Statistical Process Control; Improvement Program and Quality Costing Weighting

305EMM Total Quality Management 2020/2021
Statistical Process Control; Improvement Program and Quality Costing Weighting 50%
Submission Date 22nd June 2020
1

Late submissions will be penalised in accordance with University/Faculty policy
Learning Objectives (Numbering from MID):
3. Design a quality improvement program, select and identify suitable tools and techniques. Discuss the importance of performance measurement and explain how performance measurement system, benchmarking, and other techniques can help a company achieve continuous improvement.
4. Compare the different approaches to quality costing and evaluate the effectiveness of these methods.
7. Explain variation, apply SPC to a simple example and calculate process capability. Plan the implementation of SPC in a manufacturing organisation.
Procedure.
This is an individual assignment. Submission is online via Moodle (Submission automatically through Turnitin link).
Student Effort.
It is estimated that you should spend approximately 25-30 hours on this assignment. The written element of the assessment is expected to be no more than 3000 words.
Assessment.
The marks will be allocated as shown below. In addition:
Section A: marks will be awarded for detailed, accurate explanations and comments along with accuracy of calculations and completeness of charts.
Section B: All quotes and additional sources of information must be fully referenced. The following marking scheme will be applied. References and bibliography are not included in the page limit.
Plagiarism.
Any suspected cases of plagiarism or collusion will be dealt with via Coventry University disciplinary procedures.
Do not “cut and paste” paragraphs/chapters from sources of literature.
All quotes, figures, illustrations etc must be correctly referenced.
Marking scheme.
100-70% Outstanding. An exceptional level of ability. No weaknesses.
69-60% Very Good. A high level of ability, no major weaknesses. Clear
Understanding of the project brief.
59-50% Good. Overall good level of ability. Weakness in some areas offset by
Strengths in others.
49-40% Fair. Overall minimum standard achieved. There may be competence
in some aspects, but performance may be below standard on other aspects.
305EMM Total Quality Management 2020/2021
Statistical Process Control; Improvement Program and Quality Costing Weighting 50%
Submission Date 22nd June 2020
2
<40% Unsatisfactory. Most aspects below the required standard. There are serious
shortcomings in coverage, content and approach.
305EMM Total Quality Management 2020/2021
Statistical Process Control; Improvement Program and Quality Costing Weighting 50%
Submission Date 22nd June 2020
3
Assignment Brief.
Section A: SPC theory
1.
Sigma is a measure of variation. With the aid of diagrams and using the normal distribution
curve, explain this concept.
(15 marks)
2.
What is “Goalpost Mentality”? Why does it give producers false hope that they are satisfying
their customers? What is a better way of looking at your performance capability?
(15 marks)
3
The following results were obtained by taking samples of five (5) items at regular intervals.
Sample
Number
Sample
Mean (X)
Sample
Range (R)
1 280.6 5.5
2 280.3 4.5
3 278.6 4.0
4 281.0 6.5
5 278.8 6.0
6 280.7 6.5
7 281.0 5.0
8 279.6 4.0
9 279.8 3.0
10 280.7 4.5
11 279.6 5.5
12 281.7 4.5
13 280.8 4.0
14 281.4 6.5
15 282.0 6.0
16 281.7 6.5
17 280.5 5.0
18 279.8 4.0
19 281.4 3.0
20 279.6 4.5
a) Construct control charts for the sample means and ranges showing the control limits
and comment on the results.
UCL X = X + A2 R UCL R = D4 R
LCL X = X – A2 R LCL R = D3 R
When sample size (n) 2 3 4 5
A2 1.880 1.023 0.729 0.577
D2 1.128 1.693 2.059 2.326
D3 0 0 0 0
305EMM Total Quality Management 2020/2021
Statistical Process Control; Improvement Program and Quality Costing Weighting 50%
Submission Date 22nd June 2020
4
D4
3.268
2.574
2.282
2.114
(15 marks)
b) The specification asks for a tolerance of 280mm +/- 5mm. Calculate the process capability indices Cp and Cpk and comment on these. What level of process capability should you strive to achieve for Cp and Cpk.
(15 marks)
Section B: SPC Implementation
4
Read the texts listed (below) on SPC implementation and other appropriate texts.
Antony, J., Balbontin, A. and Taner, T. (2000), “Key ingredients for the effective implementation of statistical process control”, Work Study, Vol.49 No.6, pp.242-247.
Does, R.J., Schippers, W.A.J. and Trip, A. (1997), “A framework for implementation of statistical process control”, International Journal of Quality Science, Vol 2, No. 3, 181-198.
The above documents are available electronically via the University Library electronic databases.
You are the Quality Manager in a manufacturing company and feel it is time to implement some form of improvement programme. Describe your recommendations in a report to the Directors, which must include:
1. A method for implementing SPC across the company, including pre-requisites for implementation, the implementation process and procedures to follow to ensure that the benefits of SPC can be achieved. This should be in the form of a flow chart with an additional 1 page justification. (20 marks)
2. A summary of one relevant tool/technique which could be applied alongside statistical process control and its benefits. (10 marks)
3. Select a quality costing method and analyse the benefits this technique could bring to the company and also evaluate any issues with the quality costing method. (10 marks)
You will need to make assumptions about the company, state these clearly.
305EMM Total Quality Management 2020/2021
Statistical Process Control; Improvement Program and Quality Costing Weighting 50%
Submission Date 22nd June 2020
5
Flow Diagram Example with notes and document links.
Notes QAP 03 Contracts and Enquiries Procedure Documents
Go to
QAP 06, Purchasing and resources
QAP 09, Process Control Procedure
Enquiries by e-mail, fax,
telephone and post are all
processed.
Letter of response sent to
customer if declined or
verbal declination for
telephone enquiries.
Written
Quotation
Required
Incoming
enquiry
Incoming
Amendment
Amend
instruction to Purchase,
processing stores and
finance
Go to Filemaker
Work Instruction
and create new
enquiry
Decline quotation
letter to customer
Yes
Compile quotation for
customer and and copy
to Enquiry File
File Enquiries
Numerically
Filemaker automatically
generates a new enquiry
number. Enquiry details
recorded and checks made
for feasibility, price and
delivery
Confirm technical
feasibility price and
delivery
Incoming
Order
Feasible
If not feasible or No
deliverable, letter to
customer is sent declining
enquiry or enquiry details
re-negotiated.
If feasible, a quotation is
sent to customer and
copies filed in numerical
order.
Check order against
enquiry for agreed
terms or agree terms
with customer
Check
feasibility
Orders by e-mail, fax,
telephone and post are all
processed. Orders with
previous enquiries checked.
If the order is not capable of
being delivered, the order is
declined or the specification
re-negotiated
Go to Safes VII
Work Instruction
and follow sales order
process
Credit
Check
OK
Decline quotation
letter to customer
No
Yes
Yes
No
Pro-forma order
required from
customer
No
Purchase, processing
stores and finance
documentation
Create processing
documents
A credit check is carried out
and a proforma order
requested if credit is ‘onhold’.
If credit becomes
‘on-hold’ after receipt of
order, dispatch is stopped
until a proforma is received.
Sales order processing
takes place with Safes VII.
Process information is
generated for purchasing,
and all other departments.
This includes engineering
data for design, if required.
Amendments to orders are
notified to relevant
departments

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