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INTRODUCTIONIhsanullah (4320)Raess Khan (3305)Zainullah (4321)Samiullah (4319)

What is

Improving quality will reduce expenses while increasing productivity and market share.

5Agenda

Why does it always seem we have plenty of time to fix our problems, but never enough time to prevent the problems by doing it right the first time?

What is

What is FMEA ?7

What are Failure Mode and Effects Analysis (FMEA)

Failure Mode and Effects Analysis (FMEA) is an integral part of product and process design activity. The FMEA process is applicable in Design of Products, Processes and Services. Failure Modes and Effects Analysis (FMEA) is commonly used in a variety of industries for Risk Management, where simple quantification of risk is insufficient.

ContinueFMEA (Failure Mode and Effects Analysis) software helps organizations improve product quality by identifying the sources and effects of risks and introducing control measures to eliminate them. By implementing an FMEA tool early in the product development process, organizations can systematically identify risks at the functional, design, component, or process level and implement risk controls to effectively address them.

FMEA HistoryThis type of thinking has been around for hundreds of years. It was first formalized in the aerospace industry during the Apollo program in the 1963 .

1965 The military of the US started to apply the FMEA technique.

1977 Ford Motor started to use FMEA.

History of (FMEA)

Components of the FMEA are

Severity: If a failure were to occur, what effect would that failure have on the Product quality and on the patient (if any)?Probability of occurrence: How likely is it for a particular failure to occur?Detectability: What mechanisms are in place (if any) to detect a failure if it were to occur?

Types of (FMEA)

Benefits of (FMEA)

Objectives of (FMEA)

conclusionIt is an inseparable part of risk management and it supports the continuous improvement. The main aim of the is detecting effects and causes of failure modes that can affect the reliability, the quality and not least the safety of products, whether it is product, process, system or service analysis. FMEA analysis involves teamwork, management support, and deep knowledge of systems, products, processes, time and cost.

Therefore, to be successful, this technique should be fully implemented quality management system both within the process of both product development and processes. This will enable companies to rationalize their activities and thus reduce costs and increase efficiency.

What is Six Sigma?

Six Sigma Six Sigma at many organizations simply means a measure of quality that strives for near perfection. Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process from manufacturing to transactional and from product to service.

Six Sigma Quality

BasicsA new way of doing business Wise application of statistical tools within a structured methodology Repeated application of strategy to individual projects Projects selected that will have a substantial impact on the bottom line

DOESPCKnowledgeManagementBenchmarkingThe Six Sigma Initiativeintegrates these effortsImprovement teamsProblem Solving teamsISO 9000Strategicplanningand moreIn some aspects of quality improvement, TQM and Six Sigma share the same philosophy of how to assist organizations to accomplish Total Quality. They both emphasize the importance of top-management support and leadership. Both approaches make it clear that continuous quality improvement is critical to long-term business success. However, why has the popularity of TQM waned while Six Sigma's popularity continues to grow in the past decade?

Six SigmaIn some aspects of quality improvement, TQM and Six Sigma share the same philosophy of how to assist organizations to accomplish Total Quality. They both emphasize the importance of top-management support and leadership. Both approaches make it clear that continuous quality improvement is critical to long-term business success. However, why has the popularity of TQM waned while Six Sigma's popularity continues to grow in the past decade?

Six Sigma Methods

Production

Design

Service

Purchase

HRM

Administration

QualityDepart.

Management

R&D

ITWhere can Six Sigma be applied?

Steps

Six Sigma companies Companies who have successfully adopted Six Sigma strategies include:

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GE Service company - examplesApproving a credit card applicationLending moneyAnswering a service call for an applianceUnderwriting an insurance policyDeveloping software for a new product

In 1995 GE mandated each employee to work towards achieving 6 sigma The average process at GE was 3 sigma in 1995 In 1997 the average reached 3.5 sigma GEs goal was to reach 6 sigma by 2001 Investments in 6 sigma training and projects reached 45MUS$ in 1998, profits increased by 1.2BUS$General Electric

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At Motorola we use statistical methods daily throughout all of our disciplines to manufacture an wealth of data to derive real actions.How has the use of statistical methods within Motorola Six Sigma initiative. Over the past decade we have reduced in-process defects by over 300 fold, which has resulted in cumulative manufacturing cost savings of over 11 billion dollars*.MOTOROLA

Barrier #1: Engineers and managers are not interested in mathematical statisticsBarrier #2: Statisticians have problems communicating with managers and engineersBarrier #3: Non-statisticians experience statistical nervousness which has to be minimized before learning can take placeBarrier # 4: Statistical methods need to be matched to management style and organizational cultureBarriers to implementation

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Focus of Six Sigma*Accelerating fast come through performance Significant financial results in 4-8 monthsEnsuring Six Sigma is an extension of the Corporate culture, not the program of the month Results first, then culture change!*Adapted from Zinkgraf (1999), Sigma Breakthrough Technologies Inc., Austin, TX.

Six Sigma principles asserts

Continuous efforts to achieve stable and predictable process results (reduce process variation) are of vital importance to business success.Manufacturing and business processes have characteristics that can be measured, analyzed, controlled and improved.Achieving sustained quality improvement requires commitment from the entire organization, particularly from top-level management.

Features that set Six Sigma apart from other quality improvement initiatives include:

A clear focus on achieving measurable and quantifiable financial returns from any Six Sigma project.An increased emphasis on strong and passionate management leadership and support.A clear commitment to making decisions on the basis of verifiable data and statistical methods, rather than assumptions and guesswork.

Applications Where Six Sigma Is BetterSix Sigma initiatives are based on a preplanned project charter that outlines the scale of a project, financial targets, anticipated benefits and milestones. In comparison, organizations that have implemented TQM, work without fully knowing what the financial gains might be. Six Sigma is based on DMAIC (Define-Measure-Analyze-Improve-Control) that helps in making precise measurements, identifying exact problems, and providing solutions that can be measured.

TQM vs. Six Sigma

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ConclusionSix sigma is also different from TQM in that it is fact based and data driven, result oriented, providing quantifiable and measurable bottom-line results, linked to strategy and related to customer requirements. It is applicable to all common business processes such as administration, sales, marketing and R & D.Although many tools and techniques used in Six Sigma may appear similar to TQM, they are often distinct as in Six Sigma; the focus is on the strategic and systematic application of the tools on targeted projects at the appropriate time. It is predicted that Six Sigma will outlast TQM as it has the potential of achieving more than TQM.

TQMSix Sigma

A functional specialty within the organization.An infrastructure of dedicated change agents. Focuses on cross-functional value delivery streams rather than functional division of labour.

Focuses on quality.Focuses on strategic goals and applies them to cost, schedule and other key business metrics.

Motivated by quality idealism.Driven by tangible benefit far a major stockholder group (customers, shareholders, and employees).

Loosely monitors progress toward goals.Ensures that the investment produces the expected return.

People are engaged in routine duties (Planning, improvement, and control).Slack resources are created to change key business processes and the organization itself.

Emphasizes problem solving.Emphasizes breakthrough rates ofimprovement.

Focuses on standard performance, e.g. ISO 9000.Focuses on world class performance, e.g., 3.4 PPM error rate.

Quality is a permanent, full-time job. Career path is in the quality profession.Six Sigma job is temporary. Six Sigma is a stepping-stone; career path leads elsewhere.

Provides a vast set of tools and techniques with no clear framework for using them effectively.Provides a selected subset of tools and techniques and a clearly defined framework for using them to achieve results (DMAIC).

Goals are developed by quality department based on quality criteria and the assumption that what is good for quality is good for the organization.Goals flow down from customers and senior leadership's strategic objectives. Goals and metrics are reviewed at the enterprise level to assure that local sub-optimization does not occur.

Developed by technical personnel.Developed by CEOs.

Focuses on long-term results. Expected payoff is not well-defined.Six Sigma looks for a mix of short-term and long-term results, as dictated by business demands.