to maintaining the
status quo (restrainers or inhibitors) or solving problems
(promoters or drivers).

Gantt Chart
a type of bar chart, first developed by Karol Adamiecki in
1896, and independently by Henry Gantt in the 1910s, that
illustrates a project schedule.
Used to evaluate recommendations and show the sequence of
tasks needed to be accomplished in an established time frame.

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Materials Requirement Planning (MRP I)

Also called Manufacturing Requirement
Planning
A system that organizes the efficient use of
materials.
A computer-based system for managing
inventory, orders, purchases, and delivery of
raw materials and tools when needed.

Enterprise resource planning (ERP)

Next step in an evolution that began with
MRP and evolved into MRPII
Integration of financial, manufacturing,
and human resources modules on a single
system.
Coordinates business from supplier
evaluation to customer invoicing
Facilitates a strategic emphasis on JIT
systems and integration

Materials Resource Planning (MRPII)

overall planning and controlling a
manufacturing companys operations.
Includes concepts of MRP I but incorporates
production scheduling, personnel, finance,
and all other things that help integrate
planning and scheduling.

Computer-driven Technologies
Computer-Integrated Manufacturing (CIM) a system and
philosophy of management in which all information data
about all manufacturing functions are computer-integrated.
Computer-Aided Design (CAD)
Computer-Aided Drafting and Design (CADD)
Computer-Aided Manufacturing (CAM) utilized the
computer to plan and control the manufacturing process.
Computer-Aided Engineering a continuation of CAD. Most
CAD software has some engineering capabilities as well, like
simulation and 3D graphics.
Computer Numerical Control (CNC) allows the computer
to control several Numerical Control (NC) equipment or
machines

Other Methodologies:
Surveys - used to obtain relevant information from
sources that otherwise would not be heard from in the
context of providing helpful data.
Failure mode and effects analysis (FMEA) -tries to
identify all possible product or process failures and
prioritize them for elimination according to their risk.
Design of experiments (DOE) - a sophisticated method
for experimenting with complex processes for the
purpose of optimizing them.