tqm-6 sigma

8/3/2019 TQM-6 sigma

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Oleh:Prof Dr Ir T. Yuri ZagloelKetua BKSTI/ Ketua Departemen Teknik Industri UI


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Total quality management didefinisikan sbg mengelolakeseluruhan organisasi, sehinggasemua dimensions product danservice yang penting bagicustomer, menjadi istimewa.


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Total Quality Management

CustomerFocus

ProcessImprovement

TotalInvolvement

Leadership

Education and Training Supportive structureCommunications Reward and recognitionMeasurement

ContinuousImprovement Objective

Principles

Elements


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TQMs Principles

1. Customer defines quality2. Management provides leadership for quality3. Quality is all levels responsibility4. It needs continuous quality improvement5. Quality problems are solved by employees and

management6. Problem solving for no. 4 is based on statistics7. Training and education are the basis for no. 4


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6

ORGANIZING TO QUALITY

Definisi Kualitas:- Fitness for purpose and customer satisfaction- Conformance to requirement- Care

Artinya:Kualitas dibentuk oleh pelanggan, dan produk disain dan dibuat untuk dijualdengan maksud untuk memuaskan pelangganKualitas permintaan pelanggan di interprestasikan oleh product engineer yang membentuk spesifikasi-spesifikasi sekaligus menetapkan toleransi-toleransi

Rekayasa proses ( Proses Engineering ) bertanggung jawab dalamembentukan spesifikasi dalam operasi dan juga mendisain dan/atau membeliperalatan yang akan mengikuti spesifikasi produk.Kegiatan manufaktur menggunakan alat-alat tersebut dalam memproduksiprodukPengendalian Kualitas menjamin produk yang dibuat mengikuti spesifikasiyang diminta pelanggan

Unit Pelayanan PENGEMBANGAN INDUSTRI Departemen Teknik Industri - FTUI


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Struktur Organisasi pengendalian Kualitas(menuju TQM )

Struktur organisasi pengendalian kualitas berubah darihanya mendeteksi kualitas dibawah standar menjadifungsi pencegahan ( preventive programs )

Ciri Ciri organisasi sadar kualitas1. Ada kegiatan inspeksi pada penerimaan barang, proses

dan perakitan akhir2. Dapat menentukan dengan tegas rejected part/defected

part

3. Sistem informasi termasuk data recording mengenaikualitas yang ditolak dan diterima sudah memadai4. Sudah ada SQC ( statistical QC )5. Ada standarisasi inspeksi, pergudangan dan aktifitas

pemerataan standar ukuran ( gage measurement

maitenance )Unit Pelayanan PENGEMBANGAN INDUSTRI Departemen Teknik Industri - FTUI


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Beberapa tips untuk mengorganisasikan kualitas

Ciri-ciri Toyota philosophy/Japanese philosophy1. Invest in rationalisation2. Invest heavily in employee training and education3. Commit to quality

4. Export oriented5. Having a system for controlling the supplier6. Prevention rather than detection7. Worker can stop the line ( as long as it takes him to perform

his job properly )

Thingking Quality1. Product design2. Worker training3. Quality circle4. Screening of materials and suppliers


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1. Didik kembali para manager/supervisor2. Hubungan yang baik dengan supplier3. Top management membuat

commitment yang berjangka panjangkemudian diturunkan pada leveloperasional

4. Hindari beban terlalu berat padaproduksi5. Aplikasi SQC6. Analisa biaya kualitas7. A likasi metode en uran an stock


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Design quality : Nilai yang melekat(Inherent value) dari product

Dimensinya termasuk: Performance,Features, Reliability, Durability,Serviceability, Response, Aesthetics, andReputation.

Conformance quality : Derajat kesesuaianspesifikasi design dari suatu product atauservice.


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External Failure Costs

Appraisal Costs

Prevention Costs

Internal FailureCosts

Costs of Quality


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Conformance Cost Non Conformance Cost

Prevention Costs

Quality planning Process control

Process planning

New product review

Quality audits

Supplier quality evaluation

Training & Education

Appraisal Costs Incoming inspection and test

In process inspection and test

Final inspection and test

Product Quality audit

Maintaining accuracy of test equipment

Evaluation stocks

Internal Failure Costs

Scrap Rework

Failure analysis

Scrap and rework supplier

100% sorting inspection

Reinspection, retest

Avoidable process losses Downgrading

External Failure Costs Warranty changes

Complaint adjustment

Returned material

Allowances

Conformance Cost Non Conformance Cost

Prevention Costs

Quality planning Process control

Process planning

New product review

Quality audits

Supplier quality evaluation

Training & Education

Appraisal Costs Incoming inspection and test

In process inspection and test

Final inspection and test

Product Quality audit

Maintaining accuracy of test equipment

Evaluation stocks

Internal Failure Costs

Scrap Rework

Failure analysis

Scrap and rework supplier

100% sorting inspection

Reinspection, retest

Avoidable process losses Downgrading

External Failure Costs Warranty changes

Complaint adjustment

Returned material

Allowances

Cost of Quality


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Grafik Cost of Quality

0 100

Quality of conformance, %

C o s t p e r g o o

d u n i t

o f

p r o

d u c

t

Total quality costs

Failure costs

Cost of appraisal plusprevention

8

8

Traditional Model of Quality Costs


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Kegunaan Cost of Quality

1. Mengidentifikasi peluang laba2. Untuk pengambilan keputusan investasi3. Menekan biaya pembelian atau yang berkaitan

dengan pemasok4. Mengidentifikasi waste5. Mengidentifikasi metode yang berlebih6. Mengidentifikasi masalah-masalah mutu

7. Alat analisa vital few dan trivial many (Paretoanalysis)

8. Alat untuk mengukur Quality Improvement


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3X-UTLor

3LTLXmin=C pk

Shifts in Process Mean

Capability Index showshow well parts beingproduced fit into designlimit specifications.

Capability Index showshow well parts beingproduced fit into designlimit specifications.

As a production processproduces items smallshifts in equipment orsystems can causedifferences inproduction performancefrom differing samples.

As a production processproduces items smallshifts in equipment orsystems can cause

differences inproduction performancefrom differing samples.


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Cp = Tolerance Spread/ Natural Spread>= 1.33 (normal)

Cp = 2 (excellent)= 0,002/1000 000 = Defect per millionopportunity(DPMO)= 0,002 (ideal)

So, Motorola six sigma states with 1,5 sigmaShift from ideal condition produces DPMO=3,4


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Philosophy dan methods yangperusahaan pakai untuk menghilangkandefects dari products dan processesMengurangi variasi process yangmengarah pada product defectsNama six sigma merujuk pada variasiyang terjadi diantara plus atau minustiga standard deviasi dari output process

3


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Six Sigma membuat managerdapat menjelaskan processperformance menggunakan

common metric: Defects PerMillion Opportunities (DPMO)1,000,000x

unitsof No.xunit

pererrorforiesopportunit of Number

defectsof Number= DPMO


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Example of Defects Per MillionOpportunities (DPMO) calculation.Suppose we observe 200 lettersdelivered incorrectly to the wrongaddresses in a small city during asingle day when a total of 200,000letters were delivered. What is the

DPMO in this situation?

Example of Defects Per MillionOpportunities (DPMO) calculation.Suppose we observe 200 lettersdelivered incorrectly to the wrongaddresses in a small city during asingle day when a total of 200,000letters were delivered. What is theDPMO in this situation?

[ ]000,1== 1,000,000x

200,000x1

200 DPMO

So, for every onemillion lettersdelivered thiscitys postalmanagers canexpect to have1,000 lettersincorrectly sentto the wrongaddress.

So, for every onemillion lettersdelivered thiscitys postalmanagers canexpect to have1,000 lettersincorrectly sentto the wrongaddress.

Cost of Quality: Apa hubungan DPMO dengan over-time employment dalam mengkoreksi kesalahan?

Cost of Quality: Apa hubungan DPMO dengan over-time employment dalam mengkoreksi kesalahan?


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Define, Measure, Analyze,Improve, and Control(DMAIC)

Di kembangkan oleh GeneralElectric untuk focusing efforton quality yg menggunakanmethodological approach

Focus keseluruhanmethodology adalahmengerti dan mencapai whatthe customer wantsDMAIC terdiri dari fivesteps.


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1. Define (D)

2. Measure (M)

3. Analyze (A)

4. Improve (I)

5. Control (C)

Customers and their priorities

Process and its performance

Causes of defects

Remove causes of defects

Maintain quality


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No ,Continue

MaterialReceived

fromSupplier

InspectMaterial for

DefectsDefectsfound?

Return toSupplier

for Credit

Yes

Can be used tofind qualityproblems

Can be used tofind qualityproblems


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Can be used to identifywhen equipment or processes are notbehaving according to

specifications

Can be used to identifywhen equipment or processes are notbehaving according tospecifications

0.440.460.48

0.50.520.540.560.58

1 2 3 4 5 6 7 8 9 10 11 12Time (Hours)

D i a m e

t e r


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Can be usedto find when80% of theproblemsmay beattributed to20% of thecauses

Can be usedto find when80% of the

problemsmay beattributed to20% of the

causes

Assy.Instruct .

F r e q u e n c y

Design Purch. Training

Other

80%


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Billing Errors

Wrong Account

Wrong Amount

A/R Errors

Wrong Account

Wrong Amount

Monday

Can be used to keep track of defects or used to make surepeople collect data in a correctmanner

Can be used to keep track of defects or used to make surepeople collect data in a correctmanner


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N u m

b e r o

f L o

t s

Data RangesDefects

in lot0 1 2 3 4

Can be used to identify the frequency of qualitydefect occurrence and display qualityperformance

Can be used to identify the frequency of qualitydefect occurrence and display qualityperformance


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Effect

ManMachine

MaterialMethod

Environment

Possible causes:Possible causes: The resultsor effect

The resultsor effect

Can be used to systematically track backwards tofind a possible cause of a quality problem (or effect)

Can be used to systematically track backwards tofind a possible cause of a quality problem (or effect)


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Can be used to monitor ongoing production processquality and quality conformance to stated standards of quality

Can be used to monitor ongoing production processquality and quality conformance to stated standards of quality

970

980

990

1000

1010

1020

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

LCL

UCL


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Opportunity Flow Diagram digunakan secara grafik untuk memisahkan aktifitas2 yangmenambah dari yang tidak menambah nilai bagi produk.Failure Mode and Effect Analysis (FMEA) adalah suatu structured

approach untuk identify,estimate, prioritize, and evaluateresiko possible failures padasetiap stage dalam process

Design of Experiments (DOE)


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1. Executive leaders harusmenjadi champion dariprocess improvement

2. Diperlukan Corporation-widetraining dalam Six Sigmaconcepts and tools

3. Diperlukan continuousreinforcement dan rewards

tqm-6 sigma

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