Statistical Quality Review

1. procon Engineering private limited____________ A Statistical Quality Management Review The Statistical quality review was conducted by SaadSarfraz

2. Company Profile Master Group of Industries Establishment Manufacturing Facility Standards ISO 9002 Certification QS 9000 Series Certification

4. Sports car seats for export

5. Reclining mechanism

6. Automotive fabric

7. Roof headlining

8. Door trim

9. Steering wheels

10. Rear package tray

11. Sun visors

12. Fender liner

13. Engine under coversheet

14. Armrest

15. Cargo deck

16. Chassis frame

17. Suzuki

18. Toyota

19. Honda

20. Nissan

21. Hyundai

22. Kia Motors

23. Daihatsu

24. Hino

25. Nissan Diesel

26. Volvo

27. Yamaha Motorcycle

28. Millat Tractor

29. Al-Ghazi TractorProducts Clients

30. Statistical Quality Control Systems Categories Descriptive Statistics Statistical Process Control (SPC) Acceptance Sampling PROCON SQCS Failure Mode and Effect Analysis (FMEA) Checks Sheets Control Plans Process Flow Charts Process Quality Control Tables Cause and Effect Diagram Pareto Charts Kaizen

31. Application of Management Strategies Total Quality Management (TQM) Problem History Charts Scrap and Rework Log Quality vs. Price HACPL Quarterly Presentations Operational Manuals Diagrams Team Work Encouraged vs. Fear of Management Kaizen Target Monitoring Ergonomics

33. Features  Seat recliners and comforters

34. Reliability  Performance tests (pressure/temperature)

35. Conformance  Design diagram during production

36. Durability  Process capability

37. Serviceability  Rework Redesign

38. Aesthetics  Style, color, shape, tactile characteristics

40. Stem and Leaf Display

41. Histogram

42. Box and Whisker Plot

43. Magnificent Seven (Statistical Process Control) Major Tools Histogram or stem-and-leaf diagram Check sheet-- Pareto chart Cause-and-effect diagram Defect concentration diagram Scatter diagram Control chart

45. Chance and Assignable Causes of Variation Definition Impact/Implication on Quality Identification Failure Modes and Effects Analysis (FMEA)

46. Control Charts for Variables Definition Purpose and Usefulness X-Bar Chart and R-Chart

48. Control Chart for Attributes Definition Purpose and Usefulness P- Chart and C- Chart

50. Process and Measurement System Capability Analysis Process capability involves evaluating process variability relative to preset product specifications in order to determine whether the process is capable of producing an acceptable product To produce an acceptable product, the process must be capable and in control before production begins

51. Process and Measurement System Capability Analysis The Indices of Process Capability The processes and measurement systems considered Evaluation Criteria Results

56. Acceptance Sampling for Attributes and Variables Acceptance sampling refers to the process of randomly inspecting a certain number of items from a lot or batch in order to decide whether to accept or reject the entire batch A sampling plan is required for acceptance sampling that precisely specifies the parameters of the sampling process and the acceptance/rejection criteria

57. Acceptance Sampling for Attributes and Variables Sampling plan for attributes Lot size (N) = 100,000 Inspection level = Normal Acceptance quality level (AQL) = 2% Sample size code letter = N Sample size (n) = 500 Acceptance number (c) = 18

58. Acceptance Sampling for Attributes and Variables Sampling plan for variables Lot size (N) = 100,000 Inspection level = Normal Acceptance quality level (AQL) = 2% Sample size code letter = O Sample size (n) = 100 Acceptance number (k) = 1.765

62. ISO Standardization ISO develops international standards of quality for all industrial standards ISO has gained popularity and recognition because of the facts that it controls quality, it saves money, customers expect it and competitors use it ISO 9000 and ISO 14000

63. ISO Standardization PROCON strictly follows the ISO standards of quality and its QMS is based entirely on the ISO 9000 family The compatible standard that applies to PROCON is ISO T/S 16949 quality specification for automotive industry supplier

64. Application of Six Sigma Approach Six Sigma Quality is defined as a high level of quality associated with approximately 3.4 defective parts per million Six Sigma simply means a measure of quality that strives for near perfection A Six Sigma defect is defined as anything outside of customer specifications

65. Application of Six Sigma Approach There are two aspects to implementing the Six Sigma concept: DMAIC and DMADV The first is the use of technical tools to identify and eliminate causes of quality problems The second aspect of Six Sigma implementation is people involvement

66. Critique of the Quality Control System The objective is to study, evaluate and critically analyze the quality control system of the company The quality control measures for the most part conform to the standard operating procedure One drawback of the quality control system of PROCON is its cost Overall, the quality control system is highly efficient and effective at establishing and maintaining quality