Introduction to Process Technology Principles of Quality

Introduction to Process Introduction to Process TechnologyTechnology

Principles of Quality

Today’s AgendaToday’s Agenda

• Quality – I’ll Know It When I See It• Current Issues and Trends• Pioneers of Quality• Total Quality Management (TQM)

– The Production Line Activity• Quality Cycle• International Standards Organization (ISO)• Statistical Process Control (SPC)

– You Be the Expert• Six Sigma• Supporting Quality – Role of Proc Tech

Quality – What it Means to Me

• List your expectations for quality as a customer

• List your expectations as a member of a plant community

• List your expectations of quality as a potential plant employee

• List your expectations of quality as a potential investor (stockholder)

QualityQuality

• Product or service free of deficiencies

• Characteristics of a product or service that bear on its ability to satisfy stated or implied needs

Industry ResponsesIndustry Responses

• Total Quality Management (TQM)• ISO-9000 Series• ISO-14000 Series (environmental)• Six Sigma• Statistical Process Control (SPC)• Self-directed or Self-managed Work

Teams

Pioneers of QualityPioneers of Quality

• Dr. W. Edward Deming – every job or every task is part of a process

• Joseph Juran – Pareto Principle of 80/20

• Philip Crosby – Zero Defects

Total Quality Management Total Quality Management (TQM)(TQM)

• Customer Focus

• Continuous Improvement

• Manage by Data and Facts

• Empower Employees

Quality Improvement Quality Improvement CycleCycle

• Phase 1: PLAN– Increase current knowledge of

process– Specific objectives, questions, make

predicitons, and propose plan for testing

– Outcome of plan should consider methods, resources, schedules, and people


• Phase 2: OBSERVE & ANAYLZE– Implements data collection process

to address questions from Phase 1.– Reveals what is actually happening

and can lead to refinement of initial questions


• Phase 3: LEARN– Combines activities from Phase 1 &

2– Results of data analysis are

compared to current knowledge and theories to see there are any contradictions


• Phase 4: ACT– Results from Phase 3 are used to

decide whether to make changes to process or not.

– If change is indicated, brainstorming session can be conducted to determine what changes would result in improvement

TQM Applied

• The Production Line Activity (see handout)

International Organization International Organization of Standardization (ISO)of Standardization (ISO)

• Founded after WW II. Headquartered in Geneva, Switzerland

• Voluntary, non-governmental• Global standards of product and

service quality that aims to maintain quality standards and fixed defects and ensure repeated acceptable performance

ISO & TQMISO & TQM

• Overlapping expectations• TQM is defined in many ways,

while ISO standards are consistent

• ISO world-wide, TQM more US based

Why Companies Seek ISO Why Companies Seek ISO CertificationCertification

• Contractual – requirement of suppliers• Liability – improved product liability

procedures and documentation• Cost savings – increased efficiency, less

product loss• Competition – global advantage for

large and small companies• Customer Satisfaction – increased by

certification

ISO in the Processing ISO in the Processing IndustryIndustry

• Continuous Improvement

• Statistical Process Control (SPC)

• Process Technicians & Quality

• Global Market

Statistical Process Control Statistical Process Control (SPC)(SPC)

• Statistical Process Control – using data-driven methodology to control a process

• STATISTICAL– With the help of numbers

• PROCESS– We study the characteristics of our process

• CONTROL– To make it behave the way we want it to

behave

SPCSPC

• Product Directives – following the “recipe”– Correct feed– Temperature and pressure profile– Equipment speed– Additive setpoint– Level and flow setpoints

SPCSPC

• Sample Types – – Raw materials– Additives– Intermediates– End products

SPC Data TypesSPC Data Types

• Attributes – called discrete data. Data that can be counted and plotted as distinct or unconnected events.– Percentage of late shipments– Number of mistakes made during a

process

SPC Data TypesSPC Data Types

• Variables – called continuous data. Data that can be measured and plotted on a constant scale.– Flow through a pipeline– Volume in a tank

SPC – Select Proper SPC – Select Proper CategoryCategory

Data Attribute Variable

Pounds per square inch (pressure)

Gallons per minute

Temperature reading

Bad batches per shift

Flow through a pipe

Downtime for equipment

Days lost to accidents

Level in tank

Amount of electricity used

Percent of delayed deliveries

Quality Control ToolsQuality Control Tools

• Control Charts• Flow Charts• Cause and Effects Diagrams,

Fishbone• Pareto Charts• Histograms• Scatter Plots• Others

Fishbone DiagramsFishbone Diagrams

• Each branch of the diagram represents a different category of causes

• Typical categories:– Materials– Machinery– Measurement– Methods– People

• However, can create other/different categories better suited to your specific problem.

Pareto ChartPareto Chart

• Purpose:– Ranking problems from big to small

• Helps when:– Team needs to know which problems to address

first.

• Demonstrates 80/20 rule– 20% of the causes account for 80% of the

problems

• Highlights the important elements (the “vital few”) and the insignificant ones (the “trivial many”)

HistogramsHistograms

• Purpose:– To indicate the distribution and variation of

sample data

• Helps to:• Determine if process is in statistical

control – can indicate if “special causes” are causing control problems

• Histograms roughly approximate the normal distribution if everything is in control.

Distributions can be represented in several ways.

Control ChartsControl Charts

• A line graph that indicates:• Samples vary from the process average• If samples are in statistical control (w/in

control limits)• Purpose:

– To track process variation

• Helps to:– Determine if process is in statistical control

Control ChartsControl Charts

Maintenance ProgramsMaintenance Programs

• Corrective – waiting for failure to occur, then fix

• Preventative – conduct regular maintenance to avoid failure

• Predictive – monitor condition of equipment and use data to identify possible failure and their prevention

• Detective – regular check of alarms, detectors

Maintenance and Quality Maintenance and Quality ImprovementImprovement

• Total Productive Maintenance (TPM) – Overall Equipment Effectiveness

• Predictive/Preventive Maintenance (PPM)

• Using Quality Control Tools

• Working as Self-Directed Teams

Process Control Tech & Process Control Tech & QualityQuality

• Familiarize oneself with quality programs

• Practice quality habits• Provide good customer service –

internally and externally• Gather data for SPC tools• Follow documented procedures


• Monitor and control process operations

• Assist with maintenance tasks such as TPM or PPM

• Troubleshoot with goal of continuous improvement in mind

• Communicate effectively• Keep quality records


• Participate in quality training sessions

• Work with quality teams to achieve goals

• Utilize skills in time management, organization, planning, prioritization, and attention to detail

• CONTINUALLY IMPROVE

Summary

• Quality is applied to all aspects of the process industry

• Everyone has a role and a responsibility in quality

• There are accepted methods and statistical tools in place to perform quality analyses

Student Activities

• Quality exercise (Voice of the Customer)

• Textbook questions:– CAPT Ch. 13, pages 218 – 219,

questions 1 – 13, pages 219 – 220, activities 1 - 5

– Thomas Ch. 16, page 356, questions 1 - 10

Documents

Introduction to Process Technology Principles of Quality