Faculty of Engineering & Technology, SRM University, Kattankulathur - 603203

School of Mechanical Engineering

Department of Mechanical Engineering

Course plan

Course code Course title Semester Academic year / s

: ME0068 : TQM & Reliability Engineering : VIII : 2013-'14/EVEN

Date

: 21 DEC 2013

Section details: Section Name

Room No.

" J

IV MECI-l " f\"

IV MECI-I "B" IV MECH (.tC'~

Details of Faculty member Inter e-mail id com No.

Mr. J. Daniel Glad Stephen

MEM32/

Mr.P.Karthikeyan Mr.A. Lakshman Kumar

Student contact time ;

I

1839

[email protected]

12.30to01.15

MEC104

1821

Karth ikeyan. [email protected]. ac.in

12.30to01.15

MEC110

-

Laksh l1lankllmar.ab@ ktr.srl11l1n i v.ac. in

12.30 to 01.15

B

~

I

I

IV MECI-I ('O"

!

Mr. N. Arun

MEI-Il09

IV MECH "E"

Mr.S.Balamurugan

MEB404

IV MECH "F"

Mr. P .Yuvaraj

MEHI01

-

[email protected]

12.30to01.15

1806

[email protected]. ac.in

12.30 to 01.15

-

yuvaraj.p@ ktr.snnllniv.ac.in

12.30 to 01.15

Direct assessment details: Name of assessment Cycle test - I

Marks 10

Surprise test Cycle test - II

05 10

Model examination End semester examination Attendance

20 50 05

Topics(Ten tia tive) Till customer retention ­ Service quality Advanced Tools Till quality Management Systems Entire Syllabus Entire Syllabus N/A

Tentative date 06.02.2013

Duration 100 minutes

-

30- 45 min 100 minutes

06.03.2013 16.04.2013 -

3 hours 3 hours

,i

Mapping between instructional objectives and student outcomes S.No

Instructionalobjcctive

Student outcomc

d) An ability to function on multid iscip Iinary teams Meaning of TQM and Theories f - ­ about TQM h) The broad education necessary to understand the impact of engineering solutions in a global, economic, environmental and societal context a)An ability to all ply knowledge of mathematics, science, and engineering

2

Planning and manufacturing its tools and for qual ity, techniques

d) An ability to function on multidisciplinary teams

j-Iuman

3

involvement to improve quality and the development and transformation due to such involvement

5

Using SQC techniques and tools, the students will be able to analyse current quality level. As a team, students will be able to use advanced management tools like Affinity diagram, Relationship diagram, Arrow diagram, Root cause analysis diagram, and Quality Function Deploymcnt. By studying the importance of employee involvemcnt, motivation, empowerment, team work, customer rctention, and servicc quality, students will get the relevant broad exposure.

a) An ability to apply knowledge of mathematics, science, and engineering

By studying probability nature of failures and techniques like Failure rvlode and Effcct Analysis (FMEA), Failure Mode and Effects Criticality Analysis (FMECA), and Fault Tree Analysis (FTA), students will be able to use these tools in case studics to analyse thc system reliability.

h) The broad education necessary to understand the impact of engineering solutions in a global, economic, environmental and societal context

By studying Quality Management Systems like ISO 9000 and ISO 14000, students will be able to understand and apply the global standards.

component reliability & system reliability

To know about mean down of time, maintainability systems & condition monitoring

By studying Deming, Crosby, Juran, Taguchi and Ishikawa theories, students will get the broad exposure.

h) The broad education necessary to understand the impact of engineering solutions in a global, economic, environmental and societal context

To know about failure models, 4

Justification Goal setting - Students act as Multidisciplinary team members in role play (representing various departments of a company) to review the current quality level and --j-=-=..:....i2-:..:Cc:.::..:.. -j set goals.

a) An ability to apply knowledge of mathematics, science, and engineering

By studying Mean time to failure, Mean down time, Mean time to repair, and Fault diagnosis, the students will be able to monitor and improve the condition of system.

Syllabus:

ME0068 - TQM AND RELIABILITY ENGINERING

PURPOSE

To provide knowledge about Total Quality Management (TQM), TQM tools and techniques applied to

Manufacturing and also about reliability and maintainability of different systems. INSTRUCTIONAL OBJECTIVES At the end of the course students will be able to know Meaning ofTQM and Theories about TQM Planning and manufacturing for quality its tools and techniques Human involvement to improve quality and the development and transformation due to such involvement About failure models, component reliability & system reliability About mean down time, maintainability of systems & condition monitoring BASIC CONCEPTS Evolution of total quality Management - Definition of quality - Comparison between traditional approach and TQM, Deming - Crosby - Juran - Taguchi, Ishikawa theories - Quality costs - Product quality Vs Service quality Strategic planning - Goal setting - Steps involved in strategic planning - TQM implementation. TQM PRINCIPLES & BASIC TOOL Customer Satisfaction - Types of customers, customer suppl ier chain, Customer perception of qual ity customer feed back ­ Customer complaints - Customer retention - Service quality. Employee involvement - Employee motivation - Maslow's hierarchy of needs - Herzberg theory - Empowerment and team work. Basic Tools: Introduction to seven basic tools - Check sheets, histograms - Control charts, Pareto diagram - Cause and effect diagram - Stratification - Scatter diagrams. NEW SEVEN MANAGEMENT TOOLS & ADVANCED TOOLS Affinity diagram - Relations diagram - Tree diagram - Matrix diagram - Matrix data amdysis diagram - Process decision program chart - Arrow diagram. Advanced QC tools: Advanced QC tools like QFD - Root cause analysis - Taguchi method - Mistake proofing (poka­ yoke) - Failure mode and effects analysis (FMEAs), failure mode and effects criticality analysis (FMECAs) and Fault tree analysis (FTAs) etc. - Quality Management Systems. ImLlA13IL1TY Definition - Probabilistic nature of failures - Mean failure rate - Meantime between failures - Hazard rate - I-lazard models, Weibull model - System reliability improvement - Redundancy - Series - Parallel and Mixed configurations. MAINTAINABILITY lntroduction - Choice of maintenance strategy - Mean time- to repair (MTTR) - Factors contributing to Mean Down Time (MDT) - Fault diagnosis, and routine testing for unrevealed faults - Factors contributing to Mean Maintenance Time ­ (MMT) on condition maintenance - Periodic condition monitoring - Continuous condition monitoring - Economics of maintenance. TEXT BOOKS Joel E. Rose, Total Quality Managellleut, 2nd Edition, [(ogan Page Ltd., USA 1993 Srinath, L. S., Rcliability Engineering, Affiliated East West Press, New Delhi 1995

REFERENCE BOOKS Balagurusallly, E., Rcliability Engineering Tata McGraw Hill publishing Co., New Delhi, 1984 Greg Bounlelll reliability improvement Redundancy - Series - Parallel and Mixed figur!1lions,

COil

1'2, chapter I

1'2, chapter 6 1'2, chapter 7

MAINTAINAI3JLITY 38

I

Choice of 1ll,linlenancc

39,'10

2

Mean limc- 10 n;pail' (M1'TR)­

T2, chapter 10

41

I

Factors contributing

1'2 , chapter 10

42

I

Faull diagnosis, Rouline resting for umeve;:led f'1lllts

43

I

LO

SlI"ltCgV

Mean Down Time (MDT)

T2 , chapter 9

1'2, chapter 10

f'ac:ol's contributing lo fvka!l iVlailllcn: diagl'arll - Matl'i" clata ;lI1alysis Jiogr:llll 21

I

1)l'Oc