quality system basics

“A Quality System Approach towards Organizational Excellence”

Contact Detail: 0120 4155443, +918800425599 & 9999429052, email- [email protected] 406, KM-42, KOSMOS, Sector-134, Noida-Greater Noida Express way, Noida , UP, 201301

© Copyright Quality System Basics 2014

A Joint Venture with Quality Visual System Inc. Japan.

“A premier Quality Institution in India dedicated entirely to Quality.” QSB

Quality System Basics

Quality System Basics (QSB) is a premier Quality Institution in India dedicated entirely to Quality, which has been established and organized by group of professionals from India and Japan.

As Quality is always visible and Visualization is the essential part of Quality System. By considering this concept, Quality Visual system Inc. has been established by Takashi Tanaka San – who is a consultant to Toyota Motor Corporation, Japan at present. He firmly believes in to Toyota Management system, PDCA approach & visualization.

QSB has been established to derive the Quality Culture and more towards Quality revolution in India similar to Quality Visual in Japan.

We provide customized and cost effective solutions based on planning, measurement and improvement, which delivers the following benefits for organizations in direct or indirect ways;

v Improved customer satisfaction v Reduced costs and improved profitability v Improvement and innovation v Identification and management risk v Long term business growth with sustainability v Building Quality Culture

We recognize that these business outcomes can only be delivered by competent quality professionals and in support of this the QSB provides the following services:

v Promotion and Awareness of Quality concepts as prescribed by Japanese Union for Scientists and Engineers (JUSE) v Offer Certificate & Diploma programmes related to Quality Management to bridge the gap between Campus to Company v Develop and provide Quality professionals for Indian Industries to derive Quality culture v Promote and Deployment of Integrated Business Management system (IBMS) v Promote and Deployment of Statistical Quality tools and techniques v Promote and Derive Quality Circle concept in Education sector v Promote and Deployment of Lean manufacturing practices

About us.....

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QSB Quality System Basics

Vision: is to become World’s one of the best Quality Institution and preferred service provider to our business partners in India.

Purpose: Quality revolution in India - “A Product or Service made in India means; a product or service that the world can trust upon.”

Mission: Promote and deployment of World’s best manufacturing practices in industries by developing people in the field of Quality management, process improvements and waste elimination from the entire supply chain. In this manner we strengthen the competitive strength of our partners.

Approach: Success just does not happen, success is always planned. That’s why QSB firmly believes in the Deming approach, which is a wide-ranging, reasoned system of management that delivers consistent high performance over the long-term. It views an organization as a complete system focused on meeting the needs of the customer and other stakeholders, which means quality is the central value. Improving quality reduces wastes and hence improves productivity. Continual improvement is the key of success for any Organization which is only possible by enriching knowledge, skills & motivation of employees and derive Plan-Do-Check-Act cycle in all the processes throughout the Organization.

Core Principles: Ability enhancement Built in Quality Customer focused Emphasize on Quality Basics First time right Honesty and Hard work Integrity Never give up attitude

Open to ideas- Creativity and change Process Approach Respect for people Standardization Team approach Update yourself Visualization Waste elimination

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q  QSB Qualification Courses

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A range of quality management qualifications aimed at those new to quality or progressing through their quality career. The QSB qualifications (syllabus) are based on Qualifications and Credit Framework (QCF) and are recognized by Quality Council of India (QCI). QSB qualifications allow quality professionals to gain recognition through the achievement of role-related qualifications that not only provide a ladder to becoming chartered, but are recognised by employers and based on the Scope of Quality Knowledge.

QSB Qualification programmes are being designed for students as well as experienced Individuals. Qualification Courses are being strongly recommended to engineering students (who are ready to start his/her career) to bridge the gaps between campus to companies.

Course(s) Period Units Who can participate

Certificate in Quality Management 3 M 5 This course is suitable for anyone – engineering and management students, who requires a greater understanding of quality concepts and quality management, including newly-appointed quality personnel, quality managers, experienced individuals from various industries. Potential job roles: Product Engineer, Process Engineer, Quality Engineer, Customer Service Manager, Opera t i ons Manager, Bus iness Improvement Manager, Business Systems Manager, Senior Quality Manager, Quality Management Specialist, Supplier Quality Manager, TQM Manager, Quality Assurance Manager and so on.

Certificate in Systems Management 3 M 7

Certificate in Assuring Service & Product Quality 3 M 8

Certificate in Managing Supply Chain Quality 3 M 7

Certificate in Quality Improvement for Business 3 M 5

Certificate in Quality Management Systems Audit 3 M 6

Diploma in Quality Management 6 M 9

You can study QSB qualifications in a number of ways, including; ü Day -time classes at local college ü  Part-time (evening) classes at local college ü Week end classes at local college ü  Flexible learning programmes ü  Public training programmes

After this... Delegates will be able to: Explain the principles and concepts of quality management, Apply a quality management approach in their organisation, product and process quality planning, process approach, continual improvement, Internal& external system, process, product or service and suppliers audits, new business quality management, Plan their future continual professional needs.

Services offered ...........

The focus of quality management is to ensure that organizations have the capability to meet consistently the needs of their customers and stakeholders. This breaks down into two main areas of activity:

Ø  To act as a mentor and coach at all levels of the organization by helping those within the organization and its supply chain to improve.

Ø  To educate and develop students within Campus and provide competent Quality personnel for all business and industry sectors.

With our expertise and experience we can cater for your requirements to help you achieve results from the training you receive.

The QSB offers public as well as customized in-company trainings to suit your company requirements in all key areas. Your choice will depend both on your current requirements and your pre-knowledge.

Become a QSB member to get discount up to 40% on all trainings, seminars and courses.

Quality Management & standardization

Problem solving tools and

techniques

System Auditing

Improvement and change

Cultural change programme

Qualification Courses

Our training courses help members for 360⁰ skill enhancement and help organisations enhance their key business processes.

q  Public & Customized In-Company Trainings

To do this effectively, members and Organizations need to establish a range of capabilities:


q  List of Public Trainings & Qualifications

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System Auditing Ø IMS (9001 QMS,EMS&OHSAS) Internal Auditor Ø IMS (TS16949,EMS&OHSAS) Internal Auditor Ø IMS (EMS&OHSAS) Internal Auditor Ø IATF recognized Lead Auditor Ø IRCA accredited Lead Auditor Ø VDA 6.3 Process Auditor Ø QMS Lead Auditor Course

Cultural change programme Ø TPM: Total Productive Maintenance Ø TQM: Total Quality Management Ø FMDS: Floor Management Development System Ø TPS: Toyota Production System

Qualification Courses: Ø Certificate in Quality Management Ø Certificate in Systems Management Ø Certificate in Assuring Service & Product Quality Ø Certificate in Managing Supply Chain Quality Ø Certificate in Quality Improvement for Business Ø Certificate in Quality Management Systems Audit Ø Diploma in Quality Management Ø PG Diploma in Total Quality Management

Visit to www.qsbasics.com.to know more about trainings, events, seminars and Course details.

Quality Management & standardization Ø Policy & Quality Objectives Deployment Ø Standards Awareness Programme: QMS, EMS & OHSAS, Energy Management, Lab Management, Information Security Management Ø Advance Product Quality Planning Ø Production Part Approval Process Ø Failure Modes and Effects Analysis Ø Measurement System Analysis Ø Statistical Process Control Ø Layered Process Audit – a process improvement tool Ø Supplier relationship management Ø Creating a customer-focused organisation Ø Developing the skills of the new quality manager

Problem solving tools and techniques Ø Global 8 Disciplines – a structured problem solving approach Ø DMAIC Approach (Six Sigma) Ø PDCA Approach Ø QC Tools Ø QC Circles-12 Steps of Problem solving

Improvement & Change Ø  Lean Manufacturing practices Ø  Change Management Ø  Lean Six Sigma


q  Lean Six Sigma – Training and Certification Programme for QSB members

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Six Sigma training for Senior Leadership Ø  Lean for leadership Training Ø  Lean Six Sigma Champions Training Six Sigma Skill Development Training Ø  Six Sigma Awareness Training Ø  Six Sigma Yellow Belt Training Ø  Six Sigma Green Belt Training Ø  Six Sigma Black Belt Training Ø  Lean Six Sigma Awareness Training Ø  Lean Six Sigma Green Belt Training Ø  Lean Six Sigma Black Belt Training Ø  Lean Practitioners Certification Training (Manufacturing) Ø  Lean Practitioners Certification Training (Service)


“Lean” means “without waste”

The term Six Sigma originated from terminology associated with manufacturing, specifically terms associated with statistical modeling of manufacturing processes. The maturity of a manufacturing process can be described by a sigma rating indicating its yield or the percentage of defect-free products it creates. A six sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defective parts/million), although this defect level corresponds to only a 4.5 sigma level. Motorola set a goal of "six sigma" for all of its manufacturing operations, and this goal became a by-word for the management and engineering practices used to achieve it.

“Lean Six Sigma” means “Solution of problems and elimination of wastages from entire Business model by using six sigma methodology.”

q  An Integrated Management System approach to Business Sustainability Integrated management systems Integrated means combined; putting all the internal management practices into one system but not as separate components. For these systems to be an integral part of the company's management system there have to be linkages so that the boundaries between processes are seamless. An integrated management system (IMS) is a management system which integrates all components of a business into one coherent system so as to enable the achievement of its purpose and mission. What should be integrated? Anything which has an effect on business results must be part of the management system. Therefore, an IMS should integrate all currently formalised systems focusing on quality, health and safety, environment, personnel, finance, security etc. What this means is that all the processes and the documents that describe them would be integrated. Corporate Policies and guidelines, various Customer Specific requirements, best practices, Regulatory and Statutory requirements (as applicable) also could be integrated. Why should management systems be integrated? There are several good reasons for integration, to: §  reduce duplication and therefore costs §  reduce risks and increase profitability §  balance conflicting objectives §  eliminate conflicting responsibilities and relationships §  diffuse the power system §  turn the focus onto business goals §  formalise informal systems §  harmonise and optimise practices §  create consistency §  improve communication §  facilitate training and development 8


A model of Integrated Business Management System Approach

Lean

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Educ

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100% Customer Satisfaction

ISO/TS 16949, ISO 14001, BS-OHSAS 18001, ISO 27001, ISO 50001

Achieve Business Goals v Management Review v IMS Auditor’s training and Evaluation v Awareness, training and communication v Internal audits planning and execution v Integrated System Certification

v Policy & objectives deployment v Planning v Implementation and Operation v Performance Assessment v Continual Improvement

Inte

grat

ion

of 5

Mai

n Pi

llars

Integration of ISO standards like:

Integration based on following 10 elements:

Integrated Business Management System 9


D •  Define the process which is user friendly with adequate

process controls for prevention and detection & prepare plans

E •  Educate the manpower

E •  Execution of plans

P •  Performance monitoring, analysis and corrective actions

DEEP- Approach for Sustainability*

Total No of employees: n = Workers + Staff


q  How to integrate and implement Automotive Core tools? Ø  APQP (Advance Product Quality Planning)

ü  Product APQP ü  Part APQP ü  APQP – Supplier end ü  Launch Readiness Audits ü  Initial Supply Control

Ø  FMEA (Failure Mode and Effect Analysis) ü  Design FMEA ü  Process FMEA ü  Tool FMEA

Ø  PPAP (Production Part Approval Process) ü  PSW Sign off ü  Ramp up activity ü  Feedback and corrective actions

Ø  SPC (Statistical Process Control) ü  Variable Charts ü  Attribute Charts

Ø  MSA (Measurement System Analysis) Attribute Study

ü  Effectiveness ü  Miss Rate ü  False Alarm Rate

Ø  MSA : Variable Study ü  Bias ü  Linearity ü  Stability ü  Repeatability ü  Reproducibility

DFMEA

PFMEA & Process Flow

Chart, Process Mapping

Control plans including SPC and MSA plans

PPAP Documents - Work Instruction/ Standard Operating

Procedures/ Part Inspection standards/ SPC and MSA reports

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5S M

anag

emen

t • SERI

• SEITON

• SEISO

• SEIKETSU

• SHITSUKE

• KAIZEN Visu

aliz

atio

n • Shop floor Layout

• Visualization of 3 moving items- Physical goods, standardized work , Management Information – KPI’s

•  Color coding •  Andon System

•  Visual Controls

•  Identification of abnormal things

Elim

inat

e / R

educ

e N

VA’s

•  VSM •  OEE •  Layout •  Multi

machine manning

•  Line Balancing

•  Quick Change Over – SMED

•  Lead time reduction

•  Inventory Turn Over ratio

•  Human Error prevention

•  SPF •  Low cost

Automation

Tota

l Pro

duct

ive

Mai

nten

ance

•  Autonomous Maintenance (Jishu Hozon)

• Preventive Maintenance

• Spare parts management

• Break Down Management

• Predictive maintenance

•  Individual Improvement (Kobetsu Kaizen)

•  Quality Maintenance

•  Education and training

•  Safety, health & environment

•  Development Management

•  Office TPM Q

uick

Res

pons

e Te

am •  Multi

skilling

•  Andon

System

•  Trouble

shooting

analysis

KA

NB

AN

•  Customer

order driven

production

scheduling

•  Pull system-

Make to order

•  JIT- Inventory

management

•  Multi skilling

q  How to integrate & implement Lean Manufacturing Practices?

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Our Business Partners are: Ø  Automobile Industries & their suppliers Ø  Aerospace Ø  Chemical, Oil & Gas Industries Ø  Consumer products and retail Ø  Defence Sector Ø  Education Sector Ø  Electronics industries Ø  Food Industries

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Why to choose QSB ?

ü  A premier Quality Institution in India collaboration with QV system Inc. Japan. ü  We provide most relevant training programmes to our valued members. ü  Our qualification courses have been designed based on present industry requirements. ü  We have equal development opportunity for freshers as well as experienced individuals. ü  Job placement (mostly in Japanese MNC’s) of freshers, who had successfully completed any QSB

Qualification courses ü  QSB members earn 22% more than non-QSB members ü  We develop Customized Solutions with high degree of simplicity. ü  We make use of well proven methodologies that increase business growth rate. ü  We have a team of trainers with rich experience from respective Industries to maintain your

competitive edge in the business. ü  QSB members get professional recognition.

Ø  Farm and mining equipment Ø  Healthcare & Medical device Ø  IT & Software Industries Ø  Infrastructure Ø  Manufacturing Industries Ø  Power & Energy Ø  Real Estate Ø  Telecommunication Industries


QSB Membership Guidelines

QSB membership is a way of visibly demonstrating your competence and ability to positively impact an organization's capability to deliver quality and to identify and deliver improvement. Membership is your commitment to the profession and its professional standards. It enhances your status with colleagues and employers alike and helps you stay ahead of the competition in your career. Individual Membership Category:

Dynamic Member: Anyone who are interested to become a quality professional can apply for membership in QSB. Membership fees for Dynamic member is INR 3,000 for Associate grade, for other grades INR 5,000. Benefits for Dynamic Members: ü  He/she will get QSB membership card with Photo Identity ü  Will get 20% discount in fee of all Public trainings, seminars and certification courses ü  Will get QSB Quarterly e-magazines in your in-box ü  Will get e-training material and e-books on Quality, systems, auditing, innovation and latest quality trends ü  Will get information on newly published National and International standards ü  Will be invited in Annual seminars (no charges to attend annual seminar) ü  Will get recognition during annual seminar for best performance and contribution in present Organization If you encourage your colleagues to become members at least 10 with in a year, then your annual subscription charges for next year will be waived off.

Diligent Member: Dynamic Members will be promoted as Diligent members if they encourage their colleagues to become the QSB members and get success to add 50 Dynamic members.

Benefits for Diligent Members: (In addition to Dynamic Members) ü  Will get up to 30% discount in fee of all Public trainings, seminars and certification courses ü  First 100 Diligent member’s information will be updated on QSB website ü  Will be invited in Experience sharing programme with Quality professionals from Japan & India

Life time Member : Dynamic / Diligent Members will be promoted as Life time members if they encourage their colleagues to become the QSB Dynamic members and get success to add 100 Dynamic members.

Benefits for Life time Members: (In addition to Diligent Members) ü  Will get QSB membership card for life time (no renewable charges) ü  Will get chance to share their views during QSB seminars ü  Will get chance to visit Organizations who are practicing best quality and manufacturing principles in India as well as in Japan ü  Will get up to 40% discount in fee of all Public trainings, events, seminars and certification courses


Membership Grades: Associate –QSB (AQSB): For those who have an active interest, are considering a career in quality management, and for those studying for a qualification in quality, such as the QSB Certificate or Diploma. Practitioner – QSB (PQSB): For those actively practicing quality as part of their job role or those specializing in specific aspects of quality, such as inspection, quality control, quality assurance, systems management, audit, business improvement, supplier quality management, certification, service quality, regulatory compliance. Member QSB - Chartered Quality Professional (MQSB-CQP): For those professionals who have quality as a key discipline or as the focus of their work. The Member (MQSB) grade will recognize your professional competence and put you on equal terms with other chartered professionals, increasing your status and potential for career progression. Fellow QSB - Chartered Quality Professional (FQSB-CQP): This is the highest grade of professional recognition offered by the QSB. Fellow (FQSB) is a chartered grade providing you with Chartered Quality Professional (CQP) status, and signifies that you have demonstrated a substantial achievement or made a personal contribution to furthering the profession of quality.

Company Membership What is QSB Company Membership? QSB Company Membership provides your organisation with a framework to develop knowledge of quality approaches, tools and techniques at all levels, whether your aim is to develop people into Quality Professionals in order to lead quality, or simply a wish to ensure all staff have an awareness of the part that quality plays in your business processes. What QSB membership can do for you and your business: ü Support strategic objectives with the aid of clear processes ü Drive innovation in your business ü Gives you instant access to the latest industry reports and thinking ü Encourage staff development QSB Company Membership benefits: ü  Individual Membership discounts @ 20% ü  Provide Customized in-company trainings @ 20% discount ü  The QSB e-Library ü  A quarterly e-newsletter - Providing up to date information and news for Company Members. Membership fee: Annual subscription for Company Membership is INR 15,000 +Service taxes. Membership application form could be down loaded from website www.qsbasics.com- Membership Application form

QSB Membership Guidelines

QSB

Quality System Basics

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Its our pleasure to answer your queries. Please write us on [email protected]

or contact us on 0120 4155443, +91 8800425599 & 9999429052 For more information, visit us on: www.qsbasics.com

You tube: QS Basics

“Choose us for Sustainability”


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