Showing papers in "International Journal of Quality & Reliability Management in 1993"

Modelling Failure Modes and Effects Analysis

Abstract: Presents a critical review of the method of FMEA and in particular of the risk priority number (RPN) used for ranking failure modes. Though the method itself is of great use, the calculation of the RPN lacks a proper model as a base and is thus internally inconsistent and potentially misleading. Proposes an alternative procedure, based on a simple model and using expected costs as the basis for ranking failure modes.

Achieving the Organizational Change Necessary for Successful TQM

Abstract: Introduction Anyone who attempts to implement a TQM system in an organization is faced with one of the most complex tasks which they might ever encounter. As a form of organizational culture change, TQM requires a variety of skills and methods which have not been the traditional educational and experiential fare of the typical leader. Understanding the concept of culture in organizations is the first step. Organizational culture is based on mindsets, or paradigms. Paradigms explain why we perceive reality according to culturally-determined meanings and guidelines. Armed with paradigms, we approach the world around us and interpret what we see and experience according to our shared understandings. If we apply to understanding how societies work and operate, we include technology, politics, economics and social organization among our culturallydetermined variables. Culture operates within the same contexts when applied to understanding organizations. Although organizations often draw members from diverse ethnic groups and nationalities, cultures unique to each corporation or not-for-profit entity evolve. Generally speaking organizations developed within the Western model have similar cultures and related paradigms about how to get things done. Traditional Western paradigms are the guidelines for such activities as how and who makes decisions, production processes, hierarchy and organizational structure and quality. When organizations, particularly those operating with Western paradigms, begin the process of change necessary to adapt to the conditions, environments, and markets of this decade, it will be necessary to adopt a new paradigm more suitable for the global community. TQM has been heralded by many leaders as the paradigm necessary for this organizational transformation. A comparison of the traditional Western and the relatively new TQM paradigms illustrates the rather significant differences between the two management approaches. A successful transformation to TQM or any other paradigm, therefore, requires organizational culture change. Table I illustrates many of the critical cultural features which are involved in these changes.

Total Quality Management from Theory to Practice: A Case Study

Abstract: Most quality professionals recommend a core set of attributes as the nucleus of any quality improvement process. These attributes include: (1) clarifying job expectations; (2) setting quality standards; (3) measuring quality improvement; (4) effective super‐vision; (5) listening by management; (6) feedback by management; and (7) effective training. Based on a survey of employees at a medium‐sized manufacturing firm in the United States, it was found that management philosophy and actions can undermine even a proven total quality management (TQM) programme. For the many firms which hire outside consultants to set up a TQM programme, makes recommendations to management to ensure its successful implementation.

Organizational Culture as a Missing Link in Quality Management

Abstract: Quality management ignores organizational culture to a great extent. Establishes the relationship between organizational culture and quality management and presents a method for measuring organizational culture, illustrating the relationship in a case study. Gives recommendations for using the presented findings in practical management.

Improvement Detection by Control Charts for High Yield Processes

Abstract: Introduction Statistical process control (SPC) is by now a commonly used quality assurance tool. One of the most important SPC techniques is the use of control charts for maintaining process performance; their effectiveness lies in their ability to alert users of any deterioration of process behaviour so that potential damage can be alleviated or averted in time. As a result, the attention of control chart users, mostly technical personnel, is normally focused on process deterioration. From a management point of view, the ability to detect process improvements in the form of "out of control" states is no less important, since improvements can take place as a result of process stabilization or learning effects. In this article we address this subject with reference to a conventional process control chart and its application in a high yield or low defective manufacturing environment, and offer some practical implementation procedures. Many manufacturing processes today have attained quality levels far higher than those commonly found when Shewhart control charts were first proposed in the 1920s[1]. One of such control charts, namely np-chart for the control of nonconforming items (defectives), faces some implementation problems when the proportion nonconforming p is low and the size of each sample n is not large enough. In particular, based on 3ơ deviation from process mean, the lower control limit (LCL) is often below zero which has no physical meaning. It is often advised in textbooks or journal papers that this LCL be ignored or zero be taken instead as the lower limit. However, such practice contradicts the fundamental idea of SPC by control charts. A process is judged out of control when it, with a certain probability, performs worse than expected; in such a case action should be taken to make the necessary corrections to the process. The process may also be "out-of-control" in the sense that it has become better than expected; in such a situation useful information can be sought about how the new-found quality improvement may be sustained. This is an extremely valuable opportunity not be missed, as continuous improvement is now the cornerstone of modern quality management.

Capturing the Cost of Quality Failures in Civil Engineering

Abstract: A description of failure events during construction illustrates the urgent need to emphasize the management of quality in civil engineering projects. During the construction of a civil engineering project, cost control techniques are used to monitor cost trends and to detect cost deviations in order to control project cost. However, this technique does not reveal the cause of any failure. The nature and collection of failure costs have been part of quality costing. Hypothetical illustrations show how failure costs can be extracted during construction using a matrix. Quality cost information can be used to supplement cost control techniques for cost control purposes and in identifying weaknesses within a system.

Training and the Implementation of Quality Programmes by a Sample of Small and Medium‐sized Firms in Spain

Abstract: The importance of training in the implementation of a quality programme is well known. Training is needed to improve ability, to learn new techniques, and to stimulate involvement in the goals and objectives of the firm. Presents some of the results of a study made of a sample of 44 small firms in Valencia, on the Mediterranean coast of Spain. The research has shown what specific characteristics and obstacles training for quality has encountered in these firms. The narrow focus of the majority of these quality programmes was an obstacle to overcoming resistance to change and lack of interest, problems which were frequently encountered. The research also detected a relationship between participative management and the training of managers for quality.

Does Higher Quality Mean Higher Cost

Abstract: The conventional wisdom of managers in the US dictates that improving product quality will increase the cost of making the product which will either increase the price or reduce the profits. Shows that improving the quality of a product or service will not necessarily increase its manufacturing cost. Obtains information on fundamental theories and case histories from business literature and uses evidence to support the hypothesis from the case histories of several US companies which have achieved higher quality with lower quality costs and improved profitability. Examples from the literature include the case histories of companies such as Florida Power & Light, Globe Metallurgical, Motorola, and Westinghouse Commercial Nuclear Fuel Division. These examples indicate increases in return on assets, improved customer satisfaction, increased market share, and increased revenues and profits. Suggests that a company which can achieve successfully both higher quality and lower cost will have improved productivity, lower manufacturing costs, better quality, greater customer satisfaction, a higher market share and greater profitability.

An EWMA Quality Control Procedure for Jointly Monitoring the Mean and Variance

Abstract: Introduction Quality control charts have been used widely for the purpose of detecting changes in a process. Usually, we can represent a change in the process by a change in the parameter of the distribution of the quality characteristic being monitored. When random variables of interest follow approximately the normal distribution, interest centres on controlling the mean, μ, and/or the variance, σ. Shewhart type charts, cumulative sum (CUSUM) procedures, and exponentially weighted moving averages (EWMA and DEWMA) procedures [1-7] have been commonly used to monitor shifts in the process mean using sample means (or individual observations). Usually it is assumed that independent samples of the same size are obtained at fixed-length sampling intervals. Relatively, little has appeared about the design and use of procedures for jointly controlling the mean and process variability, the latest article being Domangue and Patch[8]. Procedures for controlling the process variability usually are based on Shewhart-type charts such as the R-chart, S-chart, or the S-chart for controlling the range, the standard deviation, and the variance respectively. There has also been numerical work on the properties of CUSUM procedures on the range or the moving range. It is well known that for larger sample sizes the sample variance, s is a more efficient control statistic for controlling the process variability than the sample range. Domangue and Patch studied the properties of omnibus EWMA schemes. They proposed an omnibus EWMA procedure based on the statistic

Employee Receptivity to Total Quality

Abstract: Discusses the results of a survey into the factors which motivate individuals to adopt, participate in and implement total quality (TQ) in their own work environments. A considerable literature survey was carried out in order to derive a framework which could be used to assess the many factors which might influence individuals. Concentrates on the results of the survey which was carried out to test the frame‐work. Data were collected by means of a questionnaire sent to 220 employees in the sales division of one company, achieving a response rate of 54 per cent, which was considered to be high for this type of project. Uses the responses to assess the influence of organizational culture, environmental and organizational change and TQ training on individuals′ decisions to practise TQ.

On Evaluating Maintenance Performance

Abstract: Maintenance costs are increasing as industry is trying to use automation and take advantage of advances in technology. Management needs to plan and control maintenance costs. Adequate techniques for developing standards for maintenance costs are not available. This article outlines such a technique and suggests means of comparing the maintenance performance efficiency of different plants/companies.

A Note on the Inspection Interval of a Machine

Abstract: Suppose that a machine is subject to failures at random with constant probability of p per unit time, and that the only way of telling whether the machine has failed is to test it. Given the above assumptions, presents a simplified equation to determine how often a machine should be inspected.

Research Report: An Expert System for Quality Management Auditing

Abstract: Reports on the development of an expert system designed for auditors of quality management, discussing its development process (QMA‐1), composition and structure. The system was tested in 20 Chinese organizations and user feedback reported. Outlines plans for future development of the system.

Design for Quality in the Shipbuilding Industry

Abstract: There is a growing understanding that the quality of a product should be built in at the design phase. More and more reports have shown that this kind of approach, named design for quality, can benefit the company to make it much more competitive. In many Eastern countries such as Japan and Taiwan, such concepts have been used for a while. The so‐called product oriented design (POD) and quality function deployment (QFD) are widely used in many industries. This may be one of the main reasons why many Eastern countries have had a very high economic growth rate during the past two decades. For a coastal nation, the shipbuilding industry is essential for defence purposes. However, to run a shipyard efficiently is not an easy job due to several of its characteristics. They are: (1) the product (a ship) size is very large both in volume and weight and each product has thousands of different components; (2) the design, planning and manufacturing process overlap very significantly and the concept of “teamwork” is therefore greatly emphasized; and (3) the production process is very complex and complicated with very many interdependences. With these characteristics, the methods of “design for quality” and “design for manufacture” seem to be ideal tools for the shipbuilding industry to maintain product quality while raising the shipyard′s efficiency. Describes how a shipbuilding company in Taiwan can apply these positive concepts to improve its performance. Discusses several practical examples to illustrate these concepts.

Reliability Consideration of a Flexible Manufacturing System from Fuzzy Information

Abstract: Introduction The short life-time cycle of a product and variations owing to market need requires manufacturing systems to be flexible. The equipment involved in a flexible manufacturing system (FMS) utilizes high precision facilities and information technology and is expensive as a result. Thus reliability considerations become important in the design of an FMS. In general an FMS system consists of three subsystems, namely:

GERT Analysis of Conditional Repetitive Group Sampling Plan

Abstract: Introduces a conditional repetitive group sampling plan. The OC and ASN functions are derived by GERT approach. The present development would be a valuable addition to the literature and a useful device to quality control practitioners and also to quality control engineers and plan designers in the development of further new plans.

The Conceptual Relationship between Construction Quality and Economic Development

Abstract: The relationship between construction and economic development has been the subject of much study in Singapore. None has, however, shown the stages through which construction quality in the industry has evolved over the last 30 years nor the significant role played by the government in achieving quality construction among indigenous building firms. Explores the relationship between the Singapore economy and quality in the construction industry. The evidence documented suggests a link between construction quality and economic development in Singapore. Proposes a conceptual framework which depicts this relationship.

Problems in Control Chart Pattern Recognition Systems

Abstract: Introduction Artificial Intelligence has been applied to a variety of areas in the fields of statistics and process control. Expert systems have ranged from statistical "consultants" to robotic vision systems. Hand outlined the development of a statistical "consultant" based on studying the way a consultant approached a problem and addressed problems that could be encountered in the development of the system[1]. Hahn defined a "statistical expert system" as an automated statistical consultant and data analyst that guides the analyst directly to a solution of a general statistical problem[2]. But, Hahn concluded, more research is needed before a general statistical expert system is successful and expert systems which are more specialized may be more feasible. There are specialized systems in quality and process control which exist in the manufacturing area. Giovannone discussed the integration of robots in several locations around Italy[3]. These robots take measurements but most of them only have an interface to a program that controls the sampling and records the information. Haton also describes the application of artificial intelligence to sample inspection[4]. The integration of vision systems used for quality inspection will expand during the next decade, according to Haton. An expert system to monitor the vision system is a possibility. Ackerman, Plsek and Surette describe some systems developed by AT&T for internal corporate use[5]. Most systems mentioned by them operate in real time and cover aspects of process control such as product yields, reliability analysis and quality cost planning. A few commercial packages implementing artificial intelligence are available for quality control. A survey of packages a few years ago indicated that a few packages by A. William Wortham and Associates analyse charts using artificial intelligence[6]. The analyses in these packages consisted of "several statistical tests, all combined through artificial intelligence to give a considered decision". There are many more software packages that perform chart analysis but do not mention artificial intelligence applications. Most of the packages only test for a small number of patterns, like shifts and trends, or use runs rules for detection. There is no mention of accuracy of these packages or the false alarm rate for the tests performed.

Analysis of Aircraft Reliability Using Monte Carlo Simulation

Abstract: Points out certain ambiguities in the usage of some reliability parameters in their application to repairable systems and presents a digital simulation model for analysing their reliability. The proposed model is useful for assessing intended changes in systems design or improvements in operational and maintenance procedures on system reliability. Outlines different steps of a computational algorithm for solving the proposed model. Describes an illustrative application of the proposed model to a fleet of trainer aircraft.

An Evaluative Study of the Attitudinal and Performance‐related Outcomes of Quality Circle Participation

Abstract: Studies two Northern Ireland manufacturing companies, Shirtco and Carpetco, to generate some quantitative data concerning possible attitudinal and behavioural outcomes of quality circle (QC) participation. Attention focused on three variables: (1) the attitudes of QC participants and those of comparable non‐participants to the work situation; (2) the quantity and quality of output achieved by QC participants and by comparable non‐participants; and (3) the short‐term absence rates of QC participants and comparable non‐participants. An attempt also was made to measure participants′ attitudes to the QC programmes. The findings at Carpetco were not encouraging, as attitudes towards QC participation were ambivalent, and there was little statistically significant evidence of QC participation producing a positive influence on attitudes or on the quantity and quality of output. Nor was there any evidence of the QC programme having generated significant cost‐savings. However, QC participation may have reduced the tendency to take casual days off work. The situation at Shirtco was rather different, as in one of the three work sections studied, QC participation may have had a positive influence on attitudes, quantity of output and amount of time spent on productive work, but not on attendance. The position regarding the other two work sections studied at Shirtco was much more equivocal. There was no evidence of any significant cost‐savings having emanated from the QC programme at Shirtco. Concludes that unless a QC initiative is accompanied by other changes in the general work situation, it will almost certainly produce marginal benefits at best. Quality circles are probably used to best effect when they comprise part of a wider initiative such as total quality management (TQM). Perhaps it is as a means of helping to put aspects of TQM into effect that the real value of QCs will be demonstrated.

Implementation of a Construction Industry Quality Assurance System

Abstract: Describes an applied research and development project at present being undertaken by the Department of Civil Engineering at Loughborough University to produce and implement a quality assurance system in a medium‐sized contracting organization. Details the methodology used, the actual work undertaken, the documentation produced, the implementation into the company and the initial affect on the Company. The scheme has operated for three‐and‐a‐half years and has six months to run.

A Cost Model for Parameter Design

Abstract: Proposes a cost model for parameter design in quality engineering. In this model the total cost is minimized to obtain the best design. The total cost includes quality loss, cost for input characteristic, and cost for objective characteristic adjustment. Presents the best mean level of an input characteristic for the parameter design, which has a quadratic relationship between an input and an objective characteristic.