1st Edition

Quality Management Theory and Application

By Peter D. Mauch Copyright 2009
    176 Pages 32 B/W Illustrations
    by CRC Press

    171 Pages 32 B/W Illustrations
    by CRC Press

    In the past, when goods and services were simpler, measurement of quality was self-evident. As business became more complicated, so too did the implementation of quality management and our ability to measure it. Ultimately, the practice of quality strayed from being a business practice to become much more of an engineering discipline producing plenty of data, but little actual improvement.

    In Quality Management: Theory and Application, highly respected quality management specialist Peter Mauch shows you how to set up a Quality Management System (QMS) that will stay aligned with your business goals. Using examples from actual situations that can be readily applied in any industrial situation, these pages will show you how to:

    • Plan for quality by setting objectives and metrics, and creating effective flexible blueprints, and procedures
    • Get staff involved by understanding how to motivate and train them
    • Establish responsibility and accountability across your entire organization
    • Create the right reporting mechanisms and learn how to analyze them
    • Understand the value and particulars of certification

    QMS is a performance-reporting system designed to accumulate and report data useful for the achievement of management’s objectives. Combining the technical aspects of quality engineering with successful business management practices, this book will teach you that quality is an ongoing practice, and that it must be implemented throughout an organization rather than stand as the responsibility of one department. Ultimately, through this system, you will align individual departments to continuously maximize quality throughout your entire organization.

    Organizing for Quality
    Objectives
    Terminology
    Introduction
    Categorizing Duties
    Leadership
    Product or Service Producing
    Support
    Incongruence
    Breaking Categories into Classifications
    Leadership Classifications
    Product- or Service-Producing Classifications
    Support Classifications
    Basic Functional Structure
    Quality Function Considerations
    Authority, Accountability, and Responsibility
    Authority Principles
    Revise and Adjust
    Communication
    Summary
    Review Questions

    Planning for Quality
    Objectives
    Terminology
    Introduction
    Business Quality Planning
    Elements of an Effective Quality System
    Marketing
    Setting Objectives
    Long- and Short-Range Objectives
    Setting Business Metrics
    Process Quality Planning
    General Information
    Details
    Failure Modes
    Control
    Project Planning
    General Information
    Status Reporting
    Detail
    Product Quality Planning
    General Information
    Detail
    Product Verification and Validation Planning
    Responsibility and Interfaces
    Information Accessibility
    Files and Records
    Validation Facilities
    Validation Personnel
    Validation Procedures
    Scheduling and Revising Validation Plans
    Policies, Procedures, and Objectives
    Policies
    Procedures and Rules
    Forms and Records
    Blueprints (Product Specifications)
    Process Flowcharting
    Standardization of Symbols
    Normal Logic Flow
    Process Flow
    Communication
    Summary
    Review Questions

    Controlling for Quality
    Objectives
    Terminology
    Introduction
    Long-Range Objectives
    Short-Range Objectives
    A Cascade Approach
    Concerns of Control
    Written Reports
    Preparing Reports
    Correcting for Deviations
    Importance of Value
    Basic Concepts
    Organizational Responsibility
    The Role of Quality Management
    Introduction to Quality-Reporting Basics
    The Business Quality Report
    Underlying Concepts
    Activity Reporting
    Journalizing Procedure
    Posting
    Product Performance Reporting
    Analysis
    Ranked Order Analysis
    Fishbone Diagram
    Controlling Nonconformance Identification
    Identification during Work
    Completion of Work
    Inspection
    Identification of Nonconforming Product
    Segregation
    Short-Run Production
    Long-Run Production
    Risk
    Disposition
    Responsibilities for Disposition
    Corrective and Preventive Action (CAPA) Methodology
    Immediate Action Required
    Magnitude of the Nonconformity
    CAPA Methodology
    Summary
    Review Questions

    Staffing for Quality
    Objectives
    Terminology
    Forecasting Human Resources Needs
    Job Descriptions
    Job Analysis
    Methods
    Results
    Position Requirement
    Education and Training
    Systems of Formal Education
    Primary Education
    Secondary Education
    Higher Education
    Adult Education
    Alternative Education
    Training
    Training Records
    Summary
    Review Questions

    Motivating for Quality
    Objectives
    Terminology
    Lead, Coach, and Guide
    Leadership Styles
    Autocratic
    Paternalistic
    Democratic
    Laissez-Faire
    Rewards Based upon Performance
    Praise and Censure Fairly
    Performance Appraisals
    Provide a Motivating Environment
    Deficiency Needs
    Physiological Needs
    Safety Needs
    Social Needs
    Esteem Needs
    Self-Actualization
    Summary
    Review Questions

    Special Topics in Quality
    Overview of Statistical Methods
    History
    Overview
    Statistical Methods
    Experimental and Observational Studies
    Levels of Measurement
    History of SPC
    General
    Risk Analysis
    Risk Analysis and the Risk Workshop
    Facilitated Risk Analysis Process
    Reliability Engineering
    Reliability Theory
    Reliability Program Plan
    Reliability Requirements
    System Reliability Parameters
    Reliability Modeling
    Reliability Test Requirements
    Requirements for Reliability Tasks
    Design for Reliability
    Fault Tree Diagrams
    Reliability Testing
    A Reliability Sequential Test Plan
    Accelerated Testing
    Software Reliability
    Reliability Operational Assessment 1
    Reliability Organizations
    Certification
    Reliability Engineering Education 1
    Systems Analysis. 1
    Characterization of Systems. 1
    LTI Systems
    Auditing
    Audit Planning and Scheduling 1
    Auditor Education and Training 1
    Audit Initiation 1
    Audit Scope 1
    Audit Objective 1
    Frequency and Timing 1
    Long-Term Planning 1
    Pre-Audit Review of System 1
    Working Papers 1
    Result 1
    Sampling Plans 1
    Audit Implementation Steps
    Notification to Auditee
    Opening Meeting
    Information, Verification, and Evaluation
    Audit Observations
    Audit Supervision
    Audit Follow-Up
    Preparation of the Report
    Content of the Report
    Reporting the Audit
    Review and Distribution
    Audit Completion
    Record Retention
    Cost of Quality
    Origins 1

    Appendix A: Business Quality Plan 1
    Appendix B: Process Quality Plan 1
    Appendix C: Product Quality Plan. 1

    Biography

    Peter D. Mauch is affiliated with Control Solutions, Inc., in Aurora, Illinois.