Differentiate managerial Tools from operational tools in context of Manufacturing industry?

Answer 1

There are different kinds of models and tools available for the corporation in its journey of quality. Depending upon the need, situation, and level, one or more of these tools and techniques could be used. These tools could be managerial or operational in nature. Here we are discussing some of these tools in the context of a manufacturing industry. MANAGERIAL TOOLS : Using the diagrammatic representation approach, certain managerial tools have been developed for step-by-step problem solving to achieve improvement. Some of these are :- i. Affinity digram ii. Relations digram iii. Tree digram iv. Matrix digram v. Matrix data analysis vi. Process decision program chart (PDPC) Tool 1 : ACCEPTABLE QUALITY LEAVEL Purpose : To provide a structure of sampling plans, risks, and inspection strategies to ensure that the customer receives the quality that the supplier has contracted to deliver. The method is normally used when each is evaluated on the basis of a set of attributes and rate as acceptable or non-acceptable. How to use? The customer and supplier agree on he quality level. This is defined as the worst quality which can be considered acceptable as the average percent defectives. AQL could vary from 01 to 1000 defects per 1000 units. They also agree on the level of inspection. The ideal situation for the supplier would be no inspection to in the worst case 100% inspection. The various stage are : 1. Normal inspection 2. Tightened inspection 3. Reduced inspection Tool 2. ERROR PROOFING (Pokayoke) Purpose : To design an operation in such a way that specific error are prevented from causing major problems to the customer. It can be used when defects occur and require 100 per cent inspection, immediate feedback and action at the • Source of the raw materials • Start of the production process • Production points where an error may occur How to use? In a pokayoke system, carry out automatic continuous inspection and if abnormalities occur, then provide feedback and take action. However, before can begin, one has to halt the process, obtain feedback and execute necessary action. All this is done at a low cost. Tool 3. KAIZAN Purpose : A Japanese term meaning ‘charge for the better’, the concept implies a continuous improvement in all company function at all levels. It is more a culture attitude and a life style rather than techniques. Japanese as a nation are bent upon improving and developing. How to use? The kaizen concept is based on people’s commitment and participation by using their knowledge experience and can, therefore, be established through any participatory activities. The beauty is that a continuous application of Kaizen can a corporation with a similar technology base that of a competitor can outperform the same in terms of productivity. Tool 4. QUALITY FUNCTION DEPLOYMENT (QFD) Purpose : It is the process optimizing the process of developing and products on the basis of customer needs. During design, commissioning, or post-commissioning to translate customer requirements into company requirements. The technique can be used in research, product development, engineering, manufacturing, marketing and even distribution areas. How to use? QFD is a five stage process as per Bossert 1. Identifying customer needs which are usually characteristics or attributes. 2. Translation of loose statements of need into definitions of requirements which are objective and definable and mesureable. 3. The specifications are converted into end product attributes. They are also called critical path characteristics. 4. Design a process to deliver the product with the expected characteristics. 5. The final stage is to plan activities to produce the output. Tool 5. FAILURE MODE EFFECT ANALYSIS How to use? To conduct FMFA effectively, one must follow a systematic approach. The recommended approach is an eight-step method that facilities the system, design, product, process and service FMFA. 1. Select the team and brainstorm 2. Draw the functional block diagram and process flow chart 3. Priortize 4. Data collection 5. Analysis 6. Results 7. Confirm/ evaluate/ measure 8. Do it all over again OPERATIONAL TOOLS Too 1. PARETO CHART Wilfred Pareto, an Italian Economist conducted a study on the income tax paying patterns of U.S. He discovered that 80% of the tax is paid by 20% of the assesses. This gave rise to the now famous 80-20 principal. The Pareto chart enables the identification of the major few from the trival many. The chart enables zeroing in on the top most for concern. How to use ? 1. Identify and tabulate all the defects in a lot. 2. Arrange them in descending order based on the number of defectives. 3. Convert the defects as percentage of total defects. 4. The defects which have the maximum percentage will have to be attack first. Tool 2. CAUSE AND EFFECT ANALYSIS Purpose : To examine the effects of problem to find out the possible causes and to point our possible areas where data can be collected. Steps : a) Brainstorm all possible causes of problem or effect selected for the analysis b) Classify the major causes under man, machine, material methods c) Draw a cause and effect digram d) Identify the root cause Tool 3. FAULT TREE ANALYSIS Purpose : To perform a quantitative as well as qualitative analysis of a complex system. How to use ? Design of the fault tree begins by specifying the non-desired occurrence. The immediate cause of this event has to be connected with the necessary sequence. This procedure is repeated until a basic fault occurrence level is reached. Tool 4. ROBUST DESIGN Purpose : To achieve the propose functioning of a component even when affected by interfering factors, whether external, internal, or manufacturing variation. How to use ? Divide the disturbing factors into the following group : i. Inner disturbances, i.e. wear and tear of the individual unit due to its operation. ii. Outer disturbances, i.e. variation of temperature and other environmental factors during usage. iii. Manufacturing variations, i.e. deviation from set target.