CM4120 Chemical Plant Operations Lab Introduction to Quality ManufacturingSlide 2Slide 3Slide 4Slide 5Slide 6Slide 7Slide 8Slide 9Slide 10Slide 11Slide 121CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingHow is Quality defined?ISO9000: The totality of features and characteristics of a product or service that bear on its ability to satisfy stated or implied need.2CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingWhat is Quality Management?Managing systems and processes for the elimination of errors.Creating an environment for continuous improvement.3CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingFormula for a generic process:A+B=Cwhere A=system contribution B=human contribution C=desired (measurable) outputDeming’s 14 Principles -- Handout4CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingWhat is a Process?A logical sequence of tasks that repeatedly transform inputs into outputs.Inputs may be people, information, or material.Outputs may be products, services, or behaviors.5CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingWhat is a System?Group of people and/or processes that are united with a common purpose.Have identifiable characteristics.Have measurable performance (quality) indicators.6CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingWhat is Variation?Measurable change in the system output(s).Inherent to all processes or systems.Common cause – built into the system.Special cause – assignable to an event.Tampering – result from tampering.Structural – regular, systematic changes.7CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingWhat is Statistical Process Control?Application of statistical methods to separate common cause variation from other causes.Uses control charting to convert fluctuations in a measured characteristic into useful information.A tool commonly used in quality systems.8CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingAdditional tools:Fishbone (Cause and Effect) DiagramsViscosity variation9CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingAdditional tools:Pareto ChartsA bar graph showing frequency of problem occurrence.Optionally, can have a “cumulative frequency” line and show percentage of total on bar graph.Used to display the relative importance or frequency of problems or conditions10CM4120Chemical Plant Operations LabIntroduction to Quality Manufacturingcause frequency percentcumulative totalmiscalculated loadings 13 37 13neutralize too soon 7 57 20added wrong qty EB 6 74 26inadequate strip 4 86 30bad viscometer reading 4 97 34loaded wrong chemical 1 100 35Viscosity Variation Problems0246810121416182011CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingAdditional tools:Deming Cycle12CM4120Chemical Plant Operations LabIntroduction to Quality ManufacturingAdditional tools:Goal