TQM Tools

TQM Tools

Following are the TQM Tools:• Bench Marking• Quality Function Deployment (QFD)• Taguchi’s Quality Loss function• Total Productive Maintenance (TPM)• Failure Mode & Effect Analysis (FMEA)(121 N. Srinivasa Gupta & Valarmathi)

Taguchi’s Quality Loss function

TQM Tools: contd- Taguchi’s Quality Loss functionIt is a simple & effective method to solve quality engineering

problemsThe method is popularly known as Taguchi method based

Design of ExperimentsHe developed the concept of robustness A robust product is one which is insensitive to environmental

variations. To evolve such a robust product the noise factors are also taken in to account while designing the experiments.

Uncontrollable variables can cause significant variability in the process or the product are called “noise factors”

The loss function based on the idea that loss to society occurs whenever there is a deviation from the largest value. The loss may be due to reduced levels of performance, poor customer service, a shorter product life, lower product reliability, or a greater number of repairs.

In short, loss to society occurs when the customer has less-than optimal experience with the product or service.

Taguchi’s Quality Loss function

Refer to PDF on Taguchi’s Quality Loss function

Total Productive Maintenance (TPM)

TQM Tools contd-Total Productive Maintenance (TPM)

Total Productive Maintenance (TPM):Importance:1. Aims to maximise equipment effectiveness-overall

effectiveness.2. Various departments-Engineering, Operations &

maintenance collectively implement it.3. Involves every single employee from the top management

to workers on the shop floor.The word total in Total Productive Maintenance (TPM) means:• Total effectiveness• Total maintenance system which include Maintenance prevention Maintainability improvement Predictive Maintenance• Total participation of all employees

TQM Tools:Total Productive Maintenance (TPM)- contdNeed for TPM:1. Quality of product depends upon the process2. Process reliability depends on the equipment condition3. Condition of equipment depends on the maintenance

philosophy followed in the industry.4. Though the product processes are automated, the

maintenance activity is yet to be automated5. Using sophisticated production equipment call for greater

skills of maintenance.Dual Goal of TPM:1. Zero defects2. Zero breakdown (100% equipment availability)Development Stages: (1) Breakdown Maintenance

(2) Preventive Maintenance (3) Productive Maintenance (4) Total Productive Maintenance.

TQM Tools:Total Productive Maintenance (TPM)- contdFive Basic Activities for the Development of TPM:

1. Elimination of all 6 major losses to improve the overall effectiveness.

2. An autonomous maintenance programme.

3. A planned maintenance programme for the maintenance department.

4. Increased skills of operation & maintenance personnel.

5. An initial equipment management programme.

It takes about 3-4 years of TPM implementation before good results can be achieved.

Failure Mode & Effect Analysis (FMEA)

Failure Mode & Effect Analysis (FMEA)

It is a system for analysing