Assignment 1
TQM Process/ System Modelling Method
Author: Hardik Bharatkumar Gala
Class code: IE673 live
Date: October 5, 2011
eLearning Pack ID : IE 673-Fall 2011-60-35
Statement: All contents of this assignment were submitted by Hardik Gala
Updated Notes:
Dr. Paul G. Ranky’s Comment: Unfortunately your DD and PD are very thin in
Assign1; also you have many syntax errors: 3/10
Grade: 3/10
Action Taken by Me: I have updated this assignment with DD’s and PD’s.
Contents:
· Introduction and Objectives
· Brief description of Models
· CIMpgr Models
· Collaboration
· More collaboration
· Process Description
· Data Dictionary
· Panorama Navigation Map
· Invent and manage
· Summary
· Further work needed/proposed
· References
· Introduction and objectives:
Metal alloys and plastic is given out as waste from the 4 collaborating companies. Plastic is used worldwide these days on a very large scale. The disadvantage of using plastic is that it does not degrade or decompose, even if it does it takes a very long to do so. The discarded plastic is given out in the waste thus increasing the dumps. The other method of disposing plastic is by melting it. But melting plastic gives rise to toxic fumes which in turn lead to air pollution. The metals like titanium and alloys like stainless steel and nickel alloys are also used on a large scale in industries. Titanium is a very expensive metal and requires a lot of processing before it can be put to industry use. Stainless steel is produced from iron ore. For producing it we have to mine iron ore and then process it to make stainless steel. Thus it’s a very long and time consuming process. Thus we cannot afford to discard the wastes of these metals and alloys. The processing of the alloys from the ores also leads to a lot of pollution.
RNR is an environment friendly company which aims at reducing pollution by finding ways to reuse and recycle plastic and metal alloys. We recycle plastic and metals in a very efficient manner which produces least amount of pollution. We recycle plastic, metals and the alloys in such a manner that the cost is very less compared to producing it the original way that is from the ore and then going through a series of processes. This method not only reduces the cost but also reduces pollution during the preparation process and reduces waste disposal.
The company's quality objectives are as follows:
· Collect the scrap metal and plastic and recycle them in the way which leads to minimal pollution.
· Produce low cost products which are environment friendly.
· Providing the customer with best quality products.
· Brief Description of Models
The method we use to model our processes is based on Professor Paul G. Ranky’s CIMpgr method. A complete CIMpgr model is a set of diagrams which systematically illustrate the object-to-object relationships between the objects, their functions and entities. The diagrams are often arranged in a layered, tree-like fashion, illustrating a parent-child relationship. It is a complex system in which at top of the tree there is a very high-level description of the entire system and further down the tree one goes, so the descriptions of the individual parts (objects) of the system become more detailed. Making a complete CIMpgr model of a system is an iterative process.
A model typically consists of three layers Layer0, Layer1, and Layer2. The first layer i.e. the top layer diagram always illustrates the basic, top layer CIMpgr object with the attributes of the object, grouped into Inputs, Outputs, Controls and Resources (I, O, C, R). The second layer diagrams typically explain more about "what is what". Each process can have not just inputs and outputs, as attributes, but also a clearer understanding of under what conditions does the process “fire”, or in other words, become an active object and performs. The unique feature of CIMpgr is represented by the way different methods and tools are integrated and applied to a practical industrial problem. CIMpgr method is integrated with six-sigma quality system methods and unified modeling language.
· CIMpgr Models
Layer 0 (Click to see the image)
This model gives the entire overview of the process. It includes the input, control, resource and output side and database. The input side is where the data enters the system which includes raw materials, customer and environment requirements and market research. The control side is where data limits or controls the processes which include budget, space and time constraints, market scope and conditions and various associations related to the product. The resource side includes collaborating companies, human and financial resources and software programming. The output includes recycled, eco-friendly and cost effective product and customer satisfaction.
Layer 1 (Click to see the image)
This diagram divides the parent layer into smaller components. It shows the main steps involved in the recycling process. The main steps are project planning followed by research and development followed by production and the last is quality analysis, marketing and sales. Project planning is the basis of the whole project. It is the foundation of the project. Research and development include finding ways to recycle the product. Production is the phase where the methodologies are put to use and products are manufactured. This phase is followed by quality analysis as that is our main aim. Lastly marketing and sales team work on selling the product in a better manner.
Layer 2 (Click to see the image)
This level shows the main aspects viz. market research and quality control analysis and testing. Market research will help us know the present market standings and strategies. With the help of market standings, surveys and customer requirements we can create a good product. Next come quality analysis, control and testing. This is very important for the success of the company. If this phase goes well, we are sure of getting a quality product.
· Collaboration
RNR is in collaboration with Contrinex, Mitsui Seiki, Trans Tech and Wild Republic. RNR will efficiently collaborate with these companies and produce ecofriendly products.
Contrinex: Contrinex is a leading manufacturer of inductive and photoelectric sensors. Stainless steel is mainly used in the production of sensors. This company produces a lot of scrap stainless steel. Thus this steel can be used at RNR to recycle. The recycled steel can be used back in the industry or else in other industries like utensils.
Mitui Seiki: Mitsui Seiki has acquired a world-renowned reputation for producing the most accurate machine tools on earth. It uses nickel and titanium alloys for tis production. The scrap alloys can be used by RNR to recycle and be used back in the same or different industry.
Trans Tech: Trans Tech is a manufacturer of engineered electrical Power Transfer Systems. It uses stainless steel for its production. The scrap can be recycled and used back in the same company.
Wild Republic: Wild Republic is a leading manufacturer of interactive and innovative toys. It produces a lot of scrap plastic. If left in the disposal it will create a lot of environmental problems. RNR recycles the scrap plastic and it is used for packaging in all the 4 collaborating companies.
· More collaboration
The collaboration with the 4 companies will earn RNR a lot of revenue. This collaboration will help in other ways as well. The reputation of the company will increase because of the good work done with these 4 companies. This in turn will help the company to make relations with other similar companies. This will help RNR serve other companies as well. Thus it will increase the revenue. Most importantly it will help reducing pollution and disposal issues.
· Process Description
1. Project planning
This is the most crucial step for any industry. If the project planning is perfect everything else falls in proper places. Planning is the key feature for the flourishing industries today. It takes into account customer requirements and expectations and environment requirements. The standards set by ISO and budget and time constraints are the controls. The collaborating companies and the project manager form the resources. The output of the planning phase is carried over to the research and development phase.
2. Research and development
The plan decided in the project planning phase serves as an input to research and development team. It analyses the plan and decides if it is feasible. The ISO, SPI and MBMA standards play an important role in this process. Technical staff, funding available and material information forms the resources. RnD team works to find ways to produce the product with the available resources.
3. Production
This is the most critical step. The process of recycling consists of multiple steps. It includes finding the useful materials from the scrap, melting or grinding them and then molding it again to usable form. Quality control and allocation of finance form the controls. Resources are equipment, skilled labor and raw materials. The final output of the production phase is the finished product that is recycled plastic, metal and alloys.
4. Quality analysis, marketing and sales
This is the final stage. This includes quality control, marketing and sales. Quality is extremely important. The quality analysts work on it very minutely because quality cannot be compromised. Next come marketing and sales team. Marketing is extremely important for the sale of product. A good marketing team with the help of sales team can help in better sale of product. The output is recycled, eco-friendly finished product ready for sale. The use of such efficient products will the earn the company satisfied customers.
· Data Dictionary
1. TQM- Total quality management which is an approach to business involvement led by the theme of quality.
2. CIMpgr- A graphical method for modeling a system
3. ISO- International organization for standardization
4. SPI- Society of the Plastic Industry
5. MBMA-Metal Building Manufacturers Association
· Panorama Navigation Map
Panorama navigation map is a tool which displays the 360 degree view of an image. It reproduces the image in a live format. It allows us to view the place even though we are not physically present. All the minute details can be viewed.
This tool will be very useful when set up in the industries. All the work can be performed sitting in the office only. There will not be any need to physically go and see the machines. This method will save a lot of time. All the levels of management can watch the processes in the industry.
It can prove as a boon to all the industries. It provides an excellent view. Any mistake been done can be rectified easily with this tool. It will allow the management to take decisions quickly without even being on site.
· Invent and manage
We at RNR Pvt. Ltd. are constantly working on inventing new processes in order to improve the quality of the product. The main aspects taken into consideration is the sustainable green engineering concepts. CIMpgr method has helped the company in running it very efficiently. We also try to invent new methods and processes so that the staff is dedicated to their work and thus increasing efficiency. All the processes are invented keeping eco-friendly product in consideration.
· Summary
The CIMpgr model gives a clear picture of the processes going out in the plant. The sustainability and green aspects and quality standards are shown clearly in the models. This model will help the clients know the product planning and the processes carried out. The quality of the product is monitored continuously thus delivering quality product. Most importantly quality control and analysis is carried out so that the quality is the best. All these things will help us manufacturing an eco-friendly product thus saving the mother earth from pollution and disposal issues.
· Further work needed/proposed
The future scope of RNR is to find even new methods for efficient recycling of waste and produce even better quality products. Further RNR would like to collaborate with more companies and thus help in finding solutions to pollution and disposal issues.
· References
1. Ranky, P.G.: An Object Oriented System Analysis and Design Method (CIMpgr) and an R&D Case Study, Published by ADAM at http://www.cimwareukandusa.com, © Copyright by CIMware Ltd. UK and CIMware USA, Inc , http://www.cimwareukandusa.com/CIMpgr1.html
2. http://www.cimwareukandusa.com/All-Green/Ranky-GreenEngineering.html
3. http://www.plasticsindustry.com/
4. http://www.iso.org/iso/home.html
