Cost Of Poor Quality Research Articles

Meningkatkan Kualitas Produk Panel Box App-Tl Aluminium dengan Efisiensi Biaya Kualitas Menggunakan Metode Continuous Improvement di PT Powerindo Prima Perkasa

Nowadays, industrial competition in an era of globalization in manufacturing can improve the quality of the products produced. PT. Powerindo Prima Perkasa is a metal and electrical equipment company. Because of the Make To Order (MTO) production process, there is often a decline in quality. The objective of the research is to find factors that cause rework, identify the cost of poor quality (COPQ) and the application of Plan, Do, Check and Action (PDCA). Data taken from May to October 2023 with an average rework cost and COPQ of Rp 6.478.871. There were 6 points of finding defects with a total of 2,455 defects. The rework problem diagram shows the two highest points of finding thin powder and scratch. Through the PDCA application, data is taken from the previous rework cause analysis diagram. Plan level, there are four improvement factors: man, method, machine, environment. Stage do, applying improvements is training, new methods, new way of working machines with waste powder 25%, monitoring new layout. Obtained 748 defects with average cost of rework and COPQ after simulation of Rp 4.832.053. The action phase followed up on the previous phase by providing standardization through training periodically at least once in 3 months, performing monitoring every day. Next, follow up improvements with PDCA through the problem diagram after the highest simulation is the aluminum plate gap defect.

Perancangan Automatic Tail Dock Berbasis Arduino Nano Pada Pesawat Menggunakan Metode PID

The aviation industry is one of the service sectors. Due to its large number of users, safety is the primary concern in this industry. To ensure this safety, routine maintenance of operating aircraft is crucial, leading to the emergence of the aircraft maintenance industry. Due to the safety factors of the workpiece, installing ladders requires a significant workforce to supervise the workpiece, namely the aircraft itself, to prevent the ladder from hitting the aircraft body, which can result in COPQ (Cost Of Poor Quality). However, the use of many workers for ladder installation is considered inefficient because the maintenance process could be expedited if these workers could be utilized to install ladders on other parts of the aircraft. Therefore, if maintenance can be completed more quickly, the aircraft can return to flight sooner, meeting the airline's flight demands. Addressing this issue, this study aims to facilitate the ladder installation and removal process, thereby reducing the potential for collisions and ensuring the ladder is positioned at the required distance. This is achieved through ultrasonic sensors mounted on the work ladder, connected to a motor via Arduino Uno. The motor will stop when the input from the ultrasonic sensor reaches the predetermined distance. Additionally, if the aircraft tail moves while the ladder is installed, the system will automatically adjust the ladder's position to maintain the necessary distance, thus minimizing losses during aircraft maintenance.

Pipes and puddles framework: Risk management in manufacturing processes to reduce the total cost of quality

Purpose: Decentralize standards to each process owner is an open issue. Centralized standards are a common situation which puts a big amount of chore tasks against continual improvement. The pipes and puddles framework was born to solve this problem.Design/methodology/approach: Pipes and puddles framework takes its ground in risk management, which is carried out from the perspective of the physics of the process.Findings: Putting a clear difference among reactive and preventive problem-solving is the first observable change when adopting this framework, which drives to keep cost of poor quality (COPQ) permanently close to zero. Another important consequence of adopting this framework is that there is no person responsible for the continuous improvement process, but each process owner is responsible for the continuous improvement of their process.Research limitations/implications: This research is still limited to a few empirical cases of use; the diffusion of its benefits and guidelines to its real implementation is an opportunity for a massive adoption. A formal representation is also necessary.Practical implications: Pipes and puddles framework brings to management a roadmap to foster the role of process owner, providing a decentralized approach towards risk management, to react to non-conformities and to implement effective channels for continual improvement.Social implications: Approach to a green factory as a direct consequence of elimination of COPQ and the empowerment of all employees by having specific roles and regular channels to effectively act as agents of continual improvement.Originality/value: The vision of each process in the firm as the interconnection of three pipes (sub-processes) is a novelty that completely solves common issues for all processes that are transversal to all others (risk management, non-conformant products, customer claims, change management, etc.).

Visual analytics and intelligent reasoning for smart manufacturing defect detection and judgement: A meta-learning approach with knowledge graph embedding case-based reasoning

Visual inspection is an important procedure in manufacturing industries to guarantee product quality and reduce costs of poor quality. Several challenges exist for manufacturing inspection automation, including the false positive and false negative trade-off, autonomous decision-making, and inspection algorithm selection. This paper addresses these challenges by proposing a two-level visual analytics and intelligent reasoning system, where machine vision identifies and locates potential defects and convolutional neural network models further classify them into acceptable and defective features. Symbolic reasoning techniques are applied for autonomous decision making on part-level judgement to enhance the system reasoning capability, including part judgement (accept, reject, rework) and rework operation assignment. Furthermore, a case-based reasoning approach for meta-learning of inspection algorithm selection is proposed, which uses knowledge graph embedding (TransR embedding) to embed cases into a two-dimensional space for case similarity estimation and case retrieval. A case of smart assembly inspection is presented to validate the feasibility of the proposed system.

Six Sigma can significantly reduce costs of poor quality of the surgical instruments sterilization process and improve surgeon and operating room personnel satisfaction

Operating room (OR) management is a complex multidimensional activity combining clinical and managerial aspects. This longitudinal observational study aimed to assess the impact of Six-Sigma methodology to optimize surgical instrument sterilization processes. The project was conducted at the operating theatre of our tertiary regional hospital during the period from July 2021 to December 2022. The project was based on the surgical instrument supply chain analysis. We applied the Six Sigma lean methodology by conducting workshops and practical exercises and by improving the surgical instrument process chain, as well as checking stakeholders’ satisfaction. The primary outcome was the analysis of Sigma improvement. Through this supply chain passed 314,552 instruments in 2022 and 22 OR processes were regularly assessed. The initial Sigma value was 4.79 ± 1.02σ, and the final one was 5.04 ± 0.85σ (SMD 0.60, 95%CI 0.16–1.04, p = 0.010). The observed improvement was estimated in approximately $19,729 of cost savings. Regarding personnel satisfaction, 150 questionnaires were answered, and the overall score improved from 6.6 ± 2.2 pts to 7.0 ± 1.9 pts (p = 0.013). In our experience the application of the Lean Six Sigma methodology to the process of handling the surgical instruments from/to the OR was cost-effective, significantly decreased the costs of poor quality and increased internal stakeholder satisfaction.

The role of cleaner production costs to reducing failure costs

Economic units can benefit from the cleaner production strategy, which aims to reduce the environmental impact of economic activities while improving efficiency and profitability. Accordingly, the aim of the research was to clarify the knowledge foundations of cleaner production costs and to indicate their role in reducing the costs of poor quality (the costs of failure). A set of conclusions has been reached, the most important of which is that cleaner production has achieved a reduction in the costs of external failure, represented by the costs of guarantee, by an amount of 12,339,000 dinars. Contributes to reducing the costs of failure, and based on the conclusions, a set of recommendations were presented, the most important of which is the need to focus economic units on the use of environmentally friendly materials, as they contribute to the production of products that meet the desires of customers, which leads to reducing costs, improving product quality, and reducing failure costs internally and externally.

Eliminate Costly Component Out Of Pocket Defect Condition during Microelectronic Component Packaging/Shipping/Handling

High value devices used in microwave modules and other microelectronic assemblies have become increasingly thin and susceptible to “Component Out Of Pocket” (COOP) conditions that can occur during packaging, shipping, and customer handling. This defect condition is especially problematic for automated assembly which strives to be touch-free and efficient with orderly device presentation. COOP is a major contributor to “Cost Of Poor Quality” (COPQ) within the business. A funded study into COOP conditions was conducted and a dozen root causes were identified. It was discovered that traditional “waffle packs” have mechanical issues related to flatness tolerances with respect to the waffle tray and lid. The addition of a standard clip further contributes to the issue, both of which are key root causes of the costly “Component Out Of Pocket” (COOP) condition. A novel Lid-Clip System (LCS2) was engineered to compensate for those mechanical issues, bringing robust captivation and preservation of devices in waffle tray pockets. Static dissipative material for lid and clip was selected to provide unparalleled ESD Class 000 protection for high value devices with the lowest voltage susceptibility thresholds.

Penilaian Postur Tubuh Pekerja Dan Perbaikan Sistem Kerja Dengan Metode Rula Dan Reba Pada Pt. Sharp Electronics Indonesia

In the current industrial age, Indonesia is making great progress every year. Especially in the development of business competition for goods and services, businessmen compete with each other to dominate the market share on which they are focused.One of the inseparable factors of industry is human resources. It is very important to maintain the quality of human resources in order to continue the production process. So ergonomics is important to keep people healthier, safer, more comfortable and avoid bad parts (bad). PT Sharp Electronics Indonesia is one of the electronic companies of Sharp Corporation engaged in the assembly of electronic products. One of the manufactured products is a refrigerator. There are some quality issues in the production process. This means that defects are often still found on the assembly line. This adds to the cost of poor quality because if a defect occurs, the part must be reworked or the part scrapped. One of the causes is improper posture, which can have a big impact on the operator's body later on. A proposed solution to this problem is to use the RULA and REBA methods to find the worker's posture rating and correct it if the posture is bad.

An artificial intelligent manufacturing process for high-quality low-cost production

PurposeTo avoid the high cost of poor quality (COPQ), there is a constant need for minimizing the formation of defects during manufacturing through defect detection and process parameters optimization. This research aims to develop, design and test a smart system that detects defects, categorizes them and uses this knowledge to enhance the quality of subsequent parts.Design/methodology/approachThe proposed system integrates data collected from the deep learning module with the machine learning module to develop and improve two regression models. One determines if set process parameters would yield a defective product while the second model optimizes them. The deep learning model utilizes final product images to categorize the part as defective or not and determines the type of defect based on image analysis. The developed framework of the system was applied to the forging process to determine its feasibility during actual manufacturing.FindingsResults reveal that implementation of such a smart process would lead to significant contributions in enhancing manufacturing processes through higher production rates of acceptable products and lower scrap rates or rework. The role of machine learning is evident due to numerous benefits which include improving the accuracy of the regression model prediction. This artificial intelligent system enhances itself by learning which process parameters could lead to a defective product and uses this knowledge to adjust the process parameters accordingly overriding any manual setting.Research limitations/implicationsThe proposed system was applied only to the forging process but could be extended to other manufacturing processes.Originality/valueThis paper studies how an artificial intelligent (AI) system can be developed and used to enhance the yield of good products.

A conceptual framework of quality cost chain in strategic cost management

PurposeThis study aims to discover a practical and effective way to apply the quality cost concept in Strategic Cost Management (SCM) framework. The interaction of preventive, appraisal and failure (PAF) activities in a company's internal value chain will be the starting point of SCM implementation.Design/methodology/approachThis study begins by establishing value chain and quality costs as the scope of conceptual analysis. Discussions on the interrelationships between activities, quality and costs were gathered to clarify conceptual and practical gaps in the scope of the study. The PAF quality cost model is applied to find viable, practical solutions. The costs of activities will serve as performance indicators.FindingsThe PAF quality cost model depicts opportunities to lower costs and increase profit in a business simultaneously; current poor quality costs are the benchmark. Identifying PAF activities and costs in the business value chain and linking it with others is crucial in evaluating SCM applications. These linkages will generate a Quality Cost Chain (QCC). The leading indicator of improvement is a higher ratio between new possible failure costs (FC) and the combination of prevention and appraisal costs (PAC) than the current value, followed by a lower total quality cost (TQC). The subsequent attention is a lower ratio between the appraisal cost (AC) and prevention cost (PC). Mathematically, for assessing the operability of new quality-related activities, ΔPACnew < ΔFCnew, TQCnew < TQCcurrent, (FC/PC)new>(FC/PC)current and (AC/PC)new<(AC/PC)current are proposed as feasible conditional-quantitative improvement criteria.Research limitations/implicationsThis study only discusses the relationship between quality costs and activities related to quality management in the PAF quality cost model, not cost behavior. This limitation opens up opportunities for future research that intends to link QCC with cost behavior in the context of managerial accounting and Strategic Cost Management. The use of QCC in certain industrial areas is the next research opportunity. The variety of PAF activities this study addresses originates from a wide range of industrial sectors; QCC research by sector may produce unique industrial quality cost phenomena.Practical implicationsQCC will make it easier for managers to evaluate how strategically their departments or activities contribute to quality costs at the departmental or organizational level, as well as to effectively and efficiently improve quality cost performance.Originality/valueThe quality-related activity and quality cost issues are still rarely treated as subjects of research studies in the field of Strategic Cost Management. Even so, the discussion tends to be very broad, complex and difficult to apply. This study combines a simple diagrammatic and mathematical approach to simplify the discussion and, at the same time, manage the value of strategic quality management.

Improve Product Quality and Production Process with Integration of Six Sigma and Quality Management System ISO 9001: A Case Study of Bakery Shop in France

This study highlights macarons product research conducted in a bakery shop in France. It is aims to optimize the quality of the macarons products via the integration of Six Sigma and Quality Management System, ISO 9001. To achieve the objective, the study first identifies the primary root cause of product defects. Besides, an alternative standard operating procedure is incorporated with the recommended improvements. The DMAIC approach is emphasized by the Six Sigma approach, which is Define-Measure-Analyze-Improve-Control. According to the data, the cost of poor quality for a month is 34,511.40 Euro. Cracked macarons (53.70%), hollow macarons (16.30%), and no feet macarons (16.10%) are three major critical defects. The macarons product has a Sigma level of 2.50. The parameters proposed in this study are low-level mixing at 80 rpm, 12 minutes of baking time, and 203°c oven temperature to improve the quality of macarons product using the Design of Experiment (DOE) of the Taguchi Method. When the major elements are controlled inside the processes, the company's chances of producing a high-quality product increase significantly. As a result of adopting Six Sigma with Quality Management System ISO 9001 into the macaron manufacturing process, defects costs and rate is expected to be lower.

Exploring the Maturity of Quality Management in Saudi Healthcare: A Mixed Methods Approach

In Saudi Arabia, managing the quality of healthcare was considered decades ago. Yet, internal and external consumers were not fully in favour of management efforts and practises. The current study was initiated by quantitatively analysing patients’ complaints that pointed out weaknesses in non-clinical services, which was assumed to be an indicator of weakness in quality management (QM). A mixed-methods approach triangulated patients’ complaints with managers’ experience to cast light on the maturity level of QM. Interpretive phenomenological analysis explored managers’ knowledge of quality concepts along with their involvement in QM. The experience of 24 managers with QM was categorised into four themes: (a) misunderstanding, for example, accreditation; (b) misconception, for example, employees’ empowerment; (c) misrecognition, for example, cost of poor quality and (d) conceptuality, for example, external threats. The current findings detected immature QM systems that would hinder the employment of quality principles. Therefore, despite the efforts and resources dedicated to the implementation of quality practises, such efforts would still fall far below expectations unless managers learn how to enable employees to do their work effectively rather than instructing them to do their work in compliance with quality requirements.

How to influence total costs of sourcing? A case study of SCOPQ with Six Sigma

Total cost of sourcing is receiving significant attention from firms in general and purchasing managers in particular. Academic research on lean and six sigma programs has evolved rapidly in the last decade. This study focuses on uncovering most effective sourcing initiatives, which aim to decrease total costs addressing quality issues and Supplier Costs of Poor Quality (SCOPQ). This research aims to update the literature on supply chain management by analysing and verifying the proposed Six Sigma framework through a case study. A case study focused on a set of interviews with practitioners based on a firm located in Germany was used that generates uncaptured insights in previous research of this area. The results of the paper highlight the relevance of building cross-functional teams for achieving continuous improvement and implementing suitable, proven, and appropriated tools. Whereas lean is preferred for scopes as part of processes with few interfaces and medium grade of difficulty, Six Sigma is the most suitable methodology for scopes with a high grade of difficulty or problems involving cross-functional processes. SCOPQ is defined as the costs associated with defects and deficiencies originated by suppliers. For instance, they could include the costs for supplier-related incidents like shortages or failure-related costs, production stop costs, rework costs, complaints, etc. This research not only validates the proposed framework through an in-firm case study, but also confirms the relevance of mitigating and avoiding biases, recommends standardizing processes and texts templates, and the regularly training of the employees involved. Besides of the main goal of investigating Six Sigma's role in reducing quality costs, research results demonstrate the advantage of standardized multilingual texts for the complaint process of global players. The study indentified the influence of English collocations into the complaint process because of the majority of the specialized literature is written in English.

IMPLEMENTASI METODE LEAN SIX SIGMA GUNA MENGELIMINASI DEFECT PADA PROSES PRODUKSI PURIFIED GYPSUM DI PT. AAA

PT. AAA is a chemical-based producer with zero defect program in term of maintaining product quality. However, there were found waste which were higher than based line quality acceptance through production process line of purified gypsum. This research aims to improve production process effectiveness in order to sustaining zero defect using Lean Six Sigma method. Define, measure, analyze, improve, and control, known as DMAIC, is used as research approach. The research begun by describing current state map to identify waste that occurs along the value stream. Followed by identifying activities based on three classifications, namely value added, non-value added, and necessary but non-value-added activities. Once such activities known, cost of poor quality and Sigma level is measured. Fish-bone diagram as well as failure mode and effect analysis are used in order to analyze risk priority number. This study found three wastes namely defect, waiting, and inventory as main focus to eliminate then improve effectiveness along production process.

Eliminate Costly Component Out Of Pocket Defect Condition during Microelectronic Component Packaging/Shipping/Handling

Abstract High value devices used in microwave modules and other microelectronic assemblies have become increasingly thin and susceptible to “Component Out Of Pocket” (COOP) conditions that can occur during packaging, shipping, and customer handling. This defect condition is especially problematic for automated assembly which strives to be touch-free and efficient with orderly device presentation. COOP is a major contributor to “Cost Of Poor Quality” (COPQ) within the business. A funded study into COOP conditions was conducted and a dozen root causes were identified. It was discovered that traditional “waffle packs” have mechanical issues related to flatness tolerances with respect to the waffle tray and lid. The addition of a standard clip further contributes to the issue, both of which are key root causes of the costly “Component Out Of Pocket” (COOP) condition. A novel Lid-Clip System (LCS2) was engineered to compensate for those mechanical issues, bringing robust captivation and preservation of devices in waffle tray pockets. Static dissipative material for lid and clip was selected to provide unparalleled ESD Class 000 protection for high value devices with the lowest voltage susceptibility thresholds.

Effect of Synthesis Procedure on Particle Dispersion and Hardness of Al- Sic Functionally Graded Metal Matrix Composite

Abstract Fabrication of Functionally Graded Metal Matrix Composites (FGMMC) especially with high ceramic reinforcement's volume fraction is highly challenging. Depending on the processing technique and process parameters various defects may arise. This research aims to find the best procedure to make FGMMCs with the highest quality and minimum cost. A new method is proposed that incorporates lost-foam and melt infiltration with semicentrifugal casting to produce FGMMC. Experiments were performed to in-situ fabricate 6061-Aluminum alloy reinforced with gradient distributed Silicon carbide particles (Al/SiC FGMMC). Effect of SiC %, Al pouring temperature and rotational speed on the fabricated specimens hardness and reinforcement gradient were investigated using design of experiments and regression analysis. Results reveal the optimum procedure and process settings based on desired properties/gradient required. Mathematical model formulated captures the effect of these process parameters on process cost, and cost of poor quality. Improper selection of those parameters may lead to extensive losses due cost of poor quality which is 12 times higher than the material cost. The proposed manufacturing process proved satisfactory in ensuring proper dispersion. A desirability function can by used to determine the process parameters and volume fraction that minimizes the defects and gives superior properties for a specific application.

Identification of Critical Success Factors for Minimization of Cost of Poor Quality from the Construction Projects

Cost of Poor Quality (COPQ) or cost of failure gets inducted in construction projects during work execution due to failure in preventing defects, reworks and wastage of resources. Poorly defined project objectives, inadequate feasibility studies coupled with poor project planning and designing lead to revision of designs and reworks at later stage during project execution, causing cost and time overrun. Losses of construction companies on this account can go up to 40% of revenues. Since these losses (reworks and wastage of resources etc.) are normally not measured and recorded in the accounting system, therefore, they mostly remain hidden and the management does not know its gravity. Therefore, there is a need for reconnaissance and finding solution to minimize the losses of construction industry. Construction industry has a significant share in the socio-economic development of any country and provides employment to skilled/unskilled labor/poor masses and helps to alleviate poverty. Success of construction industry is dependent on performance of construction companies. The performance of construction companies can be improved by minimizing the COPQ. Completely eliminating COPQ might not be possible being uneconomical, however, it can be minimized with a proactive approach and effective management of Critical Success Factors (CSF), which were yet unknown. This study was therefore taken up to identify the CSF that can help the project management to reduce or minimize COPQ. This research study was successful in exploring and identifying forty (40) CSF falling in five areas of project management (Planning, Organizing, Executing, Monitoring and Controlling) that have the potential to decrease the losses on account COPQ from construction projects. Since it would not be possible for the project management to address and tackle all the forty CSF at the projects therefore, ranking in terms of criticality has been carried out for all the identified CSF. The analysis have revealed that 17 CSF fall in the list of top ten (some CSF have equal scores). It has also be identified that Planning is the most critical stage of any project because six of the top ten CSF pertain to Planning stage. According to ranking of top ten CSF, project Planning is at the top followed by Organizing, Controlling, Monitoring and Executing. It highlights the importance of Planning in any project; therefore, project planning may be completed very carefully so that no revision is needed during the project execution stage and COPQ remains at the lowest possible level.

Relationship Between Cost of Poor Quality and Continuous Improvement

Quality is a vital factor for every organization that seeks to sustain its competitive advantage. As such, organizations, especially those operating in the manufacturing industry, have enhanced their level of awareness on matters that align with quality, especially because of ever-advancing technology. In this regard, the cost of poor quality (COPQ) has been identified as a major component that is negatively impacting the profit maximization of many organizations. COPQ causes significant losses of revenue and businesses, as it takes the form of external and internal product failures. Nevertheless, there is a relationship between COPQ and continuous improvement; COPQ acts as a driver for continuous improvement initiatives that the organization adopts to enhance its quality. Thus, COPQ and continuous improvement are related because after an organization experiences the losses associated with COPQ, then it will strategize on ways to achieve continuous improvement.

The Importance of Quality Assurance and Quality Improvement in Low- and Middle-Income Settings

Purpose of ReviewThis review will discuss the importance of quality improvement in low- and middle-income settings as well as several potential barriers to these measures.Recent FindingsThere is substantial potential for growth in the field of quality improvement in low-resource settings. The extent of quality improvement (QI) research in low-resource settings is limited but expanding.SummaryPatient harm that is attributable to the costs of poor quality is a significant factor in all practice settings but is arguably of greater impact in limited-resource settings. Due to the recognized human, physical, and technological resource limitations in low- and middle-income countries, the delivery of quality healthcare can be variable in many settings, with discrepancies in evidence-based, evidence-informed, and customary care processes. Disparities in training and development of workforce providers exist in addition to limited availability of funding for QI research. Governmental, health ministry, and health system support is also variable. Attention to all of these areas is ultimately necessary to implement affordable and realistic quality improvement initiatives, education, training, and patient safety strategies that can mitigate harms, improve and establish more reliable outcomes, and develop a culture of safety to grow more sustainable and effective workforces and systems.

Returning to Solvency Through Quality Improvement

The purpose of this qualitative case study was to explore quality improvement strategies senior manufacturing production managers use to reduce Cost of Poor Quality (COPQ) to increase profit. The participants for this study were production managers within a manufacturing company located in the southeastern region of the United States who successfully developed and implemented strategies to lower COPQ to increase profitability. Six major themes emerged from the study: continuous improvement, quality assurance, employees as agents of quality improvement, communication between stakeholders, holding all firm members accountable for quality, and training. Manufacturing managers can use these strategies to lower COPQ and increase profits, which could result in enhancing other organizations’ financial performance. Findings from this study may enable manufacturing managers to improve organizational performance when continuous quality improvement processes are implemented throughout the manufacturing process and senior leaders champion lessons learned, support the training program approach, and implement a quality assurance program that empowers frontline employees as agents of quality throughout the manufacturing process.