Share & Care - Dec 2016 PDF

This e-magazine is for FREE Circulation only
December
2016
Share
& Care
Mobile : 094428 92185
e-mail : avm@sripadhmam.com
Website : www.sripadhmam.com
Sri Padhmam Consultancy & Training What a Persons mind can conceive & believe,
1
it can achieve !
Top Performers
FMEA Mr. K M Satheesh Kumar

( Failure Mode & Effects Analysis )
Mr. L Srinath
for Mr. R Kumaresh
Hubbell Burndy, Chennai Mr. N Sathish
Coordinated by : Mr. M Manikandan

2
Sri Padhmam Share & Care E- Magazine Dec 2016 094428 92185 avm@sripadhmam.com
Top Performers
Mr. R Praveen
of Lucas-TVS, Pondicherry,
APQP
( Advanced Product Quality Planning ) Mr. R Premkumar
of Federn Fabric, Chennai,
for
Mr. Chaintanya Vikas
Lucas-TVS Suppliers, Chennai of Tyche, Hyderabad
( Suppliers of Maruti Parts ) &
Mr. Pravardhan
of KHMDL, Bangalore
Coordinated by : Mr. Ramesh &

Mr. Santhosh & team 3
Top Performers
Mr. M Kalidhas
Mr. P Saravanakumar
Kaizen & Mr. M Krishnakumar
6S Work Place Management Ms. R Priya
for Mr. P Baladhandapani
Techno Cast, Coimbatore Mr. S Sujai
Ms. Uma &
Mr. Perumal
Coordinated by : Mr. Sri Ram,

Mr. Subramaniam & Mr. Madhu 4
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 5
6
Sri Padhmam
Sri Padhmam Share &&Care
Share Care E-
E- Magazine
Magazine Dec Dec
20162016 094428 92185
094428 92185 avm@sripadhmam.com
avm@sripadhmam.com
Development
7
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
Deep dive in to
the Core tools of Automobiles
Answers for
the
5 Questions
asked last
month
1. Process FMEA will be done during APQP ..
5
a) Phase 2 b) Phase 1 c) Phase 3 d) All of them
the Core tools of Automobiles
2. In the 4th edition of FMEA..
a) Requirements are eliminated b) Requirements column is separated

Deep dive in to
Part # 5
3. MSA & SPC studies are done as a part of APQP during
Right Answers
a) Phase 2 b) Phase 4 c) Phase 5 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
Cost of Quality : A Detailed look !
3
11
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.
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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
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
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
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 !
16
I 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

Option A Option B Option C
1 Likert Scale Acceptance Criteria 1 : 10 1:2 1:5
2 Cause & Effect Diagram Out puts Possible Causes Root - Causes Probable Causes
3 Component Search Key Activity Swapping of parts Replacing of parts Re-working of parts
Keep the Routine

4 Cp & Cpk Studies Process Conditions Do not change Must Change
practices
To Validate the To validate the
5 B vs C Purpose To optimize the Results
proposed Changes present process
False alarm
6 Acceptance Criteria 2 % Maximum 5 % Maximum 5 % Minimum
Calculations
17
Added service from Sri Padhmam from now onwards ..
Audit service
Systems Audit
Sri Padhmam Process Audit
shall support you through
Systems Audit
Audits
on
Systems Audit
18
Sri Padhmam www.sripadhmam.com 094428 92185 avm@sripadhmam.com
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
Top 3 books : My Choice ! # Title of the Book Author Points of Inspiration
1 License to Live : A Priya Kumar This wonderfully crafted parable is all

Seekers Journey to about finding the direction you are
Greatness 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.
Books provide us
2 Fish!: A Proven Way to Stephen C. Lundin This interesting metaphor is all about
Boost Morale and with real Pike Place Fish Market.
lot of lights Improve Results John Christensen The author narrates it very
Harry Paul (Author), interestingly in a simple lucid style
to lead our life more
about how to apply ingeniously
Successful & simple lessons learned from the
actual Pike Place fishmongers in any
Meaningful too !
organization to energize employees.
3 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 real-
world ideas and practices that will get
you to world-class quickly. 20
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 21
21
Sri Padhmam Consultancy & Training 094428 92185 www.sripadhmam.com avm@sripadhmam.com
For downloading, please click .
Improvements are made with lot of resources !
But sustenance is suffering badly ? www.sripadhmam.com
Why & how to manage sustenance ?
Experienced personalities including HR

professionals shared their views !
It is now available in our website !

22

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This e-magazine is for FREE Circulation only

FMEA Mr. K M Satheesh Kumar

for Mr. R Kumaresh

Hubbell Burndy, Chennai Mr. N Sathish

Coordinated by : Mr. M Manikandan

Coordinated by : Mr. Ramesh &

Coordinated by : Mr. Sri Ram,

Coordinated by : Mr. Balasubramanian &

Let us become Leaders by Stature NOT just by Status !

2. In the 4th edition of FMEA..

a) Requirements are eliminated b) Requirements column is separated

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 ..

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

The major subcategories of internal failure costs are...

External Failure Costs.

Subcategories of external failure are

Liability costs : Costs or awards incurred from product liability litigation.

Statistical tools : A Close look !

Special Exercise for the Practitioners of Statistics !

Right answers for the exercise published last month !

# Statistical Tool Focus Point

1 Likert Scale Acceptance Criteria 1 : 10 1:2 1:5

Keep the Routine

Sri Padhmam Process Audit

shall support you through

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

1 License to Live : A Priya Kumar This wonderfully crafted parable is all

Team Building Program Feed-back

Experienced personalities including HR

It is now available in our website !

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