PACK-IT SOLUTIONS
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PACK-IT SOLUTIONS
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TQM 673 projects:
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IE 673 LIVE - Assignment 1 KAMIL DZWONKOWSKI ELeARNING ID: IE 673-Fall2008-70-38 Pack-It-Solutions Collaborating with:
Table of Contents
Introduction: This is a project that is concerned with four companies with miscellaneous products interconnected on development a TQM process focused on minimizing the turn-around time of shipment, storage and loses in energy and labor. Pack-It Solutions provides the tools for a client to have their chemically challenged products shipped in an Eco friendly way on a world-wide scale. Ø The equipment used in our storage facilities is interconnected with Noax Technologies industrial grade PCs. They are mounted on-board each of our fork-lifts, and constantly monitor the in-stock storage inventory. When an order is received at a truck gate, the system automatically informs the nearby fork-lift operator to deliver the shipment to a designated destination. This enables constant in-stock quantity assurance, and a short delivery turn-around time. Ø Rockwell Automation is providing our storage facilities with a number of their services, with the focus on the Electronic batch recording (EBR) and Radio frequency identification (RFID)-enabled solutions. These services provide as with a constant control of where a package is currently being handled and assurance the proper quality monitoring. Ø Bio-Pharma Solutions will implement their Baxter highly sophisticated temperature control for proper temperature, pressure and moisture setting requirements. The specially designed environment for the chemical and pharmaceutical products will insure proper conditions to keep it healthy and stain free. Ø Our fourth partner is the GE Healthcare solutions know by the name of ReadyToProcess and Wave. General Electric has integrated our packaging/valediction process in a very quince way. It was developed for seamless operations, and it consists of a series of stainless equipment to design, validate, cut cardboard, fill bottles, and melt Styrofoam. The system is intergraded with the disposables and waste equipment. The biopharmaceutical mixers, tube welders and sealers allow users to configure facilities using disposables exclusively. Project Objective: We define process as a team effort of manipulating with tools to implement number of tasks that comes form the input (for example costumer requests or storage space limitations, labor limitations, payroll restrictions), and results in an output (for example a satisfied costumer , profit higher then anticipated , excellent quality) To insure the satisfaction of all parties, highest possible quality and future successes, TQM Process are implemented and constantly improved. The output is the controlling tool in the scheme and its acts as a feedback to our procedures. The alteration which is one of the tools implemented in the strategy at our Pack-It-Solution facility involves the manipulation with value, usually by processing data, improving the turn around spectrum, reducing failure rate or total cost, changing place, form, or shape. As the feedback of the outcomes is the solution to an improvement, we pay close attention to costumer satisfaction. Nevertheless, we always stay environmentally friendly, as we recognize the surrounding world as a team effort and benefit to all people. Methodologies Applied: Analytical Modeling, implemented as quality assurance thru all stages of the processing line is the main factor contributing to success of our institution. As data failure may occur in the future, we use Statistical process control to predict them before they actually happen. CIMpgr is another approach for process modeling that we use at our institution. It consists from set diagrams, which carry the role of entities. Each entity has an object to object relationship. The links between the entities are a set of functions. The diagram is then mapped via these links, as inputs, outputs, data sources and constrains. The diagram is often arranged is a parent-child relationship that represents a linked relationship between the diagrams. The project starts with an objective, general attribute of the companies perspectives, and thru the tree link, it points out to a more detailed entity of the general project. Strategies for quality assurance: Reliability is the main objective that opens a path for developing continues improvement. Continuous improvement, as it is an essential part of Lean manufacturing allows producing a desired output with a least amount of variation. Usually the next step, once the reliability is achieved is an approach towards meeting the costumer needs. To gain the costumer satisfaction, there is a special cause variation, and common cause variations recognized. Special cause variations are regulated by the operating sector, on the other hand common cause variations are removed by the process design adjustment. Project Development: The Top layer(Layer0) diagram illustrates the basic, top layer CIMpgr object with the attributes of the object, grouped into Inputs, Outputs, Controls and Resources (I, O, C, R). It is a high level of the overall process and the company. This layer is commonly termed as the ‘parent’ layer. The Second layer (Layer1) diagram typically explains more about the main processes within the top layer .It represents a deeper prospective into these individual processes and how they affect the overall view. This layer is also commonly termed as the ‘child’ as it originates from the parent or the top layer. The Third layer (Layer2) diagram is a more distinct view to a main act. A1- Concept - Planning and Research Brainstorming and overseeing different opportunities, perspectives and ideas are the core objectives of this stage. The main inputs for our strategy of the service to be developed are the needs of our customers. We derived this conclusion on a previous research performed by the HR department of Pack-It Solutions facility. The second input that our company is concerned with is the requirement of a professional delivery, processing and storage of chemicals request from the public. Thru cooperating with a number of sophisticated processing techniques from different corporations, we are delivering a state of the art bio-chemical processing facility for the most desirable client. The major aspect of output in the case of Pack-It-Solutions is the absolutely highest possible quality, seamless processing of chemically challenged products, and delivery to a nationally wide location with a special focus into environmental friendly GREEN attitude. Tools such CORA, along with ABC costing and Risk analysis, enable us to achieve these goals. A2 – Process Engineering - Design, Engineering and Validation This is the second phase into Process Excellence, and it is concerned with more in-depth view of the entire processing aspect of Pack-It-Solutions. The core inputs are the values of project planning and research, with the resources of being concentrated in high quality with the lowest output cost. Time is also a factor, since its balances the revenue return. Phase II is represented as a detailed diagram of linked system of analysis. It consists of 2D and 3D computer modeling. It enables a Process Engineer to recognize weakest points and potential innovative way for improvement. The resultant of stage II process analysis is a perfect chemical processing service, which provides seamless operation, highest quality product in a GREEN environment. To insure excellent end-user quality the system is equipped with two a feedback loops. This insures a sampling variation, and provides self-control. A3 – Plant Operation and Validation Thru this stage the chemically challenged products are separated, condensed, transported and storage. The GREEN Trucks used by our company transport the large and bulky materials to our storage facilities. While the Energy Efficient Electric fork-lifts rise the material on the top level bins. The entire distribution system is monitored thru Noax Technologies industrial computers. When an older is received at the delivery gate, the operator of a fork-lift is immediately informed thru on board computer. The usage of GE Wave Technology enabled a seamless monitoring of our inventory floor. The system profits an organized older of storing, and chandelling the product, providing an effective logistics strategy. A4 – Seamless Production with GREEN While a lot of our services include logistics of chandelling chemical products, we are offering an innovative packaging line for bio-chemical, toxic, and pharmaceutical materials. Again, we are using GE Ready2Process technology which enables us to develop the most sophisticated packaging solutions, human safe, and environmentally GREEN. The process is monitored for QS9000 and ISO9000:2000 quality standards. That profits us with national-wide services, further world wide delivery. A separate testing facility does testing of samples of the designed packages. A5 – Logistics center and Final QA Test Feedback At the final stage we operate separate inventory facilities were we handle specially dangerous and toxic merchandise. Each product, bottle and box gets here its individual batch recording number. The company that provides us this technology is Rockwall Automations. We decided to co-operate with them since their machines can be interfaced with Noax inventory system. The facility here has also an individual air conditioning system from Rockwell, to keep our products safe and away from corrosion. Electrical transportation rollers from Rockwell are an addition to our GREEN organization. All the products that we transport thru our facility are being handled on a low power – high torque motor. There is completely no CO2 emission, and the solar umbrellas from GE mounted on the ruff provide a source of natural electrical energy to power this transportation belts. Again, from here our logistic operation GREEN trucks deliver national-wide. The back feed validation equipment again tests the timing, inventory correctness and packaging quality. Glossary of Terms/Dictionary ISO 9000: A family of standards for quality management systems. ISO 9000 is maintained by ISO, the International Organization for Standardization and is administered by accreditation and certification bodies. Process: A process can be defined as the transformation of one or more inputs (data, raw materials, customer requests, etc.) into outputs (processed data, processed materials, satisfied customers: as a service, etc.) Transformation: The transformation involves the addition or creation of value, typically by processing data, improving on cycle time, reducing failure rate, increasing robustness, reducing cost, changing place, changing form, or shape. Quality: The level of performance of a product, a service, a production process or lot, measured in terms of specified requirements. Quality assurance: All those stated, planned systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality. Quality Control: is the effort of an entire enterprise to develop, design, manufacture, inspect, market and service products that will satisfy the customers at the time of purchase and give them satisfaction for a long time after purchase. System integration: An implementation and/or testing strategy and methodology in which all the subsystems of a system are brought together at once to be tested and debugged step-by-step. Testing: Determining the capability of an item to meet specified requirements by subjecting the item to a set of physical, chemical, environmental, or operating conditions. Total Quality Management (TQM): Participative management style that stresses total staff commitment to "customer" satisfaction. It is a holistic approach to managing complex organizations and replaces top-down management with decentralized customer-driven decision making. TQM is an integrated management system for creating and implementing a continuous improvement process, eventually producing results that exceed customer expectations. It is based on the assumption that 90 percent of problems are a result of process, not employees. Inspection: The act of reviewing, inspecting, testing, checking, auditing, or otherwise establishing and documenting whether items, processes, services, or documents conform to specified requirements. Reference and Bibliography "Paul
G. Ranky, IE673 Total Quality Management, Fall 2008, e-Learning Pack ID #
IE673-FALL2008-70-38" "Paul G. Ranky" website URL Ranky, P.G.: An Object Oriented System Analysis and Design Method (CIMpgr) and an R&D Case Study http://www.cimwareukandusa.com/CIMpgr1.html#Keywords |
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