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
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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.
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– 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
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