Induction Cooktops Quality Planning and Analysis - Example

RUNNING HEAD: Induction Cooktops Quality Planning & Analysis Name: Instructor: Course Unit: Date: Introduction: In the midst of gas prices and electric bills soaring, cooking has become very expensive in different parts of the world. Individuals are hence looking for economical and environmental friendly alternatives to cut down the hefty bills they are footing at the end of every month. It is this that has triggered me to come up fundamentally with an induction cook-top that uses minimal electricity, cooks faster than gas and keeps cooler than electric cot-tops when cooking. An induction-cooker element produces a current of electricity inside the metal, of which the pan is made, and that current flow through the resistance of the metal produces heat; compared with the gas and electric cook-tops the difference is that, the heat is produced directly in the pan itself as shown in Fig. 1 below, and not in any component of the cooker. Source: Cypress Reform 2009, p. 1 Fig. 1: An induction stove Main features of the induction cook-top: Has electronic power coil that creates a high-frequency EM field that produces a flowing electric current that then generates high temperature that enters the pan directly. From fig. 1 above it is evident that not anything exterior to the pan is influenced by the heat, therefore no heat is lost, and the instant the pan is taken away from the element, heat production ends. Another implication of heat not being wasted is that, the cooking areas and the top of the stove remain cool thus no cases of burning hands for the user and inquisitive children, this then promotes cleanliness, because no soot is produced. It uses electricity that is always present and at low power consumption, thus the presences of the potentially hazardous and spacious gas cylinders are eliminated. It also has an advantage of simplicity and adaptability of installation. Part 1: Client Satisfaction: Part 1-1: Ten Stakeholders and their expectation: Stakeholders Their expectations Government Legal requirements for instance certification; Safety for instance ISO certification & environmental concerns; and job opportunities. Proponent (owner) Trades and revenue; product charge and repute; & business development. Society Presence of the invention; extra employment prospects; guarantor for communal events Suppliers Imbursement promptness; constant bid / demand; & lasting contract. End user Affordability; Dependability & Excellence. Contenders Reasonable operation; Benchmarking & Market distribute. Retailers Product Availability; Guarantee; & New Product Workforce Excellent earnings; first-rate working atmosphere; & career sanctuary. Investor Turnover; business development & long-standing big business. Delivery corporation suitable wrap up enjoin & in the fullness of time delivery Part 1-2: Tools for capturing consumer desires: These tools take account of; Consumer Interview; Consumer analysis Questionnaires; Consumer Feedback; Focus Groups; and Benchmarking. Consumer analysis Questionnaire: This tool involves presentation of written questions to the clients so that they can be answered by them in written form. The questions could be open-ended or closed. Through asking questions it labours to impact the desires of clients in diverse areas that include issues like commodity quality, and price. It comprehensively involves old and new clients, thus it is a very rich technique of innovativeness’. Consumer Interview: This technique engages verbal questioning of clients, either independently or else as a group. The interviewer can shed light on any queries that the client might not be able to understand clearly thus the certainty of getting right answers is high. This technique furthermore presents flexibility in the data collection process, for example use of less flexible methods at the time the population of consumers to question is great. Consumer Feedback: Utilizes the same method of questionnaires, but in this case the questions regarding the commodity or service are positioned at different outlets, for instance, mailed with the bills, so that response from the consumer can be got. It is to a certain extent rapid and economical technique. Focus groups: It allows a client group of not more than twelve informants to unreservedly discuss a definite subject with the assistance of a facilitator. Benchmarking: It entails the assessment of company processes metrics such as price and cycle time to another comparable company in turn to acquire superior effects in terms of consumer contentment. Application of the Client Survey Questionnaire to my Product: 1. Your Name: ____________________________________ 2. Sex: M F 3. Your Occupation: Student Business Service Other _______________ 4. Do you have a cook-top stove in your home? Yes No (If you selected Yes, answer the question 6-9, if you selected No go to question 8) 5. If yes, which type do you have? Gas Induction Electric 6. How long have you been utilizing it? 1-3 4-6 7 -9 more than 10 7. Are you satisfied with your cook-top stove? Yes No Why? __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 8. Are you going to buy a cook-top stove? Yes which type? ____________________ No Why? __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 9. What is your financial plan for a new cook-top stove? 500-1000 1000-1500 1500-2000 2000-2500 Above 2500 10. What are your ideal requirements for a cook-top stove? Preferred Not Preferred 5 4 3 2 1 a. Instant adjustments b. No wasted heat c. A cool stovetop d. Enhanced safety e. Low power Consumption f. Ubiquity g. Optimal Cleanliness i. Simple and adaptable instillation procedure m. Guarantee n. Portability o. Price / Value of money p. Durability 11. Any proposals or elements you would like to include on your cook-top Stove? __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ THANK YOU Part 1-3: Customer Requirements/Needs Using the Kano Analysis: Product Name: Induction Cook-top Stove Musts 1 Low power consumption 2 Doesn’t waste heat 3 Portable/weight 4 Enhanced safety 5 Sensors that detect the pan size thus further reducing heat loss 6 Instant adjustments 7 Ubiquity (uses environmentally clean source of fuel) 8 Size & Shape (How big the it is, and the design) 9 shock proof, and able to regulate power 10 Affordable Price/ guarantee Wants 1 Simple and adaptable instillation procedure 2 Optimal Cleanliness 3 Noiseless 4 Customize Option (colour, and style) 5 Powered by electricity 6 Automatic heat regulator 7 Able to operate at low a cooking-heat level (e.g. during gentle simmering) 8 Cooler cooking areas 9 Cool stove top 10 More guarantee Desirable 1 Allows wheelchair access 2 Durable 3 A remote controlled heat regulator. 4 Optional gas connectivity 5 Life time guarantee Part2a: Quality Function Deployment: Design Requirements Customer Requirements IGBT Automatic Power Consumption Sensors that detect pan size Automatic regulator Instant adjustments Cool stove top Noiseless Portable/Weight Simple instillation Powered by electricity Musts Low power consumption 5 9/45 9/45 9/45 9/45 3/15 3/15 Doesn’t waste heat 5 3/15 3/15 3/15 9/45 Portable/weight 5 1/5 9/45 Enhanced safety 5 9/45 1/5 1/5 3/15 Sensors that detect pan size 5 3/15 9/45 3/15 Instant adjustments 5 1/5 9/45 9/45 Ubiquity 5 1/4 3/12 9/36 Size & Shape 5 9/36 3/12 Shock proof & regulates power 5 3/15 3/15 1/5 3/15 3/15 1/5 3/15 Affordable Price/ guarantee 5 3/12 3/12 9/36 3/12 3/12 3/12 3/12 3/12 3/12 3/12 Wants Simple and adaptable instillation procedure 5 9/45 9/45 3/15 Optimal Cleanliness 4 9/36 9/36 Noiseless 4 9/36 1/4 Customize Option 5 9/45 Powered by electricity 5 3/15 1/5 Automatic heat regulator 5 1/5 3/15 1/5 Able to operate at low cooking-heat level 4 9/36 Cooler cooking areas 4 1/5 Cool stove top 4 1/4 3/12 9/45 More guarantee 5 3/15 1/5 1/5 3/15 1/5 3/15 3/15 3/15 3/15 3/15 Desirables Allows wheelchair access 3 3/9 1/3 3/9 Durable 1 1/3 A remote controlled heat regulator. 3 3/9 3/9 3/9 Optional gas connectivity 2 1/2 1/2 Life time guarantee 2 2/4 9/18 9/18 2/4 9/18 1/2 2/4 2/4 2/4 2/4 Target value Quality material Less than 2.4 kW Effective sensors that heat-proof Effective regulator Immediate response Less than 2o C Silent operations 10 pounds with Less than 5 minutes 240-250v Absolute score (total) 120 115 289 111 188 89 173 164 91 246 Part 2b: Failure Mode and Effect Analysis Part or function Potential failure Effect on system Root Cause of failure Risk before Action taken Action to reduce risk Risk after action taken P S R P S R Element (coil) Break down Out of order Poor Material 2 5 10 Use better and strong material 1 5 5 Power supplier No heat generated Out of power Bad design 2 4 8 Design better power supplier 1 4 4 Heat control device Doesn’t regulate heat Doesn’t work Bad material 3 5 15 Use better material 2 5 10 Sensor Doesn’t sense pan size Wastes heat Bad sensors 3 4 12 Use effective sensors 2 4 8 Voltage regulator Beeps as if no pan doesn’t work Low voltage 3 4 12 Design better voltage regulator 2 4 8 Part3: Supplier Selection and Evaluation: 3.1: List of 10 major parts or components of the Cook-top stove: Element/coil Cable jack Thermistors Capacitors Fan Power Supply: AC 100-240V, 50/60Hz Plates IMD pressure outer Plastic shells IGBT Automatic Self protection* Ceramic tiles/heat resistant glass *IGBT- Insulated-Gate Bipolar Transistor - is the basic element of the induction stove. IGBT functions under high voltage and high power states. Though, in view of the high cost and rigid parameters, IGBT is designed with several orders, and hence it’s vital to protect it. 3.2: 10 criteria that should be used for selection of a supplier for the IGBT part: 1 Cost 2 Various dimensions 3 Dissimilar Color System: 4 Manufacture Capacity 5 Robustness 6 Service contract 7 Location 8 Delivery Time 9 Support 10 Training 3.3: A complete Supplier Selection System Selection and Evaluation criteria Company Guangzhou Qingfeng Electronics Co., Ltd.Remove from basket [X] Better Home Appliance Co., Ltd.  [Y] Guangzhou Golden Hongfa Electronic.Co., Ltd. [Z] Cost 10 9 8 Various dimensions 10 6 6 Dissimilar Color System: 10 5 7 Manufacture Capacity 8 9 8 Robustness 9 7 6 Service contract 10 8 8 Location 8 8 8 Delivery Time 7 5 9 Support 8 6 5 Training 6 6 6 TOTAL 86 69 71 3.4: A report including explanations of reasons for the decision made: The IGBT is one of the core apparatus of this induction cook-top stove, for the fact that it is the Automatic Self Protection of the stove. In this development, involving three companies, company ‘X’ is far off ahead as a supplier compared to the companies ‘Y’ and ‘Z’. Despite the fact that it prices are high but of importance is that it brings into being the best quality in different sizes; effective automatic measures; and best heat proof qualities which is exceptionally significant. Another aspect considered is that it offers additional guarantee for its inventions than the remaining two. The durability of its IGBT’s is also uncompromised, for these reasons here in stated company ‘X’ was selected to be the successful supplier of the IGBT components. Part 4: Statistical Process Control: 4.1: A list of Ten key production processes: 1 Hardware/Register Initialization 2 Working Mode Control Module 3 LED Display Module 4 ADC Module (AC voltage, current, NTC Pan, NTC IGBT) 5 Buzzer Control Module 6 Fan Control Module 7 Button Scan (CSD) Module 8 Protection Module 9 Assembly Line 10 Testing Process to ensure quality 4.2: Five control charts including brief description of each control chart: In the above production processes, there is call for scrutinizing the degree to which our products rally requirements. The major areas to be monitored include; these that diverge from the objective specifications and these that have disproportionate inconsistency around target specifications. These shall be achieved by application of the control chart that is a graph utilized to ascertain how a process differs in the fullness of time. It has a central line for the mean, upper line for the upper control limit and a lower line for the lower control limit. These lines are established from historical data. Through contrasting present data to these lines, one can describe inferences in relation to whether the process variation is in control or is out of control, and thus impinged on by unusual causes of variation. The different control charts include; A p-chart which is an attributes control chart utilized with data collected in subgroups of fluctuating dimensions. Since the subgroup dimension can differ, it demonstrates a proportion on uncharacteristic points rather than the real count. P-charts give you an idea about how the production process varies ultimately. P-charts are utilized to verify if the process is stable and predictable, in addition to examine the consequences of process enhancement theories. The vertical axis comprises of the percentage of defectives for each sub-group and the horizontal axis the sub-group designation. An Np-chart which is utilized with data collected in subgroups that are the same size. Np-charts demonstrate how the process, determined by the quantity of uncharacteristic items it creates, varies in due course. The process characteristics is constantly illustrated in a yes/no, pass/fail, go/no go form. For instance, the quantity of incomplete catastrophe statements in a continuous daily sample of five would be plotted on the chart. Np-charts are utilized to establish if the process is steady and predictable, on top of monitoring the effects of process development theories. The distinction between a P-Chart and an Np-Chart is that a P chart illustrates the fraction defective (p), while the Np chart illustrates the number of defectives (Np). The vertical axis comprises of the number of defectives for each sub-group and the horizontal axis the sub-group designation. The C-chart is a technique that labors to establish if a measurement process has gone out of statistical control. It’s susceptible to variations in the number of defective items in the measurement process. The letter “C” stands for “counts” as in defectives per lot. The C control chart consists of vertical axis that represent the number defective for each sub-group and the horizontal axis that represents sub-group designation. The C chart presumes that each sub-group has an equal sample size which does not require to be identified. The sub-group is usually a time sequence for instance, the number of defectives in a daily production run where every day is taken as a sub-group. If the times are uniformly spaced, the horizontal axis variable could be created as a sequence. A U-chart which is an attributes control chart utilized with data collected in subgroups of changeable sizes. It illustrates how the process, calculated by the number of nonconformities for each item or collection of items, varies over time. Nonconformities are defects or occasions established in the sampled subgroup. They can be expressed as any attribute that is at hand but should not be, or any trait that is missing but should not be. For example, depression, crack, blotch, missing screw, and a split are all nonconformities. The letter “U” stands for the units as in substandard per lot. It includes of y-axis that embodies the standardized quantity of substandard per sub-group and the x- axis that signifies the sub-group description. An X-bar and R chart is a duo chart utilized by way of developments that have a subgroup dimension of 2 and above. X-bar exhibits how the average varies over time and the R chart illustrates how the range of the subgroups varies over time. It is also applied in monitoring of the effects of process enhancement theories. The vertical axis comprises of average for each sub-group. The horizontal axis comprises of sub-group designation. 4.3: A critical parameter, calculation of basic values and control chart of the parameter: In this point the Control Board is delineated as the critical parameter, it is assembled comprising of; housing, cables, and other electronic devices. Every of these parts are verified by quality control staff. For each cook-top, the number of defects established is noted and tabulated as below. Run Units Produced (Sub-group) Number of defects Defects per Unit(DPU) produced (u= c/n) UCL LCL 1 42 10 0.238 0.6951 0.1083 2 87 32 0.368 0.6055 0.1978 3 53 10 0.189 0.6629 0.1405 4 70 14 0.200 0.6289 0.1744 5 101 37 0.366 0.5909 0.2125 6 91 29 0.319 0.6010 0.2024 7 36 11 0.306 0.7186 0.0884 8 83 38 0.458 0.6104 0.1930 9 64 23 0.359 0.6394 0.1640 10 53 12 0.226 0.6629 0.1405 11 83 46 0.554 0.6104 0.1930 12 93 54 0.581 0.5988 0.2045 13 78 21 0.269 0.6170 0.1864 14 41 15 0.366 0.6986 0.1047 15 84 45 0.536 0.6091 0.1942 16 78 35 0.449 0.6170 0.1864 17 91 51 0.560 0.6010 0.2024 18 69 25 0.362 0.6306 0.1728 19 36 13 0.361 0.7186 0.0848 20 48 9 0.188 0.6761 0.1272 TOTAL 1,381 530 *NB: Average DPU (U-bar) = 530/1381 = 0.3838 = Centerline (CL) The chart designates that the process in control. The control tests that were utilized every single one passed in this case. Part 5: Continuous Quality improvement: 5.1: Seven Problem Solving Tools: Histogram Data Collection Sheet Run Chart Process Flow Diagram Root cause analysis Brainstorming Cause and effect Diagram 5.2: Five Problems that can arise while using the Cook-top and how they can be solved: No Power Continuous buzzing yet pan is on or off no heat on ceramic panel yet power is on Sensor doesn’t respond. Heat regulator doesn’t work 5.3: Rectification of a problem by using at least four tools: A basic crisis solving process comprises of the following steps: defining the problem; exploratory of the process; establish the root cause; assess the root cause; and developing the process. A). Define Problem of Cook-top (Data collection list) As the first stage of problem solving, the identification of contributing effective subjects to induction cook-top failure should be considered and ranked through the Data collection list. B). Study Process by Use of Flow chart Fail Pass Pass Fail Pass Fail The flow chart method facilitates the ease with which a specific setback can be identified. C). Identification of Root Cause through Brainstorming: D). Assess the process root cause by application of cause and effect diagram: Maintenance Lack of motivation Below standard Proficiency & Training Parts quality Dead Unit High Voltage Supplier Wrong assemblage Excess Heat References: Gryna, FM., Chua, R C H., & DeFeo, J A. 2005, Juran's Quality Planning and Analysis for Enterprise Quality, 5th Edition. McGraw-Hill Science, New York. Chapters 5-20. Chen, R., Huang, J., & Cai, V. 2009, “Induction Cooker Design With Cap sense.” Available from: . [14 May 2010] Read More