![Defects: study, identification and analysis
Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU
Lucknow in VIII semester 2019-20, and is not intended for wider circulation.
Defect and Defective
• Defect: Any nonconformance of the product with the specified requirements.
• Defective A unit of product which contains one or more defect.
• Failure to meet requirements with respect to quality characteristics are usually described
in terms of defects or defectives.
• A product defect is any characteristic of a product which hinders its usability for the
purpose for which it was designed and manufactured.
Defect classification [1]
Minor- Small, insignificant issues that don’t affect the function or form of the item (May
not be noticed by the customer.
Major - Adversely affect the function, performance or appearance of a product
Critical defects- Product can’t be used](https://image.slidesharecdn.com/rme-085tqmunit-4part1-200406090724/85/RME-085-TQM-unit-4-part-1-2-320.jpg)
![Defects: study, identification and analysis
Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU
Lucknow in VIII semester 2019-20, and is not intended for wider circulation.
• To bear cut-throat market competition, a modern business needs to
follow the principles of quality control [2].
• Must ensure Zero Defects (flawless production) concept (Philip
Crosby).
• QM instruments relies on continuous improvement, which results
from Deming’s cycle (PDCA).
• Industries often suffers from defects in their products on daily basis.
They must be identified and rectified which may otherwise results
into huge loss at later stages.
• Defect analysis generally seeks to classify defects into categories and
identify possible causes in order to direct process improvement
efforts.
• Defect analysis is done using QM tools like- Ishikawa diagram and
Pareto diagram.
Plan
DoCheck
Act
PDCA Cycle - Deming
Lean manufacturing
Systematic way of
eliminating waste and
to ensure flawless
production.
Six Sigma
Set of techniques to
reduce the rate of
defects (Variability).](https://image.slidesharecdn.com/rme-085tqmunit-4part1-200406090724/85/RME-085-TQM-unit-4-part-1-4-320.jpg)
![References:
[1] https://www.intouch-quality.com/blog/3-types-quality-defects-different-products (Accessed on 05.04.2020)
[2] Katarzyna MIDOR. An analysis of the causes of product defects using quality management tools. Management Systems
In Production Engineering. 2014, No 4 (16), pp 162‐167. (DOI 10.12914/MSPE‐04‐04‐2014).](https://image.slidesharecdn.com/rme-085tqmunit-4part1-200406090724/85/RME-085-TQM-unit-4-part-1-9-320.jpg)
RME-085 TQM unit-4 part 1
- 1. RME-085 Total Quality Management Topic: Defects: study, identification and analysis By: Dr. Vinod Kumar Yadav Department of Mechanical Engineering G. L. Bajaj Institute of Technology and Management Greater Noida Email: vinod.yadav@glbitm.org
- 2. Defects: study, identification and analysis Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU Lucknow in VIII semester 2019-20, and is not intended for wider circulation. Defect and Defective • Defect: Any nonconformance of the product with the specified requirements. • Defective A unit of product which contains one or more defect. • Failure to meet requirements with respect to quality characteristics are usually described in terms of defects or defectives. • A product defect is any characteristic of a product which hinders its usability for the purpose for which it was designed and manufactured. Defect classification [1] Minor- Small, insignificant issues that don’t affect the function or form of the item (May not be noticed by the customer. Major - Adversely affect the function, performance or appearance of a product Critical defects- Product can’t be used
- 3. Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU Lucknow in VIII semester 2019-20, and is not intended for wider circulation. Example: Minor, Major and critical defect Defect analysis of Mobile phone Defect Description Defect Classification Minor Major Critical Battery problem Yes IC Chip texture Yes Body damage Yes Software issue Yes Mobile charger Yes
- 4. Defects: study, identification and analysis Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU Lucknow in VIII semester 2019-20, and is not intended for wider circulation. • To bear cut-throat market competition, a modern business needs to follow the principles of quality control [2]. • Must ensure Zero Defects (flawless production) concept (Philip Crosby). • QM instruments relies on continuous improvement, which results from Deming’s cycle (PDCA). • Industries often suffers from defects in their products on daily basis. They must be identified and rectified which may otherwise results into huge loss at later stages. • Defect analysis generally seeks to classify defects into categories and identify possible causes in order to direct process improvement efforts. • Defect analysis is done using QM tools like- Ishikawa diagram and Pareto diagram. Plan DoCheck Act PDCA Cycle - Deming Lean manufacturing Systematic way of eliminating waste and to ensure flawless production. Six Sigma Set of techniques to reduce the rate of defects (Variability).
- 5. Defects: study, identification and analysis contd. Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU Lucknow in VIII semester 2019-20, and is not intended for wider circulation. Defect analysis steps 1. Data collection. 2. Defect cause analysis: Prioritizing root causes (Pareto diagram). 3. Identification and development of solutions for root causes. 4. Implementation of proposals for rectification of defects. Root cause analysis (RCA) RCA is systematic process for identifying Root causes of problems or events and an approach for responding to them. 5 Why concept ????? The 5 Whys method is part of the Toyota Production System (Integral part of the Lean philosophy).
- 6. Defects: study, identification and analysis contd. Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU Lucknow in VIII semester 2019-20, and is not intended for wider circulation. 5 Why concept ????? Taiichi Ohno “The basis of Toyota’s scientific approach is to ask why five times whenever we find a problem … By repeating why five times, the nature of the problem as well as its solution becomes clear.“ Problem: A good cricketer is unable to perform during match Why? Why? Why? Why? Why? Bowler is good1 2 3 4 5 Didn’t attended practice session Didn’t reviewed the bowler’s history Not familiar with the pitch Didn’t slept last night due to high fever Steps 1. Form team 2. Define problem 3. Ask Why? 4. Initiate action 5. Analyze results
- 7. Defects: study, identification and analysis contd. Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU Lucknow in VIII semester 2019-20, and is not intended for wider circulation. Fishbone diagram or Ishikawa diagram is a modern quality management tool that explains the cause and effect relationship for any quality issue that has arisen or that may arise. It provides the visual representation of all the possible causes for a problem to analyze and find out the root cause. Flavor Fig. 1 Defect analysis using Ishikawa diagram for Juice making plant Poor Juice quality Machines Method Materials Operator Surrounding Quantity Storage Ingredients Raw materials Humid Fraction of ingredients Untrained Cleaning Maintenance Bottle material Impure Faulty machine setting Improper quenching An example of defect analysis using Fish bone diagram (Ishikawa Diagram)
- 8. Defects: study, identification and analysis contd. Note: The contents used in this slide is being used for academic purposes only, and is intended only for students registered in B.Tech Mechanical Engineering at AKTU Lucknow in VIII semester 2019-20, and is not intended for wider circulation. Fig. 2 Defect analysis using Pareto diagram 0 2 4 6 8 10 12 14 16 Wrong specifications Corrosion Tool mark Wrong feed Late supply Poor finish Frequency Problem type Pareto Diagram Pareto diagram: Ranks data in descending order from left to right
- 9. References: [1] https://www.intouch-quality.com/blog/3-types-quality-defects-different-products (Accessed on 05.04.2020) [2] Katarzyna MIDOR. An analysis of the causes of product defects using quality management tools. Management Systems In Production Engineering. 2014, No 4 (16), pp 162‐167. (DOI 10.12914/MSPE‐04‐04‐2014).
- 10. Thank you