Quality costs analysis: case study in the automotive industry

Dissertação de mestrado integrado em Engenharia e Gestão Industrial

Measuring Cost of Poor Quality in Industrial Electronics

Quality is not only free but it can be a profit maker. Every dollar that is not spent on doing things wrong becomes a dollar right on the bottom line. The main objective of this thesis is to give an answer on how cost of poor quality can be measured theoretically correctly. Different calculation methods for cost of poor quality are presented and discussed in order to give comprehensive picture about measurement process. The second objective is to utilize the knowledge from the literature review and to apply it when creating a method for measuring cost of poor quality in supplier performance rating. Literature review indicates that P-A-F model together with ABC methodology provides a mean for quality cost calculations. These models give an answer what should be measured and how this measurement should be carried out. However, when product or service quality costs are incurred when quality character derivates from target value, then QLF seems to be most appropriate methodology for quality cost calculation. These methodologies were applied when creating a quality cost calculation method for supplier performance ratings.

Effects of pentoxifylline treatment before freezing on motility, viability and acrosome status of poor quality human spermatozoa cryopreserved by the liquid nitrogen vapor method

The objective of the present study was to investigate the effects of the direct addition of pentoxifylline (PF) to the ejaculates of men with poor sperm quality before freezing on post-thaw sperm motility, viability, acrosome integrity, and agonist-induced acrosome reaction. Semen specimens from 16 infertile men with impaired sperm count and motility (oligoasthenozoospermia) were divided into two equal aliquots: one received no treatment (control) while the other was incubated with 5 mM PF (treated). Both aliquots were cryopreserved by the liquid nitrogen vapor method. Motility was assessed according to WHO criteria. Acrosome integrity and spontaneous and calcium ionophore-induced acrosome reactions were assessed with fluorescein isothiocyanate-conjugated peanut agglutinin combined with a supra-vital dye (Hoechst-33258). Cryopreservation impaired sperm motility (percentage reduction: 87.4 (interquartile range, IQ: 70.3-92.9) vs 89.1 (IQ: 72.7-96.0%)), viability (25.9 (IQ: 22.2-29.7) vs 25.6 (IQ: 19.7-40.3%)) and acrosome integrity (18.9 (IQ: 5.4-38.9) vs 26.8 (IQ: 0.0-45.2%)) to the same extent in both treated and control aliquots. However, PF treatment before freezing improved the acrosome reaction to ionophore challenge test scores in cryopreserved spermatozoa (9.7 (IQ: 6.6-19.7) vs 4.8 (IQ: 0.5-6.8%); P = 0.002). These data show that pre-freeze treatment of poor quality human sperm with pentoxifylline did not improve post-thaw motility or viability nor did it prevent acrosomal loss during the freeze-thaw process. However, PF, as used, improved the ability of thawed spermatozoa to undergo the acrosome reaction in response to calcium ionophore. The present data indicate that treatment of poor quality human sperm with PF may enhance post-thaw sperm fertilizing ability.

Developing cost of poor quality calculations with emphasis on business impact

The main aim of this research was to develop cost of poor quality calculation model which will better reflect business impacts of lost productivity caused by IT incidents for the case company. This objective was pursued by reviewing literature and conducting a study in a Finnish multinational manufacturing company. Broad analysis of the scientific literature allowed to identify main theories and models of Cost of Poor Quality and provided better base for development of measurements of business impacts of lost productivity. Empirical data was gathered with semi-structured interviews and internet based survey. In total, twelve interviews with experts and 39 survey results from business stakeholders were gathered. Main results of empirical study helped to develop the measurement model of cost of poor quality and it was tied to incident priority matrix. Nevertheless, the model was created based on available data. Main conclusions of the thesis were that cost of poor quality measurements could be even further improved if additional data points could be used. New model takes into consideration different cost regions and utilizes on this notion.

Poor quality specimens delay detection of blood disorders in newborns

This sheet describes the right way to take a blood sample from a newborn infant.

Laatukustannusten sisäisen raportoinnin kehittäminen Metso Rautpohjan paperi- ja kartonkikonetehtaassa

Tässä diplomityössä on tarkasteltu Metso Rautpohjan laatukustannustiedon sisäisiä raportointitarpeita ja -mahdollisuuksia päätöksenteon tueksi. Tehty tarkastelu liittyy aiemmin Rautpohjassa luotuun laaduttomuuden kustannusten kirjaus- ja seurantajärjestelmään, jonka avulla kyseisiä kustannuksia on organisaatiossa eritelty muista kustannuksista Baan-tietojärjestelmää käyttäen. Tämän työn tavoitteena oli löytää tapaustutkimuksen keinoin laaduttomuuden kustannuksiin liittyviä sisäisiä tietotarpeita, joihin voitaisiin löytää ratkaisuja Data Warehouse (DW) -tietovarastointi- ja raportointitekniikkaa sekä olemassa olevaa laaduttomuuden kustannustietomassaa 2008 hyödyntäen. Tutkimusta varten Rautpohjan organisaatiosta valittiin kullekin toiminnolle niitä edustavat vastuuhenkilöt, joita haastattelemalla pyrittiin selvittämään sisäisiä tietotarpeita laaduttomuuden kustannuksiin liittyen. Työn tuloksena jokaiselle tutkimukseen osallistuneelle toiminnolle luotiin vähintään yksi raporttipohja, jonka avulla niille voidaan jatkossa tuottaa tarvittavaa, kohdennettua laaduttomuuden kustannustietoa omaan toimintaan liittyen. Laaduttomuuden kustannusten rinnalla tässä työssä tutkittiin myös mahdollisia kehitystarpeita Rautpohjan ympäristökustannuksien seurantaan liittyen. Suuremmassa mittakaavassa tällä työllä on pyritty tukemaan laaduttomuuden kustannusten minimointia paitsi Rautpohjassa, mutta myös Metson linjaorganisaatiossa yleisesti. Raportoinnin perimmäisenä tarkoituksena oli mahdollistaa laaduttomuuden kustannusten taustalla olevien syiden ja tapahtumien analysointi, ja sitä kautta edesauttaa laaduttomuuden kustannusten minimoimiseen tähtäävää kehitystyötä. Metso Rautpohjassa toimiviksi havaittuja laaduttomuuden kustannusten seurantaan ja analysointiin käytettyjä menetelmiä voidaan haluttaessa soveltaa myös muissa Metso-yksiköissä.

Laatukustannuslaskenta: Case teollisuuden kunnossapitopalvelut

Laatuun ja laatukustannuksiin on kiinnitetty runsaasti huomiota viimeisten vuosikymmenien aikana. Laatu koetaan kriittisenä menestystekijänä ja yritykset pyrkivät toimimaan kustannustehokkaasti, jolloin myös halutaan pienentää laatukustannuksia. Tämän vuoksi on tärkeää tunnistaa kustannuserät, jotka aiheutuvat laadusta. Kunnossapito nähdään nykyisin tuottavuutta lisäävänä tekijänä, eikä vain kustannuksia lisäävänä osa-alueena. Laatukustannuksia ja kunnossapitoa on tutkittu paljon kirjallisuudessa, muttei niinkään kunnossapidon aiheuttamia laatukustannuksia. Tässä kandidaatintyössä selvitetään yritysesimerkkien kautta, kuinka laatukustannuksia luokitellaan ja mitataan kunnossapidossa. Laatukustannuksia tarkastellaan kunnossapitopalvelun tuottajan näkökulmasta ja kunnossapidon tarkastelu on rajattu teolliseen kunnossapitoon. Työn tärkeyttä korostaa se, että laatukustannuksia on seurattu hyvin vähän teollisuuden kunnossapitopalveluissa. Laatukustannukset ovat osa yrityksen sisäistä laskentaa ja monesti laatukustannuksia saatetaan käsitellä osana yrityksen yleiskustannuksia.

Emissions and economic costs of cycling compact fluorescent lamps with integrated ballasts

This paper proposes a way to quantify the emissions of mercury (Hg) and CO2 associated with the manufacture and operation of compact fluorescent lamps with integrated ballasts (CFLis), as well as the economic cost of using them under different operating cycles. The main purpose of this paper is to find simple criteria for reducing the polluting emissions under consideration and the economic cost of CFLi to a minimum. A lifetime model is proposed that allows the emissions and costs to be described as a function of degradation from turning CFLi on and their continuous operation. An idealized model of a CFLi is defined that combines characteristics stated by different manufacturers. In addition, two CFLi models representing poor-quality products are analyzed. It was found that the emissions and costs per unit of time of operation of the CFLi depend linearly on the number of times per unit of time it is turned on and the time of continuous operation. The optimal conditions (lowest emissions and costs) depend on the place of manufacture, the place of operation and the quality of the components of the lamp/ballast. Finally, it was also found that for each lamp, there are intervals when it is turned off during which emissions of pollutants and costs are identical regardless of how often the lamp is turned on or the time it remains on. For CO2 emissions, the lamp must be off up to 5 minutes; for the cost, up to 7 minutes and for Hg emissions, up to 43 minutes. It is advisable not to turn on a CFLi sooner than 43 minutes from the last time it was turned off.

Survey on demand side sensitivity to power quality in Ireland

Power systems require a reliable supply and good power quality. The impact of power supply interruptions is well acknowledged and well quantified. However, a system may perform reliably without any interruptions but may have poor power quality. Although poor power quality has cost implications for all actors in the electrical power systems, only some users are aware of its impact. Power system operators are much attuned to the impact of low power quality on their equipment and have the appropriate monitoring systems in place. However, over recent years certain industries have come increasingly vulnerable to negative cost implications of poor power quality arising from changes in their load characteristics and load sensitivities, and therefore increasingly implement power quality monitoring and mitigation solutions. This paper reviews several historical studies which investigate the cost implications of poor power quality on industry. These surveys are largely focused on outages, whilst the impact of poor power quality such as harmonics, short interruptions, voltage dips and swells, and transients is less well studied and understood. This paper examines the difficulties in quantifying the costs of poor power quality, and uses the chi-squared method to determine the consequences for industry of power quality phenomenon using a case study of over 40 manufacturing and data centres in Ireland.

Reconfiguration of distribution networks to minimize loss and disruption costs using genetic algorithms

In this paper a computational implementation of an evolutionary algorithm (EA) is shown in order to tackle the problem of reconfiguring radial distribution systems. The developed module considers power quality indices such as long duration interruptions and customer process disruptions due to voltage sags, by using the Monte Carlo simulation method. Power quality costs are modeled into the mathematical problem formulation, which are added to the cost of network losses. As for the EA codification proposed, a decimal representation is used. The EA operators, namely selection, recombination and mutation, which are considered for the reconfiguration algorithm, are herein analyzed. A number of selection procedures are analyzed, namely tournament, elitism and a mixed technique using both elitism and tournament. The recombination operator was developed by considering a chromosome structure representation that maps the network branches and system radiality, and another structure that takes into account the network topology and feasibility of network operation to exchange genetic material. The topologies regarding the initial population are randomly produced so as radial configurations are produced through the Prim and Kruskal algorithms that rapidly build minimum spanning trees. (C) 2009 Elsevier B.V. All rights reserved.

Influence of planting date, method of handling and seed size on supersweet sweet corn seed quality

A supersweet sweet corn hybrid, Pacific H5, was planted at weekly intervals (P-1 to P-5) in spring in South-Eastern Queensland. All plantings were harvested at the same time resulting in immature seed for the last planting (P-5). The seed was handled by three methods: manual harvest and processing (M-1), manual harvest and mechanical processing (M-2) and mechanical harvest and processing (M-3), and later graded into three sizes (small, medium and large). After eight months storage at 12-14degreesC, seed was maintained at 30degreesC with bimonthly monitoring of germination for fourteen months and seed damage at the end of this period. Seed quality was greatest for M-1 and was reduced by mechanical processing but not by mechanical harvesting. Large and medium seed had higher germination due to greater storage reserves but also more seed damage during mechanical processing. Immature seed from premature harvest (P-5) had poor quality especially when processed mechanically and reinforced the need for harvested seed to be physiologically mature.

Qualifound – a modular tool developed for quality improvement in foundries

Purpose – Castings defects are usually easy to characterize, but to eradicate them can be a difficult task. In many cases, defects are caused by the combined effect of different factors, whose identification is often difficult. Besides, the real non-quality costs are usually unknown, and even neglected. This paper aims to describe the development of a modular tool for quality improvement in foundries, and its main objective is to present the application potential and the foundry process areas that are covered and taken into account. Design/methodology/approach – The integrated model was conceived as an expert system, designated Qualifound, which performs both qualitative and quantitative analyses. For the qualitative analyses mode, the nomenclature and the description of defects are based on the classification suggested by the International Committee of the Foundry Technical Association. Thus, a database of defects was established, enabling one to associate the defects with the relevant process operations and the identification of their possible causes. The quantitative analysis mode deals with the number of produced and rejected castings and includes the calculation of the non-quality costs. Findings – The validation of Qualifound was carried out in a Portuguese foundry, whose quality system had been certified according to the ISO 9000 standards. Qualifound was used in every management area and it was concluded that the application had the required technological requisites to provide the necessary information for the foundry management to improve process quality. Originality/value – The paper presents a successful application of an informatics tool on quality improvement in foundries.

Arquitetura para aquisição de respostas a perguntas frequentes

Dissertação de natureza científica realizada para obtenção do grau de Mestre em Engenharia Informática e de Computadores

Cut-off point for WHOQOL-bref as a measure of quality of life of older adults

OBJECTIVE To propose a cut-off for the World Health Organization Quality of Life-Bref (WHOQOL-bref) as a predictor of quality of life in older adults. METHODS Cross-sectional study with 391 older adults registered in the Northwest Health District in Belo Horizonte, MG, Southeastern Brazil, between October 8, 2010 and May 23, 2011. The older adults’ quality of life was measured using the WHOQOL-bref. The analysis was rationalized by outlining two extreme and simultaneous groups according to perceived quality of life and satisfaction with health (quality of life good/satisfactory – good or very good self-reported quality of life and being satisfied or very satisfied with health – G5; and poor/very poor quality of life – poor or very poor self-reported quality of life and feeling dissatisfied or very dissatisfied with health – G6). A Receiver-Operating Characteristic curve (ROC) was created to assess the diagnostic ability of different cut-off points of the WHOQOL-bref. RESULTS ROC curve analysis indicated a critical value 60 as the optimal cut-off point for assessing perceived quality of life and satisfaction with health. The area under the curve was 0.758, with a sensitivity of 76.8% and specificity of 63.8% for a cut-off of ≥ 60 for overall quality of life (G5) and sensitivity 95.0% and specificity of 54.4% for a cut-off of < 60 for overall quality of life (G6). CONCLUSIONS Diagnostic interpretation of the ROC curve revealed that cut-off < 60 for overall quality of life obtained excellent sensitivity and negative predictive value for tracking older adults with probable worse quality of life and dissatisfied with health.

Análise da eficácia da aplicação da Metodologia FMEA do Processo: Caso de estudo numa empresa certificada

Num mercado globalizado, a procura contínua de vantagens competitivas é um fator crucial para o sucesso das organizações. A melhoria contínua dos processos é uma abordagem usual, uma vez que os resultados destas melhorias vão se traduzir diretamente na qualidade dos produtos. Neste contexto, a metodologia Failure Mode Effect Analysis (FMEA) é muito utilizada, especialmente pelas suas características proactivas, que permitem a identificação e a prevenção de erros do processo. Assim, quanto mais eficaz for a aplicação desta ferramenta, mais benefícios terá a organização. Assim, quando é utilizado com eficácia, o FMEA de Processo, além de ser um método poderoso na análise do processo, permite a melhoria contínua e a redução dos custos [1] . Este trabalho de dissertação teve como objetivo avaliar a eficácia da utilização da ferramenta do FMEA de processo numa organização certificada segundo a norma ISO/TS16949. A metodologia proposta passa pela análise de dados reais, ou seja, comparar as falhas verificadas no mercado com as falhas que tinham sido identificadas no FMEA. Assim, ao analisar o nível de falhas identificadas e não identificadas durante o FMEA e a projeção dessas falhas no mercado, consegue-se determinar se o FMEA foi mais ou menos eficaz, e ainda, identificar fatores que condicionam a melhor utilização da mesma. Este estudo, está organizado em três fases, a primeira apresenta a metodologia proposta , com a definição de um fluxograma do processo de avaliação e as métricas usadas, a segunda fase a aplicação do modelo proposto a dois casos de estudo, e uma última fase, que consiste na análise comparativa, individual e global, que visa, além de comparar esultados, identificar pontos fracos durante a execução do FMEA. Os resultados do caso de estudo indicam que a ferramenta do FMEA tem sido usada com eficácia, pois consegue-se identificar uma quantidade significativa de falhas potenciais e evitá-las. No entanto, existem ainda falhas que não foram identificadas no FMEA e que apareceram no cliente, e ainda, algumas falhas que foram identificadas e apareceram no cliente. As falhas traduzem-se em má qualidade e custos para o negócio, pelo que são propostas ações de melhoria. Pode-se concluir que uma boa utilização do FMEA pode ser um fator importante para a qualidade do serviço ao cliente, e ainda, com impacto dos custos.