12 : Managing Conformance

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12 Managing Conformance

• Steel doesnt always fit and there are many
  reasons for it. A detailer can goof. The shop can
  goof. Even worse, Murphy can goof, and when I say
  Murphy, I mean an accumulation of tolerances, all
  added, like eighty-six basic steel tolerances,
  plus shop tolerances, plus the field tolerances.
  When they all add up to a misfit, then we have to
  address it. But we have troubleshooters on each
  job and they resolve them
• Gene Miller, Mosher Steel

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Managing Conformance

• the principles of conformance management systems
• the quality model
• QUENSH systems
• creating a culture of improvement
• quality awards and self-assessment
• standardisation and pre-assembly
• conformance management in a project environment

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The Principles of Conformance Management

• inspection
• quality control
• quality assurance
• approaches to quality management
• empowermentltgtblame orientation
• reactive ltgt proactive

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Conformance Management
empowerment
total quality management
quality assurance
quality control
inspection
blame orientated
reactive
proactive
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What is Conformance to Quality?

• the notion of tolerance
• acceptable quality level
• sampling approach
• zero defects
• quality is free - Crosby
• the quality loss function
• process capability
• reliability engineering

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Quality Loss Function and Zero Defects Approaches
to Conformance
quality loss function
zero defects
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Process Capability
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Reliability Engineering

• failure mode and effects analysis
• probability of occurrence
• probability of detection
• severity of impact
• the Risk Priority Number
• the reliability profile
• design life set in relation to life-cycle cost
  analysis

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The Reliability Profile
total risk of failure
design life
commissioning
failure due to wear out
risk of failure
failure due to non- conformance
externally induced failures
time
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Inspection

• conformity evaluation by observation and
  judgement accompanied as appropriate by
  measurement, testing or gauging
• the audit approach
• sampling
• requires dedicated resources

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Quality Control

• the part of quality management focused on
  fulfilling quality requirements
• the 7 QC tools
• Ishikawa
• process maps
• cause and effect diagrams
• data logging
• statistical process control

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Pareto Diagram The Causes of Defects
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Ishikawa Diagram The Causes of Accidents
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Quality Assurance

• the part of quality management focused on
  providing confidence that quality requirements
  will be fulfilled
• quality management systems
• first party
• second party
• third party (ISO 9001 -2000)
• quality policy and the project quality plan
• QA certification arrangements
• the Glaxo project QA plan
• BS 8800
• ISO 14001

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The UKs QA Certification Arrangements
Department of Trade and Industry
British Standards Institute
policy and standards
UK Accreditation Service
accreditation
Certification Body
assessment and surveillance
application for certification
Firm
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Creating a Culture of Improvement

• the limitations of inspection, QA and QC
• first order control loops
• operationally orientated
• TQM as a project philosophy
• the culture of the project - its values
• safety culture
• creating a culture of improvement
• quality awards and self-assessment

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Generating a Culture of Improvement

• the part of quality management focused on
  increasing the ability to fulfil quality
  requirements
• empower those doing the work
• training is crucial for success
• organisational learning is the aim
• align incentives with desired performance
• senior management commitment is essential

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Quality Awards and Self-Assessment

• the EFQM model
• Baldridge in US
• framework for developing a vision
• develop understanding of the business
• enter for the European Quality Awards
• diagnostic tool to enable
• benchmarking
• self-assessment

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Standardisation and Pre-assembly

• standardisation
• standard components and modules
• economies of scale
• pre-assembly
• pre-fabrication and sub-assemblies
• controlling the working environment
• mass customisation
• combining the two
• volumetric modules

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Quality Management in a Project Environment

• issues
• incremental cycles of improvement
• repeated sampling
• equity in investment and return
• applications
• sampling is at the component/ sub-assembly level
• standardisation across projects
• measuring process capability
• empowering the workforce