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Total Quality Management: BITS Pilani

Quality by design is a concurrent engineering approach where multidisciplinary teams design products and production processes simultaneously to ensure quality and customer satisfaction. It aims to reduce costs and time to market through improved communication and collaboration between functions like design, production, and suppliers from the beginning. Implementing quality by design requires establishing cross-functional teams, improving communication channels, collocating team members, and utilizing tools like CAD, rapid prototyping, statistical analysis, and continuous improvement processes.

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202 views23 pages

Total Quality Management: BITS Pilani

Quality by design is a concurrent engineering approach where multidisciplinary teams design products and production processes simultaneously to ensure quality and customer satisfaction. It aims to reduce costs and time to market through improved communication and collaboration between functions like design, production, and suppliers from the beginning. Implementing quality by design requires establishing cross-functional teams, improving communication channels, collocating team members, and utilizing tools like CAD, rapid prototyping, statistical analysis, and continuous improvement processes.

Uploaded by

naveen
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Total Quality

Management
Naga Vamsi Krishna Jasti
BITS Pilani Asst. Professor
Mechanical Engineering Department
Hyderabad Campus
BITS Pilani
Hyderabad Campus

Quality by Design
Scope

 Introduction
 Rationale for implementation
 Benefits
 Teams
 Communication models
 Implementation
 Tools
3 MM ZG522 - Total Quality Management BITS Pilani, Hyderabad Campus
Introduction
 Quality by design is the practice of using a multidisciplinary
team to conduct thinking, product design and production
planning all at one time.
 It is also known as concurrent engineering , simultaneous
engineering or parallel engineering.
 Quality by design is a team of specialist who simultaneously
design and develop a product to ensure ease of producibility
and customer satisfaction.
 SEQUENTIAL ENGINEERING : In the past the major function
within an organization would complete their task by “throwing
it over the wall” to then next department in the sequence and
would not be concerned with any internal customer problems
that may arise.
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 QUALITY BY DESIGN :
– Require the major function to be performed at the same
time.
– Engineers, production and business as well as suppliers and
customers brainstorm together to develop that consider all
facts of functionality as well as its costs.
– Better quality product are manufactured for less cost with
shorter time to market.
– Communication flows better.
– For eg. It would be difficult for the electrical engineers to
know why the structural engineers design section in a
component that would require special processes in order to
run wires through the product.
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Product development flow diagram

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Product development time line

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Product design change impact on cost

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Rationale for implementation
 Product design for all industries are becoming more crucial to
any product’s marketability.
 In past customers have very few brand to choose from, so price
was dictated by the cost of production + reasonable profit.
 Design changes that occur late in the product development
cycle cause increased lead times and thus higher cost.
 Quality by design helps control design changes by shifting all
the design to the beginning of the project rather than
throughout its whole life cycle
 This increase the time required for initial design and increase
the future benefits.
 For eg. A change made during the design stage could cost up to
10 times
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Benefits
 Customer trends to drive the market demand and an
organization should have the ability to react 6 months
before the competition can increase the profits.
 Timing is important, but customer will switch brands if
they get a similar product of same quality for less
money.
 Quality by design provides manufactures with the tool
and communication and management techniques
required to develop product in a timely and cost-
efficient manner from the beginning and throughout a
product’s life.
10 MM ZG522 - Total Quality Management BITS Pilani, Hyderabad Campus
– Faster product development.
– Better quality.
– Less work in progress.
– Fewer engineering changes order.
– Increased productivity.
– According to national institute of standers and
technology implementation of QbD method can reduce
engineering changes by 65% to 90%.
– This decreases cut product development times by 30%-
70%,reduces time to market by 90% and increases
quality by as much as 200% to 600%
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Teams
 The team include product developers from marketing,
research and development ,design production, test and
logistics.
 Supplier and customer should also be included in the team.
 The implementation of quality by design team requires top-
down commitment.
 Team members should be committed to the projects not
with their functional departments.
 There should be better communication and interaction
between the team members.

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Communication Models

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Communication Models

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Leadership skill

 Use technology that fits the situation.


 Communicate effectively.
 Build a community based on high quality based on
high quality values among members.
 Establish goals, expectations, purpose and vision.
 Focus on result.
 Coordinates across boundaries and organizational.
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Implementation
 The easiest way for an organization to progress towards
a quality by design environment is simply to gather
together everyone.
 Allow communication channel to open and meet face
to face with internal and external customers and
suppliers.
 There should be a regular meeting at set intervals to
renew communication power.
 Collocating the team members this will increase the
communication between project manager and team
and thus simulates continuous improvement
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Tools

 Cad and cam are the bridge between design and rapid
prototypes.
 CAD can be converted to tool path to geometry and
then downloaded directly to a computer numerically
controlled machine(CNC).
 A model then be cut for design team to evaluate and
discuss in terms of design options.

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Organization tools
 Computer networks.
 ISO 9000
 ISO 14000
 Total productive maintenance.
 Quality function deployment
 Information technology
 Electronic meeting software
 Enterprise resources planning software

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Product development tools

 CAD software.

 Solid modeling software.

 Finite element analysis software.


 Parametric analysis software.

 Rapid prototyping techniques.


 Failure mode and effect analysis

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Production tools

 Robotics
 Computer aided manufacturing
 Computer numerical controlled tools
 Continuous process improvement
 Just in time production
 Virtual manufacturing software
 Agile or lean manufacturing
 Advanced measurement and verification like CMMs
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Statistical tools

 Statistical tolerance stack up analysis is performed to prevent any


functional or assembly problem due to incorrect tolerances
 Reliability and life data analysis is performed to estimate measures such
as Mean Time Between Failure which is the time period by which 10% of
the parts or systems will fail.
 Response surface methods used to optimize the process
 Design of Experiment used to identify critical parameters.
 Statistical process control used to monitor process variations and correct
problems before producing scrap.
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Summary

 Introduction
 Rationale for implementation
 Benefits
 Teams
 Communication models
 Implementation
 Tools
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THANKING YOU

23 MM ZG522 - Total Quality Management BITS Pilani, Hyderabad Campus

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