1020235331                                       MODERN QC TOOLS
Syllabus Contents.
Unit I BASICS OF QUALITY CONCEPTS
Definitions of the terms – Inspection, Quality, Quality Planning, Quality Control,
Quality Assurance, Quality Management – Dimensions of quality –Basics of Total
Quality– Quality Statements – Strategic Planning – Evolution of Quality
Management – Quality Awards – Introduction to TQM – Pillars of TQM –
Characteristics – Basic concepts – Quality Objectives – Team Building – Barriers
to TQM implementation – Potential benefits of TQM – Quality council – Duties
– Responsibilities –Strategic planning – Factors influencing Quality Costs –
Customer Focus – Employee Involvement
6
Unit II CONTINUOUS PROCESS IMPROVEMENT
Input / Output process model – Juran Trilogy – PDCA (Deming Wheel) cycle
– 5S Concepts – SEIRI, SEITON, SEISO, SEIKETSU and SHITSUKE – needs
and objectives – effective implementation of 5S concepts in an organisation –
Kaizen – Gemba Kaizen – Housekeeping- Quality Circles and the Trade Unions
– Reengineering – Characteristics– Advantages -Criticism of
Reengineering-Supplier relationship
6
Unit III STATISTICAL PROCESS CONTROL
Definition – Statistics Data- definition, types and uses. Measures of general
Tendency and Dispersion – Mean – Median – Mode – Introduction to measures
of dispersion – Population and Sample – Statistical Process Control and SQC
definition– Process Capability – Sampling -Control Charts and its types –
Comparison of Variable and attributes – X bar and R (Problems), Attributes –
p, np and c Charts.-Process capability analysis, Definition, steps and its uses.
6
Unit IV SEVEN TOOLS OF QUALITY
Seven tools of quality (Q-7 tools) – Check sheet – Histogram – Cause and effect
diagram – Pareto diagram – Scatter diagram – Flow charts – Control charts –
Construction of above tools, types, Uses and Limitations
6
Unit V
NEW SEVEN MANAGEMENT TOOLS, QUALITY MANAGEMENT
SYSTEMS
New seven management tools- Flow and its uses – Affinity diagram –
Interrelationship digraph or Relationship diagram – Tree diagram – Matrix
diagram-Prioritization matrices – Process decision program chart – Activity
network diagram. -Construction of above diagrams. Six sigma –Objectives,
Methodology and Benefits – DMAIC -Quality Management System – ISO 9000,
ISO 14000 Documentation and Implementation – Total Productive Maintenance
–Concepts and Needs.
6
Theory portions 30
Practical Exercise 20
Revision + Test 10
Total 60
Practical Exercise
1. The Six Sigma process typically follows the DMAIC framework: Define, Measure,
Analyze, Improve, and Control.
2. Write the detailed steps for Lean Manufacturing.
3. Explain the statistical methods to monitor and control a process in SPC.
4. Write steps to practice kaizen.
5. Write the procedure to followed for Failure Mode and Effects Analysis (FMEA)
6. Write the step by procedure for the RCA method of problem-solving.
7. Implement 5S on the shop floor and document the details.
8. Create the SPC for the dataset. Use control charts
9. Carry out the Root Cause Analysis (RCA) for the sample
10. Carry out Pareto Analysis. and document the finding.