Title: Assignment # 5
Author: Kanwal Rafiq
Class: IE673
Date: July 29, 2009
ELearning Pack ID: IE673-Sum-2009-28-07
Kanwal Rafiq has performed all the work for this assignment.
Table of Content
Introduction and Objective of Project
The objective of this project is to integrate RFID (Radio Frequency Identification) to KERVS’ processes. RFID will be used to conform more closely to the customers’ requirements that were identified in the CIMpgr, CORA spreadsheet, and the PFRA generated in the previous projects. In addition, to market our company, a quality focused press release will be written which will be done by implementing the ISO 9001:2008 quality principles. Lastly, an audit will be performed to ensure KERVS is in fact following the ISO 9001:2008 principles throughout its processes.
Methodologies Applied
RFID (Radio Frequency Identification) is the use of an object incorporated into a product for the purpose of identification and tracking by use of radio waves. RFIDs are used with high powered scanners that receive the information from radio frequency waves. It is a method of storing information of a specific product on a special tag that contains information such as the size, weight, part number and other valuable information. RFIDs are very useful because products do not need to be scanned on an individual basis. This not only ensures a faster way to track one’s inventory but it also a more accountable and efficient method.
There are eight principles on which quality management standards are based on. These eight principles are known at the ISO 9001:2008 quality principles. Utilizing the ISO TQM standard principles helps implement a quality system that offers
The eight ISO9001:2008 quality principles are as follows
1. Customer Focus – Organizations should meet their customers’ requirements as they depend on them.
2. Leadership – Leaders should create and maintain an environment where people can work towards the organization’s interest.
3. Involvement of people – People’s full involvement allows their abilities to be used in the organization’s best interest.
4. Process approach – Activities should be managed as a process to ensure the best results.
5. Systems approach to management – In achieving the organization’s objectives, identifying and understanding the processes as a system are crucial to its success.
6. Continual Improvement – The organization should strive for continuous improvement.
7. Factual approaches to design – Decisions are made more effectively when based off of analytical data.
8. Mutually beneficial supplier relationships – A mutual beneficial relationship enhances the value of the product at hand.
The Main Body of the Project
Integration of RFID technology in CIMpgr, CORA, and PFRA
The CIMpgr method was revisited in this project in the attempt to integrate the new RFID technology that our customers’ require. Along with integrating the RFID, KERVS also reworked its process layers by incorporating all the methods learned in Dr. Ranky’s TQM class. There are 3 layers in KERVS’ process – layer 0, layer 1, and layer 2. (For a word document of the layers click here.)Layer 0 gives a brief description of the process, whereas layer 1 and layer 2 go more into detail about what each process entails. The four main processes for KERVS are design, manufacturing, inspection/testing, and marketing.
The new RFID technology and the other TQM methods were added to layer 0. As can be seen in KERVS layer 0 of the CIMpgr model, RFID technology and the TQM methods such as CORA, process control charts, and PFRA were added as resources we used to provide a better quality product to our customers. In layer 1, for the design process, A1, the RFID system was used as a resource to come up with the design. Also, CORA was implemented during that step of the process to get an idea of customers’ requirements to better help us in implementing a good design that will satisfy our customers’ needs. Again in layer 1, a RFID team was used in our manufacturing process to enhance our RFID tags. Before doing so, the PFRA was used to identify all the risks associated with the different processes as well as in our RFID technology. This helped us identify our areas where improvement was needed and corrective actions were taken to mitigate the risks. In the inspection and testing process, we utilized a radio frequency testing machine to ensure our RFID tags were working correctly and would not fail. In layer 2 of KERVS’ process flow, CORA was utilized in the benchmarking process to help us better identify how well we were satisfying our customers’ needs as opposed to our competitors. Also, RFID technology was introduced to the public as it is a beneficial tool that most customers require. This was done to attract the general public and show how we are advancing into better technology.
Along with the CIMpgr method, our CORA table was revisited to integrate RFID. CORA is aimed at minimizing dissatisfaction, financial loss due to inadequate requirements and poor communication between customers and providers. This tool is integrated into 4 modules – user requirements, engineering solutions, parameter calculations and benchmarking. The main goal of CORA is to study the customer and the future user, and then collect, analyze, and reason over customer requirements. The CORA chart previously done helped KERVS realize where it needs to improve to be a company of choice amongst its competitors.
A new customer requirement was added to this CORA method which was the RFID tags. The Absolute Importance Rating (AIR) was calculated for these RFID tags and it was found to be 210 which is extremely high as compared to the other engineering solutions. Therefore, it is very important that KERVS consider investing in the RFID tags. Using the RFID tags will help improve our ratings of some of the customer requirements. For example, availability of valve specifications and operating information will improve by using the RFIDs since we can incorporate that information into the RFID database. Delivery schedules can be better met by utilizing the tags which will help identify the products that must go out for shipment in a certain week, day, etc.
Lastly, the RFID technology was integrated into our PFRA method as well. PFRA is a team oriented problem solving method which concentrates on minimizing dissatisfaction and financial loss for process related failure risks. PFRA is applied during the planning stages of a process and any changes are documented on a regular basis. PRFA tackles negative quality issues and is typically concerned with any events that can cause any process to fail.
Being that RFID tags are going to be implemented into KERVS’ process, it was very important to analyze the risks associated with using them. RFID tags were added to the previously constructed PFRA. The severity rating, detection rating and occurrence rating for the RFID tags were calculated to be 9, 5, and 5 respectively with a RPN value of 225. This value is extremely high and needs immediate attention to correct the issue. The recommended corrective action was to come up with a better radio transmitter design. If this issue is not mitigated, it will cause failure for our tracking system and the correct product information will not provided resulting in unhappy customers which will eventually lead to loss of business.
The risks of all the other 5 processes, check for valve integrity (i.e. cracks and thin wall), examine material composition of valve (should contain from 3.75% to 4.25% Chromium), examine valve for heat resistance, check pressure setting for valve and check integrity of packaging depends on the effectiveness of the RFID tags. Therefore, it is very important that this issue is remedied. This should be the first process that should be corrected because once we have a better design for the RFID tags, it will reduce if not eliminate the risks of the other 5 process.
Collaborating Companies
KERVS will continue to maintain good relationships with its collaborating companies so it can improve upon the quality with help from them being that they are a new set of eyes that can help us identify any areas of improvement. Komat’su will continue to provide the hybrid forklift for KERVS so that we are continuing our green initiative and continue to be economically friendly. Also, using these forklift will ensure KERVS warehouse employees are taking the valves off the shelves with more care so the packaging is not damaged. Bogen will supply Student Filmmakers with the imaging products needed to create our KERVS’ advertisement. Not only do we make the quality valves but we must advertise them to attract more business. We will make sure our new RFID technology is advertised widely to inform our customers of our success. This will help enhance on KERVS’ image in the valve manufacturing field. Also, more up to date manufacturing machines can be discovered in the Student Filmmakers magazines. FB Systems will continue to provide the products and services needed to maintain the safety aspect of our products as safety is our number one priority for ourselves and our customers.
Press Release: KERVS Implementation of the ISO 9001:2008 principles
Customer Focus – KERVS is very keen on satisfying its customers as they are a huge factor in the company’s success. Using the results from our CORA method, we can get an idea of what is important to our customers. KERVS will also send out surveys to our customers after having sold our valves to get some feedback on the quality of the product and the overall service. This will help us improve upon our process ensuring our customers’ demands are met and they are happy with the end product.
Leadership - In the success of a company, it is very crucial that important information is communicated down from the highest level down to the workers. This means of communication helps close any barriers or misunderstandings between the managers and the workers. KERVS will hold daily POD (Plan of the Day) meetings every morning at the start of the work day. Doing so will ensure, any new ideas or information has been communicated before work commences. This also allows for any issues to be brought up and addressed.
Involvement of People – People are the core of a company as they are the ones who have to believe in the company’s vision. They are also our source of troubleshooting to ensure we have a quality product to provide our customers with. Our company has a very diverse group of individuals with diverse ideas that KERVS can definitely benefit from. KERVS has several different committees that it encourages employees to be a part of to share any ideas that will benefit the company. An example of some of these committees would be Tool Committee, Safety Committee, R&D Committee, etc. Having our employees partake in a specific committee allows them to voice their opinions, ideas, and concerns to better the company.
Process Approach – To ensure the best results, all activities should be managed as a single process. KERVS did just that by utilizing the CIMpgr method to break its processes down into layers.
Systems Approach to Management – KERVS will focus on identifying, understanding and managing the specific processes required to produce the desired product. KERVS management will be involved with controlling all of the processes as a system.
Continuous Improvement – Continuous improvement is vital to the success of the company not just for the present but mostly for the future of the company. KERVS will train its employees and support continuous research to improve upon its products. The PFRA will be used to help identify areas that need improvement.
Factual Approaches to Design – KERVS will make all of its decisions based on actual data gathered from research and testing. Control charts and PFRA will be analyzed to help make decisions.
Mutually Beneficial Supplier Relationships – A mutually beneficial relationship with other suppliers enhances the value of the product being produced by having a fresh set of ideas from people other than your own company. It also helps build a good rapport with other business partners in the industry. KERVS will continue to maintain a good relationship with its collaborating companies by sharing knowledge and experience.
Application of Learned Methods
The methods learned in this class has helped KERVS analyze its overall process and helped improve the quality of its product. This class taught KERVS the importance of TQM and the quality standards that are necessary to make a successful company. Below are some of the methods learned and how they were implemented within KERVS.
Results of the Audit
Purchase Controls – KERVS is supported by its collaborating companies as well as other suppliers. KERVS is very picky when it comes to picking a supplier for its products. For one, all of our suppliers must abide by the ISO 9001:2008 principles. KERVS believes in products of the highest quality and will not purchase anything from its suppliers that is cheap and will compromise the quality of its products. The delivery of the products is also an important factor when dealing with different suppliers ensuring parts are delivered in good condition and on time.
Audits – To ensure the highest quality of products received from its suppliers, KERVS performs on site audits annually of its potential suppliers. After the audit is completed, the results are shared with the potential supplier. If the results are sufficient, a contract is signed with the supplier to provide KERVS with the products it needs for its business. However, if the results are not good, KERVS will provide correct actions the supplier must take if they wish to be a supplier for us.
Incoming Inventory – KERVS takes random samples for the products coming into the warehouse from its suppliers. Our quality assurance team will inspect these samples and if the inspection fails, the supplier will be contacted about the problem. If the problem persists, another audit will be performed on site. We will remind the supplier about the quality agreement we came up with at our initial audit. If the supplier cannot abide by the agreement the contract will be terminated and we will go elsewhere. KERVS will not compromise the quality of its products by any means.
Non-Conformance – All products that do not conform to KERVS quality standards will be sent back to the suppliers. In addition, KERVS will demand an investigation be done to determine the cause of the nonconformity to prevent this problem from occurring again.
Traceability – KERVS uses RFID technology to be able to trace and track every part in its warehouse. Using this tracking system will reduce human error and improve the efficiency of inventory tracking.
Controls of Production Document – All of KERVS’ production documents are kept in an electronic database for ease of retaining information and being able to trace history of the specific documents. Our database management team ensures the documents are available and periodically updated.
Controls of Production Equipment – KERVS will ensure all of our equipment has RFID tags issued. This will help us track which piece of equipment is due for maintenance and other such important information. This will help us keep our production equipment in good condition thereby enhancing machine reliability.
CAPA or PAR/CAR – KERVS makes every effort to identify and solve any problems that occur during the manufacturing and production stages. The Process Failure Risk Analysis (PFRA) is also performed for areas that might cause problems in the near future. Once the problem areas are identified, KERVS will take corrective actions to eliminate the problems.
Product Realization – KERVS utilizes the CORA method to ensure all of its customers’ requirements are satisfied in the end product. The CORA tool helps us check our product before it leaves our warehouse for the customer. We also send a feedback survey with the product so that we can improve our product based on their feedback.
Customer Service – KERVS has a 24 hours 7 days a week customer service center to help assist its customers with any questions concerns or complaints. All complaints are filed in our database which helps us track how well we are doing in satisfying our customers.
Customer Satisfaction – KERVS sends out surveys to it customers to find out how well we are doing. This also helps us improve on anything to continuously satisfy our customers. Complaints are handled with the highest priority ensuring we have done something about the complaint.
Recalls – KERVS handled its recalls with the highest priority. In the case that a huge volume of recalls occur, KERVS will inform its customers of the recalls and have the product replaced at no cost. Though this will cost us money, we care about our customers and always put them first. KERVS will also conduct an investigation on the reasons the part failed and update their PFRA with the findings from the investigation.
Continuous Improvement – With all the technological advancements going on, KERVS realizes that is it very important for us to continually improve on our process for the future of our company. We focus on research to improve the overall process to benefit our company. Our management team also ensures its employees are fully trained for their own development needs which in turn will benefit the company.
Eco-Friendliness – In an effort to protect the environment, KERVS partakes in several green program initiatives. We have implemented a recycling program encouraging its employees to recycle and educate others on its importance. Also, meeting are held via projector screens eliminating paper. All company vehicles are hybrid type a well.
Summary
From this project, the importance of following the TQM ISO 9001:2008 principles is clearly understood. In this specific assignment, RFID tags were implemented in the previously completed assignments. By use of these tags, KERVS was able to improve upon the quality of its products. The RFID technology was utilized in the CIMpgr, CORA, and the PFRA to better analyze the process with the final customer requirement added in. From the CORA method, we were able to see that this customer requirement was very important and that it is definitely worth investing in. From the PFRA, we saw that there was a huge RPN value for the RFID tags, which required immediate corrective action. Finally, an audit was performed on KERVS’ overall process where all the learned methods were applied.
Further Work Needed
Continuous improvement is necessary to survive in this challenging economy. In keeping with this continuous improvement plan, KERVS will continue to conduct research to find better and more efficient ways to develop their products trying to cut costs while increasing quality. We will also work to ensure we are eco-friendly in every aspect possible.
Bibliography
Ranky, Paul. “Ranky-eBook-IntroTQM.” Chapter 8.
Ranky, Paul. “Ranky-eBook-IntroTQM.” Chapter 9.
Ranky, Paul. “Ranky-eBook-IntroTQM.” Chapter 20.