The Concept of Quality 2 Current 1950s Preventing Screening out - PDF document

The Concept of Quality 2 Current 1950’s Preventing Screening out defects & failures defects WEEK 5 Inspection Processes PROJECT QUALITY MANAGEMENT TCM 545/645 – Project Control Systems Dr. Richard Gebken TCM 545/645 - Project Control Systems The Concept of Quality The Concept of Quality 3 4  Meeting specifications … Quality implies:  Prevents being taken to court  Fitness for the intended purpose  Performance  Ensures payment  Safety  But is not sufficient to ensure:  Reliability  Customer satisfaction  Ease of handling  Good reputation  Logistical support  Repeat business  Environmental safety  …  Value for money  Absence of defects TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems The Concept of Quality The Concept of Quality 5 6 Quality implies that everybody:  Quality does not necessarily imply:  Knows what is expected  Most expensive  Most sophisticated, most features  Is able & willing to meet those expectations  Most reliable  Knows the extent to which the project meets the  Good quality implies cost-effectiveness and expectations fitness for a specific intended purpose  Has the ability & authority to take required  Quality is not the same as Grade corrective actions  Grade is a rank or category of type of item e.g. grades of steel include categories such as stainless steels, tool steels, steels for pressure vessels, etc. TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems 1

Project Quality Management Process Quality Movements Project 7 Quality Control  1950s Dr Deming in Japan Similar to (QC) Figure  Total Quality Management (TQM) 6.1 from Process to ensure class  Just in Time (JIT) conformance to plan textbook  Six Sigma Planning for Quality Assurance Project Quality (QA) Process to plan QA Process to ensure quality 8 TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems Tools & Techniques for Quality Planning Quality Planning 9 10  Company-wide planning of quality systems Inputs Tools & Techniques Outputs  ISO 9001 specifies requirements for system • Enterprise • Cost-benefit • Quality environmental analysis management plan factors • Benchmarking • Quality metrics  Planning for specific project • Organizational • Experiment design • Quality check lists process assets • Cost of Quality • Process  Integrated with rest of project plan: provided for in • Project scope (COQ) assessment improvement plan schedule & budget statement • Group decision • Quality baseline • Project making techniques • Project  Also integrated with risk management plan, safety management plan • Other in-house management plan, procurement plan, communications plan, …) • Other in-house tools plans and factors updates • Reports and analyses TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems Techniques for QA Tools & Techniques for Quality Assurance during System Development 11 12 Quality Assurance Close-out & Inputs Tools & Techniques Outputs (QA) on a Project Continuous Improvement • Quality management plan • Quality planning tools • Requested changes and techniques • Quality metrics • Recommended QA toolbox: Learning opportunities: • Quality audits corrective actions • Process improvement plan •Training of project team members • Project close-out meeting • Process analysis • Organizational • Work performance information • Configuration management system • Phase close-out meetings process assets and • Quality control tools • Approved change requests updates and techniques • Configuration identification • Close-out reports • Quality control measurements • Project management • Other in-house • Implemented • Design reviews and audits • Report of non-quality costs plans and updates tools/techniques • Change requests • Quality function deployment • Other in-house • Corrective actions outputs and reports • Classification of characteristics • Defect repair • Failure mode and effect analysis • Preventative repair • Modeling and prototyping • Other in-house factors • Laboratory tests and other experiments • Inspection • Checklists TCM 545/645 - Project Control Systems 2

Techniques for QA Techniques for QA during System Development during System Development 13 14  Configuration Management Configuration Management  Design Review  Configuration Identification (defining the system)  Audit  Configuration Item (CI) – an item to be tracked & controlled as individual entity (Also see Chapter 2)  Classification of Characteristics  Master copies maintained in secure configuration center  Failure Mode and Effect Analysis  Configuration Control (defining “as built” status)  Modeling & Prototyping  Discussed under “Quality Control” TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems Techniques for QA Techniques for QA during System Development during System Development 15 16  Design Reviews  Design Reviews  Attended by  Insure that design is acceptable in all respects:  Formal Design Review representatives form  Design assumptions valid several functions:  No omissions or errors  Preliminary Design Review: Does concept fit requirements?  Construction /  Cost of ownership Manufacturing  Critical Design Review: Do details meet specifications?  Safety & product liability  Operations  Functional Readiness Review: Is manufacturing process OK?  Reliability  Maintenance  Availability  Product Readiness Review: Do products meet requirements  Procurement  Manufacturability when manufactured according to design documentation?  Legal  Shelf life  Quality  Informal Design Review  Operability  …  Maintainability  Patentability  Ergonomics TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems Techniques for QA Techniques for QA during System Development during System Development 17 18 Audits versus Design Reviews  Audits Design Review Audit  Verify that management processes comply with  Internal or external  Internal or external requirements  Verify that technical processes (e.g. welding) comply  Design aspects  Variety of aspects with specifications  Formal or informal  Formal  Determine project status  Room for innovation  Strictly verification TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems 3

Techniques for QA Techniques for QA during System Development during System Development 19 20 Classification of Characteristics Example Classification of FMEA Characteristics Large numbers of  (Failure Mode & Effect Analysis) characteristics  Critical Pareto principle: small   Major A Determine: number of characteristics have most serious impact  Major B  Ways (modes) in which system may fail Basis for decisions regarding   Minor modifications, waivers and deviations  Effect of identified failure modes Classification of  characteristics in high-level systems guide designers of lower-level systems Not to be confused with  classification of defects TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems Techniques for QA Techniques for QA during System Development during System Development 21 22 Modeling & Prototyping FMEA List relevant components 1. To assess and reduce specific risks – typically linked to Identify possible ways of failure specific project phase 2. Describe effects of failure  Physical models 3. Assess probability of failure 4.  Full-scale, functioning models Assess seriousness of failure event 5.  Mockups Rate criticality, based on 4 and 5 above 6.  Scale models Prepare plan to prevent failure 7.  Mathematical & computer models TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems Project Quality Management Process Tools & Techniques for Quality Control 23 Project Quality Control Inputs Tools & Techniques Outputs (QC) • Quality • Cause & Effect • Quality control measurements management (fishbone) diagram • Validated defect repair plan • Control Chart • Quality baseline and updates • Quality metrics • Flowcharting • Recommended corrective & • Process • Histogram preventative actions improvement • Pareto Chart • Requested changes plan • Run chart • Recommended defect repairs • Work • Scatter diagram • Organizational process assets performance • Statistical sampling and updates Quality Assurance (QA) information • Validated deliverables • Quality inspection • Approved • Other in-house outputs and • Defect repair review change requests Close-out & reports Planning for Project • Other in-house tools • Deliverables Quality Assurance Continuous Quality (QA) on a Project • Other in-house Improvement factors 24 TCM 545/645 - Project Control Systems TCM 545/645 - Project Control Systems 4