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2016
December

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What a Persons mind can conceive & believe,

1
it can achieve
!

Top Performers

Mr. K M Satheesh Kumar

FMEA
( Failure Mode & Effects Analysis )

Mr. L Srinath

for

Mr. R Kumaresh

Hubbell Burndy, Chennai

Mr. N Sathish

Coordinated by : Mr. M Manikandan

2

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Top Performers
Mr. R Praveen
of Lucas-TVS, Pondicherry,

APQP

Mr. R Premkumar

( Advanced Product Quality Planning )

of Federn Fabric, Chennai,

for
Mr. Chaintanya Vikas

Lucas-TVS Suppliers, Chennai

of Tyche, Hyderabad

&
Mr. Pravardhan

( Suppliers of Maruti Parts )

of KHMDL, Bangalore

Coordinated by : Mr. Ramesh &

Mr. Santhosh & team
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Top Performers
Mr. M Kalidhas
Mr. P Saravanakumar

Kaizen &
6S Work Place Management

Mr. M Krishnakumar

for

Mr. P Baladhandapani

Techno Cast, Coimbatore

Mr. S Sujai

Ms. R Priya

Ms. Uma &

Mr. Perumal

Coordinated by : Mr. Sri Ram,

Mr. Subramaniam & Mr. Madhu
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Top Performers

SPC
( Statistical Process Control )

Mr. Charles

for

Mr. T Tharmaraj

Poclain Hydraulics, Pondicherry

Mr. Rajesh Kanna &

Mr. V Jayabalan

Coordinated by : Mr. Balasubramanian &

Ms. Preethi
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Development

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LEADERSHIP

Emerges on his / her own !

Just by Position !
All by Actions !

Can be Appointed !

Let us become Leaders by Stature NOT just by Status !

8

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Deep dive in to
the Core tools of Automobiles

Answers for
the

Questions
asked last
month

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Deep dive in to
the Core tools of Automobiles

1. Process FMEA will be done during APQP ..

a) Phase 2

b) Phase 1

c) Phase 3

d) All of them

2. In the 4th edition of FMEA..

a) Requirements are eliminated

b) Requirements column is separated

3. MSA & SPC studies are done as a part of APQP during

a) Phase 2

b) Phase 4

c) Phase 5

Part # 5

Right Answers

d) Phase 1 itself

e) None of them

4. Non-random patterns in the SPC are ..

a) Trends

b) Runs

c) Both a & b

d) None of them

5. Characteristics Matrix is closely linked to ..

a) Design FMEA

b) PPAP documentation

c) MSA studies

d) None of them ( Process FMEA )

10

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Cost of Quality : A Detailed look !

11

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Quality Costs : A detailed Look

Internal Failure Costs.

Internal failure costs are incurred when products, components, materials, and services fail to meet
quality requirements, and this failure is discovered prior to delivery of the product to the customer.

These costs would disappear if there were no defects in the product.

The major subcategories of internal failure costs are...

Scrap : The net loss of labor, material, and overhead resulting from defective product that cannot
economically be repaired or used.

Rework : The cost of correcting nonconforming units so that they meet specifications.
12

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Quality Costs : A detailed Look

In some manufacturing operations rework costs include additional operations or steps in the
manufacturing process that are created to solve either chronic defects or sporadic defects.
Re-test : The cost of re-inspection and retesting of products that have undergone rework or other
modifications.
Failure analysis : The cost incurred to determine the causes of product failures.
Down time : The cost of idle production facilities that results from non-conformance to requirements.
The production line may be down because of nonconforming raw materials supplied by a supplier,
which went undiscovered in receiving inspection.
Yield losses : The cost of process yields that are lower than might be attainable by improved controls
(for example, soft-drink containers that are overfilled because of excessive variability in the filling
equipment).

13

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Quality Costs : A detailed Look

Downgrading : The price differential between the normal selling price and any selling price that might
be obtained for a product that does not meet the customers requirements.
Downgrading is a common practice in the textile, apparel goods, and electronics industries.
The problem with downgrading is that products sold do not recover the full contribution margin to profit
and overhead as do products that conform to the usual specifications.
External Failure Costs.
External failure costs occur when the product does not perform satisfactorily after it is delivered to the
customer.
These costs would also disappear if every unit of product conformed to requirements.
Subcategories of external failure are
Complaint adjustment : All costs of investigation and adjustment of justified complaints attributable to
the nonconforming product.
14
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Quality Costs : A detailed Look

Returned product / material : All costs associated with receipt, handling, and replacement of the
nonconforming product or material that is returned from the field.
Warranty charges : All costs involved in service to customers under warranty contracts.
Liability costs : Costs or awards incurred from product liability litigation.
Indirect costs: In addition to direct operating costs of external failures, there are a significant number
of indirect costs.
These are incurred because of customer dissatisfaction with the level of quality of the delivered
product.
Indirect costs may reflect the customers attitude toward the company.
They include the costs of loss of business reputation, loss of future business, and loss of market
share that inevitably results from delivering products and services that do not conform to the
customers expectations regarding fitness for use.
Will Continue

15

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We are offering many Statistics based Workshops such as

Statistical process control, Six Sigma awareness, Control Charts,
Capability studies and Design of Experiments ( Shainin ).
This exercise will help those who had undergone the above
mentioned programs by us !

Statistical tools : A Close look !

Special Exercise for the Practitioners of Statistics !

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Statistical Tools : A Close look

Right Answers !

Right answers for the exercise published last month !

Please select the best Option & Circle
#

Statistical Tool

Focus Point

Likert Scale

Option A

Option B

Option C

Acceptance Criteria

1 : 10

1:2

1:5

Cause & Effect Diagram

Out puts

Possible Causes

Root - Causes

Probable Causes

Component Search

Key Activity

Swapping of parts

Replacing of parts

Re-working of parts

Cp & Cpk Studies

Process Conditions

Do not change

Must Change

Keep the Routine

practices

B vs C

Purpose

To optimize the Results

To Validate the
proposed Changes

To validate the
present process

False alarm
Calculations

Acceptance Criteria

2 % Maximum

5 % Maximum

5 % Minimum
17

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Audit service

Added service from Sri Padhmam from now onwards ..

Systems Audit

Sri Padhmam

Process Audit

shall support you through

Systems Audit

Audits
on
Systems Audit

18

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Habit of reading books is a proven source of inspiration !

From now, some of our circle members are sharing the
book(s), which has inspired them so far !

Mr. Rajini is known for me for more than 8 years ! An excellent

Training & Development Manager with lot of enthusiasm and
positivity in him ! His belief in my little talents gives me too,
lot of energy !

19
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Top 3 books : My Choice !

Books provide us

Title of the Book

Author

License to Live : A
Seekers Journey to
Greatness

Priya Kumar

Fish!: A Proven Way to

Boost Morale and
Improve Results

Stephen C. Lundin
with
John Christensen
Harry Paul (Author),

This interesting metaphor is all about

real Pike Place Fish Market.
The author narrates it very
interestingly in a simple lucid style
about how to apply ingeniously
simple lessons learned from the
actual Pike Place fishmongers in any
organization to energize employees.

The Mastery Manual

Robin Sharma

Yet another master piece from Robin - A

life-changing guide for personal and
professional greatness!
The Mastery Manual is packed with realworld ideas and practices that will get
you to world-class quickly.
20

lot of lights
to lead our life more
Successful &
Meaningful too !

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Points of Inspiration
This wonderfully crafted parable is all
about finding the direction you are
destined to head in and creating the life
of your dreams. Author Priya kumar
narrates it in a mind-blowing way.
At the end of the book, youll surely find
something or get some insight for
your life.

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 I like your way of telling about

core members positive
character !
In your program, you made me
to abolish the negative
thoughts and converted me a
positive thinker !

Team Building Program Feed-back

from the Delegates of TGI Packaging, Chennai

Sri Padhmam Develops the Employees. In turn, they develop the Organization !

Satyam Grand Resort, Chennai

Sri Padhmam Consultancy & Training

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Improvements are made with lot of resources !

But sustenance is suffering badly ?
Why & how to manage sustenance ?

For downloading, please click .

www.sripadhmam.com

Experienced personalities including HR

professionals shared their views !

It is now available in our website !

22
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