Industrial Engineers

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Industrial Engineers the Quality ProfessionTC
ChongOctober 4, 2002
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Agenda

• The Manufacturing Environment
• Roles Responsibilities of Quality Engineering
  Department
• Process Improvement Using Statistical Techniques
• Six Sigma A New Approach to Quality

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• The Manufacturing Environment

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Quality Slogan

• Putting you first keeps us first.
• Chevrolet

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Quality Slogan

• The relentless pursuit of perfection.
• Lexus

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Organizational Objectives

• Customer Focus
• Improve customer satisfaction
• Quality Leadership
• Reduce variations and defects
• Business Excellence
• Continuous improvement
• Lean Manufacturing
• Eliminate waste and reduce cost

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Organizational Objectives

• Business survival depends on how well we satisfy
  our customers
• Customer satisfaction is a function of quality,
  price and delivery
• Quality, cost and prompt delivery are dependent
  upon capability

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Maximizing the Customer-Supplier Interaction
Delivery
Customer
Cycle Time
Supplier
Need
Price
Do
Cost
Quality
Defects

Supplier strives for performance on
Cycle Time, Cost and
Defects
to meet Customers increasing expectations on
Delivery, Price and Quality.
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• Roles Responsibilities of Quality Engineering
  Department

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Typical Manufacturing Organisation Chart
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Typical Quality Organisation Chart
CFT denotes Customer Focus Team
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Roles Responsibilities

• Customer Quality
• Interface with customer on quality issues
• Understand customer requirements
• Establish quality control plan
• Lead continuous process improvement
• Support New Product Introduction (NPI)

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Roles Responsibilities

• Supplier Quality
• Supplier management
• Supplier survey, audit, qualification and
  appraisal
• Support local sourcing initiatives
• Supplier quality improvement
• Performance measurement
• Supplier Corrective Action Request (SCAR)
• Incoming quality control

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Roles Responsibilities

• In-Process Quality
• Supports production schedule
• In-Process audit
• Final quality inspection
• Process and equipment buy-off
• Statistical Process Control
• Establish, maintain and improve

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Roles Responsibilities

• Quality System
• Quality Management System (QMS)
• Establish, maintain and improve QMS
• ISO9000, ISO14000, TL9000, QS9000,
• Product safety registration
• UL, CE, TUV, CSA, CCC, PSB,
• Document Data Control
• Calibration
• Inspection, test and measuring equipment

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• Application of Statistical Techniques

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Statistical Techniques

• Some common statistical techniques
• Acceptance Sampling
• In-coming quality control, final quality control
• Statistical Process Control
• Control charts, process capability indices
• Process Optimisation
• DOE, ANOVA, regression analysis
• Gage Repeatability Reproducibility (GRR)

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SPC Application

• Screen printing process control
• Solder paste height measurement
• Use semi-automatic laser vision system for
  measurement
• GRR of equipment found to be less than 2
• Random sampling

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Location Diagram
IC24(3)
IC6(2)
IC11(1)
IC43(5)
IC27(4)
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Location Diagram
CR4
PS1
C14
E33
U1
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Weekly SPC Performance

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SPC Control Charts Cpk Computations

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An Application Case Study

• High failure rate of 50,000 DPPM during
  functional testing of a telecommunication product
• Failure associated with test step measuring the
  amplifier output
• Test data are found to skew towards the upper
  specification limit
• Failure rate reduced to lt 100 DPPM after EC
• DPPM denotes defect parts per million
• EC denotes engineering change

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Histogram of Test Data
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Block Diagram
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DAC vs Regulator Voltage
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Improvement after EC
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• Six Sigma A New Quality Approach

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Six Sigma

• What is Six Sigma?
• Systematic approach to reducing defects which
  affect what is important to the customer
• Achieved through the use of qualitative,
  statistical and instructional devices for
  observing process variables and their
  relationships as well as managing their
  characteristics
• Sigma is a statistical unit of measure that
  reflects process capability. The sigma scale is
  correlated to characteristics such as DPU, DPPM,
  probability of failure/error.

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Six Sigma Performance
?
PPM
Process Capability
Defects per Million Opp.
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Six Sigma Practical Meaning
99 Good (3.8 Sigma)
99.99966 Good (6 Sigma)
20,000 lost articles of mail per hour Unsafe
drinking water for almost 15 minutes each
day 5,000 incorrect surgical operations per
week Two short or long landings at most major
airports each day 200,000 wrong drug
prescriptions each year No electricity for
almost seven hours each month
Seven articles lost per hour One unsafe minute
every seven months 1.7 incorrect operations per
week One short or long landing every five
years 68 wrong prescriptions per year One hour
without electricity every 34 years
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The Goals of Six Sigma

• Defect Reduction
• Yield Improvement
• Improved Customer Satisfaction
• Higher Net Income

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Business Survival
Customer Satisfaction
Quality, Price, Delivery
Process Capability/Performance
Level of Process Variation
Knowledge
The Ability to Learn Faster than the Competitors
is the Only Sustainable Advantage
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The Traditional Approach
Plan-Do-Check-Act cycle (PDCA cycle) is a
continuous improvement model that teaches that
organizations should plan an action, do it, check
to see how it conforms to plan and expectations,
and act on what has been learned.
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The Six Sigma Approach
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In A Nutshell

• Industrial engineers are well trained to take on
  a career in quality engineering
• Quality engineering are evolving to be an
  integral part of the business model
• The Six Sigma approach is gaining wide spread
  attention in all business sector, in particular,
  the manufacturing industry

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• Thank You.