Industrial Engineering for Science Consuming Industry. Part 1. Tutorial

THE POLICY IN THE AREA OF QUALITY IS ORIENTED

AT:

1.Optimal consumption of resources and means to decrease the cost price of services and offer competitive prices through implementation of administrative and process innovations.

2.Priority prevention of possible decrease of the quality of services, not only correction procedures when it happens.

3.Systematic training of employees in the area of quality, involvement of each employee to participate in the development of provided communications service, their encouragement to increase quality.

4.Constant monitoring of the quality of works and services with the organization of the system of fast response to possible decrease of quality.

5.Access f Clients to the information about current state of the company and the quality of services they consume.

ORGANIZATION STRATEGY IN THE AREA OF QUALITY

Increase of the quality of company’s work through continuous study of the needs of Clients and Partners and the use of its results for the increase of the quality of offered products, works and services by innovative development of all the components of the production potential of the company with the overall quality control at each stage of its activity.

Individual Students Work

Individual Students Work is carried out in the free form of making written conspectuses containing the following information:

1.Evolution development of the Overall Quality Control Theory.

2.Quality management strategies and technologies implemented in the most successful foreign companies.

3.Special quality control functions in national and foreign

practices.

4.Modern Quality control mechanism. Process approach to quality management in science intensive companies.

Topic 2.2. Instruments of analysis and quality control evaluation, lean production technologies in the process of competitiveness growth of science intensive companies in the international market.

2.2.1.Main types of lean manufacturing and the types of wastes.

2.2.2.Six sigma. Pareto Curve. Ishikawa Diagram.

2.2.3.Complex evaluation of quality control of an object.

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Practicum 2.2 Quality management in the strategy of science intensive production development in the conditions of international competition. Solution of a situation problem on the application of various quality management methods at science intensive production companies.

Master’s students are offered to plot Ishikawa Diagram and Pareto Diagram for the company they selected in the previous Practicum as well as offer quality management system correction algorithm to reduce losses and increase production efficiency on the basis of plotted diagrams. International relations of studied companies are to be taken into consideration.

Central Questions

To justify the use of instruments for the evaluation of the quality management systems at the given science intensive companies, which determine their competitiveness. To analyze the influence of internal conditions and external factors on the efficiency of development of science intensive companies during selection of quality management mechanisms.

Methodological Guidelines

It is necessary to pay attention at the fact that the elements for the management efficiency analysis can be found with the strategic analysis instruments, to determine the specific of the internal environment of a science intensive company as well as to evaluate the dynamics of external factors of its development.

During the study of topical materials, using the approaches provided in the lectures, it is necessary to determine the factors exerting the major influence on the quality control at a science intensive production company in the context of international environment, and to offer respective alternatives for its further development.

Student’s Self Study Tasks

Individual Students Work is carried out in the free form of making written conspectuses containing the following information, as well as the solution of the following situation problem:

1.Seven main instruments of control and the role of quality circles in their study.

2.Organization design as an instrument of efficient quality management.

3.Plotting of Pareto Diagram by the given statistical data. Clarification of the diagram plotting principles.

For manufacturing lines produce the following sanitary ware

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products during a working shift: 1) flat steel flanges; 2) shaped parts (couplings, revisions); 3) stationary louvered grilles; 4) parallel flanged gate valves. Table 1 represents data on the number of quality and defective products.

Production of Sanitary Ware Materials

1.On the basis of provided initial data, make a preliminary conclusion about the manufacturing line, which makes defective products the most.

2.Check if the conclusions are correct by plotting Pareto Diagram and making АВС-analysis.

Topic 2.3. International Systems of Certification and Standardization as Quality Management Instruments for Science Efficient Companies.

2.3.1.Determination of general certification concepts.

2.3.2.The system of standardization of products and production lines. Legal aspects of standardization of products, services and quality systems.

2.3.3. The role of standardization in the quality assurance of products and services. International standards for the ISO 9000 quality systems and their structure.

Practicum 2.3. International systems of certification and standardization as quality management instruments of science intensive companies. Test for the topic “International systems of certification and standardization as Quality Management Instruments for Science Efficient Companies. The test contains two questions for the each of three variants, two sets are provided for the test work.

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Variant 1

1.1.Using the selected science intensive company as an example, demonstrate the organization of standardization activities at an international level.

1.2.What types of international certificates do you know?

Variant 2

2. Describe the tubes of international standards and characterize

them.

2.2. List certification stages and characterize them, using the selected science intensive company.

Variant 3

3.1.Use the science intensive company you selected to demonstrate the purposes of standardization in the international practice?

3.2. List the certification stages of quality systems and characterize

them.

Variant 4

4.1.What are the purposes for the development of technical regulations?

4.2. List and characterize international certification schemes, use practical examples you know.

Variant 5

5.1.Characterize objectives and tasks of standardization from the viewpoint of state and Science Intensive companies?

5.2. What are confirmation of conformity and certification and how are they interconnected?

Variant 6

6.1.Why are the international standards important for the state and science intensive companies?

6.2.What does international certification of production and quality systems demonstrate?

Central Questions

Determination of general certification concepts. Standardization system for products and productions. Legal foundations for standardization products, services and quality systems. International standards for the ISO 9000 quality systems and their structure.

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Methodological Guidelines

It is necessary to present the Master’s students the materials on the purposes and objectives of certification, to form the understanding of the regulatory basis of certification for science intensive companies both on national and international levels.

In addition, it is necessary to outline general provisions of the international standards ISO 9000 and analyze the goal set of quality systems. To consider standardization purposes for science intensive productions, their tasks and complexity. It is also necessary to analyze the difference between Russian and international certification systems and study its interaction with international standards in general and for science intensive production companies.

Student’s Self Study Tasks

Individual Students Work is carried out in the free form of making written conspectuses containing the following information:

1. Certification background for the quality management. 2.International practice of certification.

3.International ISO 9000 standards and the QS-9000 system for quality management and assurance.

4. Audit of quality systems.

13. Examples of tests

Module /Section 1. Design of Reliability in an Organization System and Administration of Science Intensive Companies in the Conditions of Global Economy

1.The science developing the methods for determination, control and reliability assurance of systems. It is based on a dialectic approach, which orients scientists that complex phenomena can be cognitive in principal. It is:

a.the reliability theory*;

b.the relativity theory;

c.the probability theory;

d.the risk-management theory.

2.The property of an object to sustain, within certain limits, all its parameters related to its ability to carry out certain functions in certain modes and conditions of application, maintenance, storage and transportation:

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a.survivability;

b.durability;

c.reliability*;

d.viability.

4.It has certain designated purpose and is discussed at the stages of requirements engineering, design, production and service:

a.Subject;

b.Product;

c.Object*;

d.System.

5.Reliability is:

a.Intrinsic property of an object, determined by its production technology and demonstrated during its service;

b.An ability of an object to have all the parameters sustainable in time and within predetermined limits, which characterize its ability to carry out required functions in certain modes and conditions of application, maintenance, storage and transportation;

c.A property we can make no conclusion about unless observe it in a period of time;

d.All the answers are right*.

6.System reliability for science intensive systems:

a.is the moment of system progress to a certain level of selfpreservation (at the selected moment of time and characterizes dynamic equilibrium);

b.describes reproducibility of the progress during development, the ability to reproduce efficient progress to self-preservation*

c.characterizes «persistence» of this process during innovative development;

d.all the answers are wrong.

7.Reliability management system in science intensive companies is supposed to have the following qualities:

a.Adaptability and innovativeness;

b.Preventiveness and balance;

c.All the answers are right*;

d.All the answers are wrong.

8.Reliability characteristics are:

a.durability;

b.readiness;

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c.controllability,

d.there is no right answer*;

9.Faultness is:

a.an ability to maintain innovative activity and susceptibility to innovations during a long (strategic) period of time

b.a state of a system with all the elements carrying out their innovative functions; *

c.a state of a system, when it is able to implement innovations;

d.All the answers are right.

10.Susceptibility to innovative management effects is:

a.controllability;*

b.durability;

c.readiness;

d.there is no right answer.

11.A stage of reliability management is:

a.development of activities for the increase of reliability of enterprise economy systems through decrease of probability of risks and losses from risks;

b.risk identification,

c.risk revealing;

d.there is no right answer*.

12.Synthetic research discipline, whichstudies the influence of random events on various areas of humanactivities causingphysical or propertydamage:

a.probability control;

b.risk analysis;

c.risk management*;

d.estimation of damage.

13.Event or a group of related events causing damage to an object, which possesses the given risk:

a.Chance;

b.Probability;

c.Damage;

d.Risk*.

14.Risk control stages are:

a.selection of methods of the influence on a risk;

b.risk revealing;

c.risk evaluation;

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d.All the answers are right*.

15.Risk management stages are:

a.Making a control decision;

b.Influence on a risk;

c.a and b answers are wrong*;

d.a and b answers are right.

16.The influence on a risk is carried out:

a.Reduction, preservation, liquidation;

b.Reduction, preservation, transfer*;

c.Increase, preservation, transfer;

d.Disregard, increase, liquidation.

Module / Section 2. Quality management in the system of organization and administration of science intensive companies in the international environment

1.At present, theISO9000standardprovides thefollowingdefinitionof quality:

a.«Quality is «degree to which a set of inherent characteristics fulfils requirement»».

b.«Product quality is the set of characteristics, stipulating its suitabilityfor satisfyingcertainneeds inaccordance withits purpose».

c.«Quality is the set of object characteristics, related to its ability to satisfy existing and expected needs».

2.Kano model includes the following groups of characteristics:

a.Quantitative, surprise characteristics;

b.Obligatory, surprise characteristics;

c.Obligatory, quantitative, surprise characteristics

3.Process control on the basis of application of statistical methods appeared for the first time:

a.at the phase of screening;

b.at the phase of quality control;

c.at the phase of quality management.

4.First professionals in the area of quality (inspectors or supervisors) appeared for the first time:

a.at the phase of screening;

b.at the phase of quality control;

c.at the phase of quality management.

5.The ISO 9000 version of standards, that is valid today, appeared in:

a.1987;

b.1997;

c.2000.

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6.At present, developed countries demonstrate the following priorities:

a.quality of company;

b.quality of production processes;

c.quality of life.

7.TQM (Total Quality Management) is:

a.a complex management system aimed at constant quality enhancement based onparticipation of allthepersonnel of anorganization;

b.an approach to the involvement of company employees into the quality enhancement process;

c.a system of relationships suppliers and customers.

8.The main constituents of a product quality are:

a.technical characteristics;

b.safety and reliability;

c.technical, aesthetic and ecological characteristics, safety and

reliability.

9.Ziethaml service quality model («GAP» model) is intended for:

a.making specification of services;

b.determination of possible failures, resulting in low level of client satisfaction;

c.for making a service plan.

10.Poka-yoke procedures are used:

a.only in production industries;

b.only in service industries;

c.both in production and in service industries.

11.The TQM approach means that quality is provided and advances:

a.at the design and production stages;

b.at the design, production and after-sale service stages;

c.at the stages of marketing research, design, production and aftersale service stages.

12.The TQM approach implementation participants:

a.by all the units and subdivisions of a company;

b.only the quality control unit;

c.company administration and the quality control unit.

13.The TQM approach efficiency depends on:

a.first of all, on medium-level managers;

b.first of all, on company administration;

c.first of all, on the quality control unit of a company.

14.The TQM approach implementation requires (select the wrong point):

a.continuing development of all existing procedures and processes

in a company;

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b.increase of the number of control operations during production

processes;

c.involvement and training of all personnel;

d.monitoring of suppliers and the quality of their products.

15.The following approaches are used for the implementation of the decision making principle based on facts:

a.Statistical methods;

b.Deming Cycle;

c.Shingo System;

d.benchmarking.

Ответственный за выпуск И. А. Фролова

Kazan National Research Technological University Publishing house

Offset laboratory of Kazan National Research Technological University

420015, Kazan, Karl Marx street, 68

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