Ver. Spring 2007

Jump To the Main Contents

Administrative Issues of this Course

Introduction to the Topic

Brief Schedule of the Course

What is in my eLearning Pack this Semester?

Detailed Weekly Schedule of the Course

Final Deadline to Submit ALL Assignments

Anonymous Total Quality Feedback Form

This is your latest, therefore the most current schedule. Last update: December 16, 2006, (Update history: October 25, 2006 )

Please Read This! It Contains Vital Information about the Course as well as All the Assignments, Homework and Grades!

PLEASE save the TREES! Please DO NOT Print this syllabus. Use this web site to read it in this electronic format; it will be updated during the semester. Thank you!

Welcome to IE673 Spring 2007; The Live, Hybrid and Distance Learning Class (sharing the same syllabus): Total Quality Management

Learn About Total Quality Management, Based on a Set of Analytical, Quantitative and Open-source Computational Methods and Tools. Our purpose is to help you to Improve Total Quality in Product and Process Design, in Manufacturing, in IT, in Biomedical Engineering, in Pharmaceutical Engineering and Various Service Industries.

by

Paul G. Ranky, PhD
Full Tenured Professor
Registered Chartered Professional Engineer
Member of the American Society for Quality (ASQ), Audit Division and Lean Enterprise / Advanced Manufacturing Division
Also Member of ASEE, IEEE, IEE, FEANI, SAE, PMI
Department of Industrial and Manufacturing Engineering and IT
NJIT, University Heights, NJ 07102 -1982

This course introduces the concept of total quality management, and presents methods, tools, technologies and case studies for product, process and service quality improvement. The emphasis is on prevention through quality engineering, design, and implementation. We go beyond traditional statistical process quality control methods and tools, although we integrate these valuable methods into our framework. We present practical, as well as research-level cases and challenges focusing on design, manufacturing, real-time systems, supplier and logistics management, project management, quality assurance, process control, construction management, pharmaceutical packaging, automotive assembly, electronic assembly, robotics, and many other cases. We include competitor analysis as appropriate. We learn about process modeling, customer requirements analysis, risk analysis, design of experiments, TQM graphical methods, and an in-depth description of ISO 9001:2000 international quality standard; a must for quality audits and certifications.

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A NEW, and unique feature of this course: International Collaboration between us, and other university students! As part of an informal academic collaborative effort I set up with other universities in Hong Kong/China, Japan, United Kingdom and Europe, we provide here links to international Masters students' work. Please feel free to review, comment, and get involved. This is an attempt to increase the global aspects of this course for the benefit of all students and faculty involved. This link came from Hong Kong MS students, working on an interesting team project (Parking Guidance System PowerPoint Slides).

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IE673 is a simultaneously analytical, as well as practical course loaded with useful knowledge, that you can turn into improvement opportunities in almost any factory, institution, or organization, or system.

As one of my former students, Major Jack Parker, US Army, National Guard Bureau, Training Division, Washington, DC states about the course:

'As I developed the assignments, I really could have spent the rest of the year going through the principles and methods I learned in this course. Your course materials provided a great education for me in TQM. I look forward to applying my new knowledge in the Army in every means I find possible and feasible. Thanks again for your great instruction and materials.'

Other former students write the following about the course:

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All in all it was a wonderful experience hope to see you in the Concurrent Engg class this spring semester
Thankyou, Ahsan Ali

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Thankyou.
This class was a wonderful experience; you are great, Syed Ali

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Dear Professor:  Thank you so much.  This has really been quite an experience and I am now so glad I did go forward with it; the journey was good… Diane Bove

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Thanks for your patience. By the way, I've just purchased an Apple iMac and its great!!!! I will never purchase a PC again. Crystal

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Thank you very much it was a very interesting semester. I have learned a lot in this course. Have a happy and safe holiday. I will see you next semester because I am taking IE655. Brahan Rupan

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I want to thank you so much for sharing your incredible knowledge of this subject with me and the class. You really made me stretch my capabilities this semester with this class and I have a great sense of accomplishment. So thank you again and I hope you and your family have a great holiday and good luck to you. Thanks again and I hope that the work that I am submitting to you is worth an A, because that would mean a lot come from you. Sincerely, Victor J. McLoughlin

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It was an amazing course, I found it is very helpful and very interesting.
Unfortunately I am graduated, otherwise I will definitely be in your next
class. Thanks for your help. I have a suggestion about the course though. I just feel the statistical analysis part might can be extended a little bit, maybe it is because I am from math and my major is Stat.:)
Have a nice weekend and a great holiday. Thanks again. Chunsheng Yang

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Thank you again for a very enlightening semester. Roldan Rivera

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Thanks for a great class and semester! Regards, Chad Gassert

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Thank you for the great learning opportunity. Olukayode Dada

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I would like to tank you very much for a very interesting and
important course. I really feel that I learned many things this
semester. Your approach in teaching and conveying your ideas is very
unique. I did not see this being done in any of my other NJIT
classes. Great job and I look forward to taking more classes with
you. Thank you: Kanar Rabah

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I enjoyed your class and I decided to signing up for  IE 655  class also.
Regards, Krzysztof Rapciewicz

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I had a pleasant experience in my career at NJIT. Thanks for all the important and vital things you taught me, while i didn't find them useful in the first class since i had not worked for corporate America I most certainly found them useful now. Respectfully, Francis Garcia

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Dr. Ranky, Thanks for your patience, and helpful suggestions throughout the semester.

By enrolling in this class and learning the TQM principles proved to be highly
beneficial; learning to build my 1st website was icing on the cake.

I certainly got my money's worth. In fact, I will even go as far as saying
that this class was a bargain. The wealth of knowledge that I now have at my
fingertips from your e-textbook is invaluable. The excel and visio templates
were extra treats that helped facilitate our learning - thanks for your effort
in putting all that material together!

Warmest Regards, See you in IE 655, Bryant R. Jackson - brj2, Electronics Engineer

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Thank you for this very nessecary tool to put in our arsenal of
learning. Roldan Rivera

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I just wanted to say that this semester has been very useful and that I
have already started to incorporate the lessons learned, in conjunction
with Lean Six Sigma, at my job to evaluate Processes. Hope that you have a wonderful holidays. David Sabanosh

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Last but not least let me take this opportunity to thank you for the knowledge you passed on in the classroom and I look forward to applying this knowledge in the real world. Thanks for the learning experience, George Authur 

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Being in your class was a learning experience, I now look forward to putting the knowledge gain into work practice. Thank you, John K. Wilson Jr.

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Prof Ranky, I just wanted to thank you for inviting Frank Reick to class last Monday.
His discussions were very enjoyable and his frankness, honesty, and
overall genuine qualities make it obvious why he is successful and why
you have made him a friend. Please pass on my thanks to him...
Regards, Charlie Maraldo

Enjoy some pictures of this enjoyable session we had with Frank: Frank-Reick-Pic1, Frank-Reick-Pic2, Frank-Reick-Pic3

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' Dear Professor Ranky, This is Eduardo Canales. I had taken IE_673 last semester with you as part of my master degree in EM. I just want to thank you for such a valuable tool you taught us as it is TQM. Right now, I am working on a matrix evaluation and I remember. I had your Ranky Cora excel tool, which I am using.
The fact that it's in a CD and it's on excel make it practical and fast to use. But not only is the Ranky Cora but all other tools that are in the CD.
Again thanks for your teaching and guidance.
Sincerely, Eduardo

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Dear Professor Ranky, I would like you know that I truly enjoyed your class yesterday. After graduating from NJIT with a degree in CoE { computer engineering] I was unable to find a job that I liked and would like to make a career in and felt horrible that I went to school for engineering and came out with pretty much nothing. That was when I decided to look for something in the Finance field and fortunately I was able to land a job, and I like dealing with money and control it has on society. Yesterday’s class made me realize why I did engineering and I was good to know that I didn’t lose the love I had for math, science, inventions... just engineering in general.
 
I am looking forward to class next week!

Regards,
Alka

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[History: Prof Ranky has invited Frank Rick, an inventor and engineer, and holder of 40 (!) US Patents to talk to our class on innovation and quality issues. Note, that if at all possible, in every semester I try to invite an excellent guest speaker in the program]

... I must say that this class has been very interesting so far and I really enjoyed the speaker last week. Having him come to class and talk about Real Life Experiences is a very rewarding experience that no Professor at NJIT has offered to me during my college experience. I hope we can have a few more?
 
Thank You
Keith Mueller.

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Dear professor:

Since I don’t have project management experience, I felt difficult to
get into it in the beginning of this course. After I briefly went
through your eBook, I got some sense. When I read the detail of each
chapter, I found that the course is so practicable, useful and very
attractive. The TQM methods are not just useful in project; they could
be used everywhere, even in living activities. Now I like the course
very much, I believe I have been getting the essence of the course; it
must help me in my career. Thank you very much. I am very appreciated.

Thanks again.

Yours truly,

Haiming Sun.

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Prof. Ranky,
I've just finished viewing both of the DVD's you provided for the
IE673 class (sorry it took me so long to watch them both) and must
comment about how close they both struck to my own professional
experiences. I currently work as an engineering manager for a lighting
company that does about half of it's North American business in
automotive supplying such items as dome lights, turn signals,
instrument panel lighting, etc to various foreign and domestic
carmakers. About two weeks ago I had the opportunity to visit the BMW
plant in Spartanburg, SC (BMW owns Mini, right?) because of some
components we were supplying to a Tier 1 in the area. What a
tremendous operation! As far as automotive in general, I can say one
thing about...it's tough!

In my former company, I was a Product Development manager for a
precision stamping company. Once used a CMM not unlike the one in the
Mini video (a bit smaller though). That company manufactured a number
of metal shielding components for computers, cell phones and the like.
Interestingly enough, we were working with two big RFID companies,
namely Alien and Matrics (now Symbol) to develop a way to stamp the
RFID antennae instead of chemically etch or conductive print them.
Anyway, wanted to thank you for the opportunity to reminisce about
some of my working experiences.

Wayne

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Prof,

Thank you very much. I really enjoyed your class and feel disappointed that it is all almost over...
I have a better idea about TQM and I find myself emphasizing the same in my other management classes , at work, and even with my other outside contacts. It definitely made me think twice before I even react myself to the customers and my fellow workers. I highly appreciate the way you have compiled the study materials.

I am sure I am not the only one who is benefiting from this course. Probably many others. I have even recommended this course to my other class mates.

Thanks for all your help and support.

With Best Regards,
Indira Girija

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Hi Prof Ranky
 
I was wondering since it will be the last class next week... Can we see the other FORD ROUGE video that you shot.
 and possible other videos that you have shot ( e learning) similar to that one you showed us last week,
 I would enjoy it very much if we could....
 
Thanks.
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Professor Ranky:

I would like to express that I admire your way of teaching. I have to admit that I learn a lot of interesting topics and subjects during the Summer of 2005 through "Cuncureent Engineering" and this Fall through "Total Quality Management", not to mention that I learned how to create the website and post my assignments on it which I had no clue about it before.

The good thing that I can apply use all of what I learned in my work (in small scale) and even in my day life.
So. thank you very much.
Baher Girgis

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Hi Prof. Ranky
  
Thank You for a really exciting semester. I must say one thing... When I first was going into a masters program I was headed towards Civil Engineering. I am glad I chose Engineering Management. Your class has really opened up doors and ideas for me that I never knew existed.....
 
I do appreciate and have enjoyed your approach to getting us to learn this material. It has been very enjoyable.
 So I thank you
 K. Mueller

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I have successfully completed my final semester, with this I complete my
Master's in Engineering Mgmt. and all set for the Graduate walk slated for
May'06.

I will be joining full time with GE as a Project Application Engineer based at
Lombard(IL) by 3rd week of Jan'06. My education and work experience will help
me take up this challenging & exciting position.

It has been a great learning experience for me to be associated with you, It
would not have been possible for me to contribute without your help and
support. I value your contribution in my development as person and
professional. Thank You All.

With Best Wishes & Regards,

Rajesh

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Professor Ranky,
I am excited to be taking your class again. TQM (Spring 05 was
excellent).

David Adwedaa

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Good Evening Professor,
Last semester's class was incredible since it is helping me in different areas of my current job. My Director wants to digitize all the documents in our department. I am trying to convince them to put them on a website that is accessible only to the people that should have access.

I thought of that idea after taking your class! I have thought about many ideas that can be implemented thanks to the new concepts that I learned last semester. It was a very hard class!, but well worth it.
 
Alexis Rodriguez

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Thank you for the course. I really enjoyed it and learned a lot. The
project was very interessting and challenging too.
Thanks & Regards,
Ashley

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Dear Mr. Ranky.

Thank you for your advice and for this past semester. I hope you liked my
work. The tools you taught us will be really helpful. Hope to keep in touch
and it would be my pleasure if we even do scuba diving together. Thanks
again.

By the way I just received an invitation from GAP headquarters to San
Francisco for a final interview...


Cengiz Dincer

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...Interesting class last night. Sorry for butting in maybe a little too
much but I was trying to be helpful - As I am sure Diane was also. I
also feel you need not apologize for your teaching style. Your
experiences are relevant and are appropriate for inclusion in the
discussion.

Charlie Maraldo

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Hope all is well with you, I just wanted to wish you Happy Holidays! I am in California now and will be going tomorrow for a 2-week vacation. I am really enjoying my job at Boeing and I appreciate all the advice you've given us throughout the TQM course. Hope you have a wonderful time!
Warmest Wishes,
Linda

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My response: I have to admit, that student comments like the ones above make me not just incredibly happy, but also make me work harder every semester to give you the best and latest, and to continuously update and improve this course. I know it is popular because we all learn useful methods and tools, as well as see the REAL WORLD via virtual factory tours on videos, and then apply the analytical methods; I am delighted, that you like my DVD videos too!

Note, that this is a combined Welcome Letter and Course Outline for both the live, as well as the distance learning class. Please read it carefully. You will find all essential course information here.

Please note, that this document will be updated during the semester. If anything is unclear please contact me. According to NJIT's policies, in this course the NJIT Honor Code will be upheld, and that any violations will be brought to the immediate attention of the Dean of Students. Also, students will be consulted with by the instructor and must agree to any modifications or deviations from the syllabus throughout the course of the semester. As you see, I fully believe in teamwork, because in a team 2+2 = 5 (... and we need extra good hands in any project, don't we...)

Mailing Address: Paul G. Ranky, PhD
Full Tenured Professor
Department of Industrial and Manufacturing Engineering and IT

NJIT, University Heights, NJ 07102 -1982

You can email me at NJIT: ranky@njit.edu (Please note, that for reliability reasons I have added another email address: cimware@mac.com . Please use this and send again your email if you don't get an answer from me within 4 working days. I can read the cimware@mac.com account over the Internet anywhere where I have Internet access, therefore even if I am away at a conference on NJIT business, we can be in touch.)

Tel at home (in case of an emergency only, 24 hrs, but preferably during normal hours, 8.00 am to 10.00 pm) you can call me at home: (201) 493 9561

Note, that my office is in ITC 2519 at NJIT.

My office hours for the Spring 2007 semester are to be announced soon. Other office hrs. are available unless I am away on official NJIT business. If these are inconvenient hours for you please ask for an appointment by email, and I'll be happy to see you as soon as I can.

Find out more about the Professor’s past and current research work and background at (don't miss some of my best diving pictures...):
http://www.cimwareukandusa.com/aboutpgr.htm

Academic Calendar

Please look up the NJIT website: Short summary:

Sunday
January 14
First Day of Sunday Classes
Monday
January 15
Martin Luther King's Birthday-No Classes Scheduled
Tuesday
January 16
First Day of Classes
Monday
January 22
Last Day to Add a Course
Tuesday
January 23
W grade posted for all Withdrawals
Monday
January 29
Last Day for a Refund based on a Partial Withdrawal
Tuesday
March 6
Last Day for a Refund based on a Complete Withdrawal
Monday-Sunday
March 12-18
Spring Recess-University Open-No Classes Scheduled
Monday
March 26
Last Day to Withdraw from Cours(s)
Monday
April 2
Summer & Fall Registration Begins
Friday
April 6
Good Friday-No Classes Scheduled
Saturday 
April 7
Saturday Classes Meet
Sunday
April 8
Easter-No Classes Scheduled
Tuesday
May 1
Friday Schedule-Last Day of Class
Wednesday
May 2
Reading Day
Thursday-Wednesday
May 3-9
Final Exam Period
Thursday
May 10
Spring Grades Due in Registrar's Office
Thursday
May 17
Commencement (Tentative Date)

What are Hybrid Courses?

hy·brid - noun - something of mixed origin or composition; something, such as a computer or automobile plant, having two kinds of components that produce the same or similar results.

Hybrid courses (also known as blended or mixed mode courses) are courses in which a significant portion of the learning activities have been moved online and time traditionally spent in the classroom is reduced but not eliminated.

The goal of hybrid courses is to pair the best features of face-to-face teaching with the best options of online learning to promote active and independent learning and reduce class seat time.

Using instructional technologies, the hybrid model forces the redesign of some lecture or lab content into new online learning activities, such as case studies, tutorials, self-testing exercises, simulations, and online group collaborations.

This site (ref.: http://media.njit.edu/hybrid/) was created in support of NJIT's Pilot Program in Hybrid Learning and the Weekend University.
 
"Within five years, you'll see a very significant number of classes that are available in a hybrid fashion," says John R. Bourne, a professor of electrical and computer engineering at Franklin W. Olin College of Engineering who is editor of the Journal of Asynchronous Learning Networks. "I would guess that somewhere in the 80- to 90-percent range of classes could sometime become hybrid."

And he says he expects to see more students choose to take online courses even if they live on campus.
"Hybrid Teaching Seeks to End the Divide Between Traditional and Online Instruction" by Jeffrey R. Young, March 22, 2002, Chronicle of Higher Education

Ref.: http://media.njit.edu/hybrid/


IMPORTANT NOTES TO ALL STUDENTS :

  1. Please read this new syllabus carefully. Having read and understood it please email your instructor the following (you can copy paste the list below into your email for consistency):
  2. Please note, that in case your email is not answered it means that my response wasn't delivered due to email address / account issues at your end, or perhaps at the NJIT end... Sorry, You have to fix your side, I'll fix my side. If everything fails, pls. call by phone (as above).
  3. Naturally my email at NJIT can fail too, as it has in the past. In this case either wait until NJIT resolves this, or call if urgent (you have my home telephone number above, in case of an emergency).
  4. Last year's statistics shows that over 50 percent of the questions asked by students about this course were actually answered in this combined Welcome Note/ Course Syllabus... (it is getting better...) therefore PLEASE READ it ... it saves time for all of us, most importantly for you!
  5. Due to the fact that I teach and supervise several students, I cannot confirm the receipt of your homework assignments, but when you get my comments and the grade you'll see that I am working on your assignments too. It is important that you prepare them as well as you can, on time, although I will try to tolerate lateness if there is a good reason for it.
  6. PLEASE set up your own web page including your photo in the webpage, use NJIT's FREE web server, or your company's, or your own, or other solutions that work... it is your choice... PLEASE submit your assignments electronically. Since I deal with typically over 800 assignments every semester ALL YOUR ASSIGNMENTS MUST BE submitted electronically. If you do this over the web, it becomes very easy after Assignment 0...
  7. PLEASE do NOT use MS-Publisher as a web authoring tool, since according to last semester's experience it has linking problems even within an entirely MS 'industry standard' environment... not to mention the internationally accepted Internet community... 'If they cannot see your web pages then why to bother at all...' therefore make sure that your web pages are being used for knowledge collection and knowledge management and therefore are accessible from anywhere in the world!
  8. Please make sure that your URL works before you send me an email with a URL in it so that I can click on it and directly link to your assignment(s). The best approach is to set up your own web page, and then add every assignment to this URL as you develop them. This will be an extremely valuable knowledge documentation method to learn and resource when you apply for a job! If you don't know how to set up a webpage I will help you during the first week of classes. Please let me know if you need help!
  9. When you are done, you trigger my grading process by sending me an email with your URL in it.
  10. ESCAPE route: every semester about 3% of my students decide not to develop a web page... this is a poor decision, nevertheless in some cases I can see the reasons... therefore if you don't want to develop a web page, pls. send me your work in compressed PDF format (not zillions of Word and Excel files please!) Of course your PDF file will not be as active as a web page with all hyperlinked companies, text in .html, images in .jpg, .xls files with the spreadsheets, videos in .mov. or .AVI, etc. but still better than sending zillions of files by email that I cannot integrate for you... Please remember: there are other great software and knowledge communications tools out there besides Word... maybe it is time for you to master them, because you'll be left behind VERY RAPIDLY... actually you are already behind if you even think about going down this rute... (sorry this is the truth...)
  11. As you post a new assignment, or an improved version of an already graded assignment PLEASE email me about this with the proper link (the full URL in the email, so that I can just click on it and I am at your webpage).
  12. We plan to use the Highlander email-to-class system offered by NJIT, therefore pls. READ the email address you have offered to NJIT, ELSE I CANNOT BE IN TOUCH WITH YOU BY EMAIL; since this is the ONLY email my NJIT system knows about you (even if you have 6 others... hope all challenges are clear...)
  13. The NJIT Honor Code will be upheld, and that any violations will be brought to the immediate attention of the Dean of Students. Students will be made aware of any modifications or deviations from the syllabus throughout the course of the semester. 
  14. These are the steps my students suggested in the past to follow when uploading webpages to the NJIT server (Note: I use professional servers; I do not use the NJIT server, therefore if you need help in terms of VPN (Virtual Private Network) links, or how to download software from the NJIT website, or why your webpage does not work with the FTP (File Transfer PRotocol Program NJIT offers) PLEASE contact the NJIT computing helpdesk, NOT me. Also suggest, that you network with other students in the class, or via chatgroups (instant messaging systems); I will help in this as much as I can by emailing these important links to everybody during the first week of class, as soon as I get the class roster from NJIT's Registrar.

    As an NJIT undergraduate, graduate, live and/ or Distance learning, or in other words eLearning Student, or hybrid course student you are entitled to benefit of significant FREE computing resources, meaning hardware, software, as well as on-line email, web-site storage space, and related Internet and NJIT intranet server services. The steps below intend to help you on how to set up a web page for documenting your assignments for this course. Please read and follow each step. Obviously if you already have a web page, either through work, or business, or otherwise, please feel free to use that, or the one you prefer. (All we want is for you to learn the method, and then put all your assignments on the web, learn how to manage your knowledge over the web, and then email your URL with your assignments to the instructor for grading). Note, that you can use any suitable web authoring software. NJIT has a few on free offer too.

    These are the steps to follow (as provided by NJIT's IT and Computing Services):

    Hopefully all works... I'd like to see your beautiful webpages!

    1. Visit: http://csd.njit.edu/resources/webservices.php and read the instructions for Home page Setup. If you don't understand the details offered, please contact NJIT Academic Computing at Tel: (973)-596-2900, and they'll take you through. (Note, that lines can be busy during peak times, such as at the beginning of the semester, or towards the end of the semester, therefore to sort this out the earlier the better!)
    2. You should have an index.html file as your 'title page', because search engines will find you via the index.html file, and your hyper links to other files should be programmed passing through this index.html file.
    3. Please make sure, that you create your index.html file in your public_html directory and have all your other .html, .jpg, .xlx, .mov, etc. files in the same directory, else you will have a 'path error', meaning that your files will not link when viewed by others over the Internet.
    4. Last, but not least: ALWAYS test your uploaded assignment using your own, as well as somebody else's computer, to make sure, that everything works fine. (If you don't have a second, independent computer on the web, ask one of your classmates, or friends to check it for you, by sending him/her an email with a full URL in it, like this: http://www.mycoursewebpage.edu). Also note, that besides the class discussions (live class), the eLearning pack CDs have several examples on the architecture of simple and complex web-pages. All of these are in open source, please study them! We'll discuss some of this in class too!
  15. One of my students offered this explanation on how to upload webpages to the NJIT server: (new version: October 27, 2005) Click to see it in .html

    Also, another student of mine suggests to use Netscape for free webpage design. This is the link: Netscape 7.2 is free for download for both PC and Mac at the following URL:

    http://browser.netscape.com/ns8/download/archive72x.jsp

    Last, but not least: ALWAYS test your uploaded assignment using your own, as well as somebody else's computer, to make sure that everything works fine. (Also, ask one of your classmates, or friends to check it for you, by sending him/her an email with a full URL in it, like this: http://www.mycoursewebpage.edu. Always include the full URL into the email, else it won't link directly).

    Also note, that besides the class discussions (live class), the eLearning pack CDs have several examples on the architecture of simple and complex web-pages. All of these are in open source, please study them! (Note, that open-source does not mean that you can upload an entire eBook of mine, or video onto a server on teh web. This would be a major copyright violation!!!! Try to stay out of trouble, PLEASE!)

    As always,

    Happy Learning,

    Professor Paul G Ranky, PhD

  16. The 21st Century Engineer must be a professional information searcher, information and knowledge creator, as well as somebody who can reason over several different sets of information and then select the best possible solution path under constraints... not an easy task. In order to help this process, in this course we'll visit NJIT's wast and advanced electronic library, see some of the typical information searches and how the results can be evaluated. For our purposes, we'll use NJIT's SCOPUS electronic database. You can reach it via: http://www.scopus.com.libdb.njit.edu:8888/scopus/home.url, all you need is your UCID and password (as offered by NJIT to every NJIT student) to access this site.


Contents (IE673)

NJIT IE 673

Welcome to IE673, one of the most useful TQM courses you’ll ever take! Please read these notes. If anything is unclear please call me or email me. I am here to help you! Prerequisite: instructor’s approval.

Narrative Description of the Course: Total quality management is an approach to business involvement led by the theme of quality. It involves the continual satisfaction of customer requirements at the lowest cost by harnessing the efforts of everybody in the company. Quality assurance means sustaining a system which prevents defects. This includes quality control and quality engineering. Quality control means establishing and maintaining specified quality standards of products / processes / or a service; quality engineering is the establishment and execution of tests to measure product quality and adherence to acceptance criteria.

This course explains the importance of reducing variation for the purpose of implementing total quality in every process of the enterprise. Furthermore, IE673 represents a modular product, process, service design, implementation and management approach to the introduction of various TQM methods, tools, technologies and their management issues within a variety of small, medium and large enterprises.

As often defined "quality is the overall level of product /process / service excellence". It is also quite obvious that without similarly "excellent people, equipment and software" , or in other words, resources, one cannot provide the desired level of quality at the predefined cost. According to Jaguar Cars, "Quality is making money out of satisfying customers. Quality comes first". John F. Akers, former CEO of IBM, defines quality as follows: "Quality is everyone's job. Quality is essential merely to stay in the race". Others claim that: "Quality means putting the customers first every time".

Dr. Akimasa Kurimoto, Yamazaki Machinery (Japan) states that: "The success or failure of the new business strategies is, in general, attributed to the capability of the company to create its culture in ways that would make the new business strategy work. Quality is a fundamental management philosophy, causing cultural change of mind and attitude. Total quality management is the prime corporate business strategy to facilitate the best blend of management and working practice".

Lucas Engineering & Systems (UK and USA), defines Total Quality as follows: "The term Total Quality of Performance relates not just to the technical quality of products but rather to the quality of performance of every function in an organization. This is in recognition of the fact that the quality and cost of a product depend upon its design, the lead times and the reliability of the processes operated by many contributory departments (both manufacturing and administrative), the choice of materials and the effectiveness of supporting structures".

Mike Robson, international (US-based) quality expert, claims that: "We all want quality and excellence. Excellence is a journey, not a destination. There is no magic to quality". The conclusion is that every manufacturing (and other) enterprise needs a Total Quality system which is:

The main problems when applying traditional quality management philosophy include the following:

On the contrary, modern, progressive thinking we follow in this class claims: because Total Quality Management involves every person, aspect and machine (i.e. product, process, control and resource) of the organization, it requires a total commitment. It is not a quick "test and fix" approach. It is a preventive system designed into every aspect of the World Class Design, Manufacturing and Service enterprise, including product design, manufacture, management, administration and others. In accounting terms modern TQM is costing less than conventional quality systems do, because they can and do prevent failures!

In order to learn the above outlined principles, methods, tools and technologies, the course is supported by a comprehensive eLearning package (for both live, hybrid and distance learning students these packs are the same in structure). An eLearning pack typically contains an eTextbook, , we call it eBook on CD or DVD, some printed material, and other web-browser readable, open source 3D interactive multimedia CD-ROMs, DVD videos and others. The eLEarning PAcks contain real-world research and industrial case studies, as well as open source, professional active code and spreadsheets, that the students can customize when developing their assignments with their own data. (PLease note, that open source does NOT mean, that you can break the copyright law and put an entire eBook CD, or a DVD video on the web !... even if it is going to be on your own server!!!!!) You may of course customize the speardsheets and submit them as your assignments on your webpages with credits given.

The fundamental goal of TQM and TQC (Total Quality Management and Control) is to program, measure and keep process variability under control. During our studies in this course we discuss several methods, tools and technologies to achieve this goal. One of these methods is identified as six-sigma. In order to give an introductory-level example of our approach, the figure below illustrates the mathematical versus the industrial interpretation of six-sigma. (When reviewing this figure don't forget to play our short sample video, hot-linked to this figure. This is only a short video, because it is run from the server over the Internet. In the eLEarning Pack you'll find several CDs, and maybe even DVDs with significant video and multimedia content, including 3D videos and animations!)

To summarize, the methods taught in this course are relevant not just to TQM as applied to design, manufacture, test of products, but to a large variety of services too, because they reduce development costs, and improve working capital management, and increase customer satisfaction by offering powerful methods and software tools.

Upon completing this program of study the candidates will be able to understand and apply TQM Engineering, and related management methods and tools.

Why is the course needed?
There are many methods and solutions to innovate and develop new products and processes, to cut down waste and to improve an organization, a design office, a manufacturing enterprise, a product, or a process. One major discipline is Total Quality Management.

There is no doubt that modern Total Quality Management sounds impressive, but it is also expensive, because it aims at perfection in every aspect of the organization. On the contrary, many large and small companies claim that total quality is a business strategy. It is "a matter of life or death". According to Harold Geneen, of ITT, USA, "Quality is not only free, it's our most profitable product line".

But how can this be true ? As a simple and quick justification process, think for a moment of the fact that following the traditional quality management philosophy, the fewer the faults, the higher the cost, whereas applying our progressive total quality approach, the fewer the faults, the lower the cost (not to mention the possibility of the cost of a major recall!)

In other words, modern Total Quality Management means:

It is essential to understand that none of the progressive TQM methods we teach in this class work in practice unless they are applied to all levels of the enterprise, including the internal, as well as external supply chains. TQM methods and the quality culture has to be introduced gradually and should be managed by people who understand and support the principles, know how to deal with co-workers, and know the tools. It is a complex process, and a major implementation challenge!

TQM has its best chance if implemented in a modern, digital factory, in which every major process is monitored, based on analytical, quantitative and computational methods... (you can read more on this interesting topic...)

The table below illustrates the way enterprises must develop into international market facing systems, employing knowledgeable and empowered professionals, who are capable of creating and managing new knowledge for the enterprise; exactly the kind of workforce this course is developing.

To summarize, modern TQM address the whole enterprise, including products, processes, controls and resources, or in another domain humans and machines, the business systems, product design, process planning, manufacturing planning, the shop floor, packaging, maintenance, and service, including multiple life-cycles, via the internal, as well as the external supply chains.

For Whom is the Course Intended?
I have designed this course for Graduate / Master of Science programs in IE (Industrial Engineering), in EM (Engineering Management), in MnE (Manufacturing Systems Engineering), Pharmaceutical Management, Project Management, as well as an elective course for Graduate Mechanical Engineering, Graduate Computing Science and Graduate Environmental Engineering students. Note, that we follow a modular, object - oriented (OO) approach that makes the topic very adaptable to a variety of different environments. This approach has been successfully tested and run for several years at NJIT as well as on a consulting basis at large companies, such as IBM, Ford Motor Company, Jaguar Cars, GM/EDS, Boeing, Raytheon, and others.

Furthermore, the course is aimed at graduate research students, professional engineers and managers working in industry, wishing to learn about new, TQM methods, tools and technologies and management methods, for the purpose of improving products, processes and services.

Live, Hybrid and Distance Learning Students purchase their educationally priced eLearning Packs from the NJIT Bookstore (pls. contact Frank, or the NJIT Bookstore over the web). PLEASE NOTE, that all of the eLearning Pack materials are copyrighted and therefore are for individual use only. You can put selected objects (e.g. images, or video clips, or others up-to-10% of the total content) with proper references to the original material (in the usual format: 'Courtesy of xyz, published by ABC...) into your assignments and post them onto your website, but it is ILLEGAL for you to put an entire eBook (as an example) onto your webpage. I mention this here because some students break the copyright law and therefore can get into major legal trouble with publishers; something I do not want you to experience, because it is expensive and nasty...

Every eLearning Pack architecture is the same, but in terms of actual content is different, because it is customized. This is what you'll find in an eLearning Pack for this course:

The eLearning Packs will give us a great opportunity to work on projects in collaboration with the Four Selected Companies (also in your eLearning Pack). PLEASE NOTE, that each eLearning pack is different, nevertheless the methods we use are the same. Each student should therefore use one eLearning Pack. Also note, that you will need a multimedia PC (approx. 500 MHz, with a CD drive and 800x600 resolution screen min., 1024x768 or better screen preferred), a link to the Internet and email, as well as a recent version (not older than yr. 1998) version of MS-Excel in your machine. PLEASE NOTE, that as a student of NJIT, you are entitled to educational software and hardware discounts, and site licenses, therefore make sure that you take advantage of the huge educational discounts offered (even if you work for a company). (See the NJIT's bookstore, as well as contact NJIT's computing help desks at http://njit.edu for further details).

Reading for a degree... A few words about 'reading for a degree'... for hundreds of years, academics and other professionals all over the world emphasized the importance of reading for a degree. Here is a short list of excellent resources that will help you to deepen your understanding in the subject area of this course. Please read more on the subject if you can:

Schedule: This semester is 15 weeks long. You have to complete and submit 6 assignments (see them below in detail). There is no final examination, the course is assessed based on the 6 assignments. Since each eLearning Pack is different in content, each of you work with me on different assignments, using the same methods base. The schedule and deadlines for all assignments are below. All assignments should be in electronic format. If there is something not clear, please email, or call, or make an appointment and see me. There is a limited number of rework options (typically one per assignment) to assure that you do your best and learn the most, and of course get the fair grade for your efforts. I am keen to help, but I need your help to be able to help you. Your hard and timely work is the best help for all of us! I follow a fair system; ask my past students...

Class 1/ NJIT Week 1 (Note that class numbers correspond to the semester week numbers at NJIT). Introduction and overview of the course as well as the subject: What is TQM? Why do we need TQM, and what are the main drivers? TQM in a traditional and in a modern design and manufacturing, and service - oriented enterprise. An overview of the course, the eLearning Pack, and student requirements analysis (i.e. what students would like to learn whilst studying in this course). Part 1: TQM in a traditional and in a modern design and manufacturing, and service -oriented enterprise. An overview of US and international TQM standards. TQM process and enterprise models. Engineering management focus on how to find and reduce quality-related waste, and how to create TQM models, that are analytical, quantitative and computational, as well as have a chance of getting implemented in an enterprise. An overview of modern TQM knowledge documentation and knowledge management methods and issues; An overview of the assignments in this course, and a discussion on what the students have to accomplish to pass this course with a high grade.

Student Activities (this is what you should do to get an 'A' in this class, and most importantly learn the subject):

  1. Read this syllabus. Know your deadlines, what is needed and by when. You'll have lots of freedom to innovate in this class. Enjoy this, work hard and do not abuse this freedom I give you to learn and explore.
  2. Review your eLearning Pack companies. Who are they? What are they doing? How can they help you with your new product / process innovation? You must work with them... the boss says so... global collaboration is a MUST for all of us!.. this helps to learn this process.
  3. Review all other resources in your eLearning Pack. See what you have and how do the resources relate to the study program in this class. There are CDs /DVDs supporting each assignment. Look at them and see what they cover.
  4. Start to read the eBook offered in the eLearning Pack. Most assignments are supported by individual, or multiple Chapters in the eBook: Label 1: Intro to TQM eBook. Look at it as a useful resource helping you with assignments, methods and tools.
  5. To prepare for the first assignment (Assignment 0, since this is the zero stage) invent a new TQM - focused company that you will develop (virtually) with the collaborative companies (the 4 companies in your eLearning Pack). Your company should develop TQM - focused products, processes, and/or services; something that you are already familiar with. There are plenty of opportunities! Just think and invent. Can think BIG, don't have to implement it all!

Class 2 / NJIT Week 2 Part 2: TQM in a traditional and in a modern design and manufacturing, and service - oriented enterprise. International TQM standards. An overview of TQM methods, graphical, statistical and simulation tools and some technologies supporting design, manufacturing and service quality. Object - oriented (OO) TQM process and enterprise models are introduced. Engineering management focus on how to find and reduce quality-related waste; and how to create TQM models, that are analytical, quantitative and computational, as well as have a chance of getting implemented in an enterprise. Read Chapters 1 and 2 in the eBook: Label 1: Intro to TQM eBook.

Students present their TQM Project Plans:

Assignment 0: live students present on January 25, 2007, DL students submit by January 25, 2007 by email/or better: web: Each student will be given about 5-6 minutes to explain in class a single page executive outline of their project plans! Live students present in class; Both live and DL students email their assignments to the instructor as a one page, executive summary describing the way your virtual company (i.e. the 5th company) will collaborate with the 4 companies (to be found in your customized eLearning Pack). I am keen to see how will they develop TOGETHER a new quality product, process, or service.

Note: Your product / process, or service you plan to develop MUST be TQM-oriented and you have to spell out the TQM aspects clearly! (Max. 10%) (This is also a good time to start to set up your own webpage... you can use any server you like; NJIT offers you FREE webhosting. You might want to get a pro. service and pay for it, or try something FREE from the web, like www.tripod.com (my students tell me it is OK, I am not sure, I have NOT tested it).

Include your project Title, Author (Your Name and Your PHOTO, your Class code: IE673 live of DL, Date, your eLearning Pack serial number and the collaborative companies you have ( a MUST!). I will respond to this by email, comment and hopefully accept your plans. Note, that in this and other assignments in this course I give you a lot of freedom to innovate. This is why I do not specify every assignment step-by-step in every detail, and treat you as a problem solving machine... I want you to learn to think, act and innovate better and better all the way... I hope you like the idea, because innovation is the ONLY future for us in a global economy... (See our discussions on Globalization in the TQM eTextbook CD in detail).

To help you, these are the detailed steps you should take:

Typical Mistakes: Why am I loosing grade points in this assignment?

Classes 3, and 4 / NJIT Week 3 and / NJIT Week 4 US and international TQM standards (goals, architecture, pitfalls, practical implementation issues and rules). Object oriented TQM information system models and process modeling (CIMpgr, object oriented TQM process modeling is explained and discussed through exercises and examples). There are some good articles on CIMpgr at ADAM over the web at http://www.cimwareukandusa.com in the ADAM with IT magazine. Read the case study oriented (CIMpgr) articles and see the OO process model examples. (There is a good overview in the TQM CD, plus there are several templates you can use). You’ll grasp it quickly. You can draw these diagrams with any simple 2D drawing tool, maybe best with VISIO, or CORAL Draw, or PowerPoint, or ADOBE Illustrator, on the PC and OmniGraffle on the Mac in Unix, or others. Please note, that the templates on the eBook CDs are in the latest Visio. Visio is available FREE from the MS website for 1 month, or from NJIT for longer. Read Chapters 3, 4 and 5 in the eBook: Label 1: Intro to TQM eBook.

PLEASE do NOT send me Visio or other source files. Treat me as a global collaborator. I have the web and Excel... and Office... Email me a webpage URL, or in the worst case an MS-Word file with a .jpg image of your models in it.

Submit by February 9 (note, that 'End of Week', for all cases in this course means Friday, 5.00 p.m. of that week)! Assignment No. 1: A TQM Process / System Modeling Method (as Part of the Internal and External Supply Chain) (After having submitted this to me I’ll make comments on it that you suppose to consider and then rework your assignment). (Max. 20%)

Please note, that the best assignments show evidence that the student has worked through the learning material provided on CD-ROMs, web and in the eTextbook. Therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided on the CDs into your assignment; nevertheless never forget to credit the source of such objects in the bibliography. (Obviously it is illegal for you to put the entire eBook on the web, because that would violate international copyright laws.)

In terms of assignment documentation method, please follow the Appendix of the eTextbook CD-ROM in your Learning Pack.

Please follow this structure for your assignment:

Typical Mistakes: Why am I loosing grade points in this assignment?

Classes 5 and 6 / NJIT Week 5 and 6

QFD (Quality Function Deployment); TQM Requirements Analysis is discussed with 3D Virtual Reality examples as an integrated Total Quality Management methodology. Read Chapters 6, 7 and 8 in the eBook: Label 1: Intro to TQM eBook. Also watch the Industrial Case Study DVD-Videos in your eLearning Pack.

Student Activities:

  1. Carry on reading the eBook offered in the eLearning Pack.
  2. Based on the CORA CD: The CORA CD educates a requirements analysis (i.e. an extended QFD) method and offers examples and solutions, as well as active code-tools for you to execute (in the form of MS Excel templates).

Class 7/ NJIT Week 7

QFD (Quality Function Deployment) / Requirements analysis is discussed with 3D Virtual Reality examples as a Concurrent Engineering methodology. Focus on the Assignment this week! We like professional quality assignments! Process Improvement and Process Control Analysis, and a Quantitative, Computational Solution: Control Charts for Variables and Attributes. Mathematical modeling with examples. Design of experiments and the extended Ranky/Taguchi method. (You can find this TQM methodology including examples in the TQM eTextbook CD-ROM in your eLearning Pack).

Submit by the March 2. Assignment No.2: QFD (Quality Function Deployment; Component Oriented TQM Process Related Requirements Analysis).

Read the main eTextbook of the course, on CD-ROM by Ranky, Paul, G.: An Introduction to Total Quality Management & Control and ...

When developing the QFD1 matrix for a TQM product / process, or service try to put down all

Please note, that the best assignments show evidence that the student has worked through the learning material provided in the eLearning Pack, therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided on the CDs into your assignment; nevertheless never forget to credit the source of such objects in the bibliography.

Typical Mistakes: Why am I loosing grade points in this assignment?

Class 8 / NJIT Week 8

The integration of quality into every process; An overview of TQM methods, graphical and statistical tools. Read Chapters 10 and 11 in the eBook: Label 1: Intro to TQM eBook.

Submit by March 23. Assignment (No.3): Process Improvement and Process Control Analysis, and a Quantitative, Computational Solution: Control Charts for Variables and Attributes (Max. 20%)

Select an area in your company, that needs to be improved by employing Process Control methods. Show how a Quantitative, Computational Solution can help. Use Control Charts for Variables and Attributes and make up the missing input data, if necessary. (As industrial examples, watch the Industrial CAse Study DVDs again. Try to identify areas, that are measurable and statistically controllable. Make up missing data; we are keen on learning the methods!)

Read the main eTextbook of the course, on CD-ROM by Ranky, Paul, G.: An Introduction to Total Quality Management & Control and ... as well as the following (early beta versions) of Introduction to Statistical Quality Methods and Open Source Tools:

Text intro. files:

Version: StatToolsIntro_Descr_ver2.doc,

Version: ControlChartVar_Descr_ver3.doc

and for attributes: ControlChartAttr_Descr_ver2.doc, all in Word at present.

Statistical intro. spreadsheets and templates to work with (just click on the filename to download it):

OrgOfData_Testrun1.xls

OrgOfData_Testrun2.xls

OrgOfData_Templ.xls

CorrectedpChartConstantSize_templ.xls

.

StatToolsIntro_testrun1.xls

StatToolsIntro_testrun2.xls

StatToolsIntro_templ1.xls

StatToolsIntro_templ2.xls

.

Version: ContChartVar_Testrun_ver2.xls

Version: ContChartVar_Templ_ver4.xls

Version: ContChartVar_Analysis_ver2.xls

.

pChartConstantSize_testrun_ver2.xls

pChartConstantSize_templ_ver2.xls

..

pChartVartSize_testrun_ver2.xls

pChartVartSize_templ_ver2.xls

.

cChart_testrun_ver2.xls

cChart_templ_ver2.xls

.

uChart_testrun_ver2.xls

uChart_templ_ver2.xls

.

Please note, that all above are still Beta versions... and the documentation sounds a bit French, since my RA with whom we have created this was Fanny Bensaid from France. AIf you find a bug, you'll get extra 10% to your full semester TQM grade! Also, we welcome any suggestions. The docu. is still not good enough, but Fanny and I are working on it... As an alternative, you can use a pro tool: MINITAB. The benefit of our simple toolset is that you get the source code. Enjoy!

Typical Mistakes: Why am I loosing grade points in this assignment?

Class 9 / NJIT Week 9 (Please note, that during the Spring Break we don't have a class, nevertheless students are requested to study the identified areas, as described below, using their eLearning Packs).

The Lean Six Sigma Methodology for TQM in Design, Manufacturing, Assembly and Service. An overview of Design For Quality, Assembly, Disassembly, the role of Quality Standards and Quality Circles, and other TQM methods, with 3D Virtual Reality examples and classroom exercises. Read Chapters up to 13 in the eBook: Label 1: Intro to TQM eBook.

Class 10 / NJIT Week 10

JIT and Kanban (Lean) production control methods for design, manufacturing, assembly and service quality Improvement. TQM tools. Networked TQM and TQC in collaborating digital enterprises, and the role of modeling and simulation; Quality leadership, strategic management, and customer satisfaction issues; Globalization, and quality culture issues; Teamwork and how to build great quality teams;

Classes 11 and 12 / NJIT Week 11 and Week 12

The Importance of quality in management, in service industries. Quality communication skills, education, training and TQM knowledge documentation and knowledge management methods and tools; Quality Ethics, TQM culture, benchmarking and globalization; Continuous quality improvement methods and examples.

Based on the Industrial Case Study CD-ROM:
Focus on the TQM engineering related challenges/ questions in this CD. Try to answer 10 selected questions of your choice! Incorporate these answers into the Assignment below!

Submit by April 6. Assignment No.4: The focus of this assignment is: Process Failure Risk Analysis, as Part of an Industrial TQM Process Improvement Study Based on our PFRA Method and Tool (Max. 20%) Read Chapter 9 in the eBook: Label 1: Intro to TQM eBook.

As you prepare for this assignment, read about Process Failure Risk Analysis, closely related to a method also known as FMEA, Failure Mode and Effects Analysis. (You can find this in the main eTextbook of the course, on CD-ROM by Ranky, Paul, G.: An Introduction to Total Quality Management & Control and ...).

For the Industrial Case Study, use the Major Industrial Case study DVD videos in your eLearning Pack.

Typical Mistakes: Why am I loosing grade points in this assignment?

Class 13 / NJIT Week 13 (It's almost over... just a few days left...)

TQM audit. Course summary and overview: How the learned methods and tools fit together, and how we can integrate them for specific applications.

Class 14 / NJIT Week 14: TQM Audit and How to Improve a Selected, Industrial System: TQM in a Global, Distributed, Just-in-time, Digital Economy using the learned methods and technologies, including RFID. Read the remaining Chapters in the eBook: Label 1: Intro to TQM eBook, and watch the RFID DVD-Video.

Submit by April 20. Assignment No.5: TQM Audit and How to Improve a Selected, Industrial System using RFID / TQM methods: TQM in a Global, Distributed, Just-in-time, Digital Economy. Also, write a quality-focused press release to market your company, that has developed the new quality system (Max. 20%). In terms of a guide on how to do this, use the already discussed eight ISO 9001:2000 quality principles.

Class 15: LAST CLASS!!!! Assignment Reviews / Discussions This Week! We'll discuss any questions you have. I'll spend the entire lecture period helping anyone who needs help. For DL students please join the class if you can, or contact me by email, or phone, or see me in person (please make an appointment in advance via email; thanks).

11.59 pm, Thursday, May 3, 2007 = ABSOLUTELY THE LAST DAY TO SUBMIT any new or reworked assignments! All submissions MUST be electronic = by email / web.

Schedule and due dates: As above. The total course duration is 15 weeks. Students will be required to complete each assignment. Assignments totaling 110% max. Grade "A" for this class requires min. 92% total. Note, that we don't have a Midterm or a Final exam, because of the integrated nature, the computational requirements, and the research contents of the customized assignments, BUT you must complete Assignments 0, 1 and 2 by around Midterm (see above) if you want to get an 'A', and the rest by the end-of-semester deadline (see above) at a high quality. Thank you for helping me to be able to help you!


The Results of the Anonymous Total Quality Feedback Form: IE673 (December, 2006)

Laboratory Development Review for Grad. Classes (Ranky, December 2006)

I would like to introduce several laboratory activities to my graduate classes, and therefore I am asking you the following: (Please rate 0 to 10, 10 being the most important / agree, AND please comment if you can! THANKS!)

Q1. Would you like to have our classes in a lab-setting? (i.e. the class and the lab is one integrated whole, as in a studio, with computers, equipment, demos, nice chairs and tables all in one, in a large room)?

100% stated: yes, absolutely no question about that...

Q2: Do you think automated inspection methods and tools are important? (e.g. machine vision, sensors, etc.)

Over 95% stated yes, and rated 10

Q3: Do you think rapid prototyping and rapid manufacturing to achieve quality products and processes is important?

Over 80% stated yes, and rated 10

Q4: Do you think digital design and digital manufacturing (PLM, Product Lifecycle Management) in the TQM context is important?

Over 80% stated yes, and rated 10

Q5: Do you think automation, sensors, robots, in-process inspection to secure zero defect production is important?

Over 95% stated yes, and rated 10

Q6: Do you think medical engineering / pharma. quality process demos are important?

Over 80% stated yes, and rated 10

Q7: Do you think design for quality, design for safety, illustrated with real-world labs. is important?

Over 95% stated yes, and rated 10

Q8: Do you think lean design, manufacture, service, enterprise... is important?

Over 95% stated yes, and rated 10

Informal Quality Feedback Form (Ranky, December, 2006)

Please review the following topics for this class by rating each topic between 0 to 10 (0 = meaning not important / poor quality and 10 = extremely important / excellent!). This feedback form will help your instructor to maximize quality satisfaction.

1. Web-based syllabus (... OK it is long, but is it helpful? Did you read it?):

Over 95% stated yes, and rated 10 ('Typical response: ... it is long, but has all the detail...')

2. eLearning Pack with DVDs and 3D interactive eBooks. (Do you prefer interactive, full color learning resources, or static, black & white traditional printed books?:

100% stated yes, prefer the interactive eBooks versus the traditional printed textbook. Some asked for a printed version too (pls. note, that every eBook can be printed from a browser if you have the money for the ink... some are over 800 pages long...obviously interactive active code, videos, spreadsheet cannot be enjoyed on paper...)

3. Engineering management focus on how to find and reduce quality-related waste:

Over 95% stated yes, and rated 10

4. Object-oriented TQM information system models and process modeling

Over 95% stated yes, and rated 10

5. CORA: QFD (Quality Function Deployment); Requirements Analysis

Over 90% stated yes, and rated 10

6. Process improvement and process control analysis: quantitative methods: control charts for variables and attributes

Over 80% stated yes, and rated 10

7. A real-world challenges and examples on DVDs, based on virtual tours

Over 90% stated yes, and rated 10

8. TQM -oriented risk analysis: PFRA: Process risk analysis

Over 90% stated yes, and rated 10

9. How the learned methods and tools fit together, and how we can integrate them for specific applications

Over 90% stated yes, and rated 10

10. TQM globalization issues

Over 95% stated yes, and rated 10

11. TQM continuous improvement methods and tools illustrated by industrial and R&D case studies

Over 95% stated yes, and rated 10

12. Any other 'Hot TQM / Engineering Management' topics we should cover? Please list and explain.

RFID is a hot topic; also six-sigma challenges in industry; more virtual factory tours on DVD; any realistic issues in the real-world; practical solutions;

=============The Results of the Anonymous Total Quality Feedback Form: IE673 (January 23, 2003) =================

Please rate the following topics planned to be covered in this class by rating each topic between 0 (not important / poor) and 10 (extremely important / excellent!) on the right hand side of the sheet please!

This feedback form will help your instructor to dynamically adjust the breath and the depth of the topics to be covered in this semester in this class to maximize your level of quality satisfaction.

Topics (as per the web-based syllabus) Your rating (0 -> 10)

Web-based syllabus
(TQM improvement opportunity: most students haven't seen the syllabus at the time we have started the class... Solution: NJIT should put the live course syllabi (prepared by faculty) with a hot link to the course registration page on the web too... the DL course syllabi are already hotlinked to the web, and this system works reasonably well)

eLearning Pack (Because of the above, the students did not know about the eLearning Packs)

What is TQM? Why do we need TQM, and what are the main drivers? TQM in a traditional and in a modern design and manufacturing, and service -oriented enterprise. (Rated: Very High)

TQM in a traditional and in a modern design and manufacturing, and service -oriented enterprise.
(Rated: Very High).

An overview of US and international TQM standards
(Rated: High).

TQM process and enterprise models.
(Rated: High).

Engineering management focus on how to find and reduce quality-related waste, and how to create TQM models, that are analytical, quantitative and computational, as well as have a chance of getting implemented in an enterprise.
(Rated: Very High).

An overview of modern TQM knowledge documentation and knowledge management methods and issues.
(Rated: Medium)

An overview of the assignments in this course, and a discussion on what the students have to accomplish to pass this course with a high grade.
(Rated: Medium).

Object oriented TQM information system models and process modeling.
(Rated: Medium)

QFD (Quality Function Deployment); TQM Requirements Analysis is discussed with 3D Virtual Reality examples as an integrated Total Quality Management methodology.
(Rated: High).

Process Improvement and Process Control Analysis, and a Quantitative, Computational Solution: Control Charts for Variables and Attributes. Mathematical modeling with examples.
(Rated: High).

The Lean Six Sigma Methodology for TQM in Design, Manufacturing, Assembly and Service.
(Rated: High).

The Five 'S's explained with examples (i.e. Sort, Set, Shine, Standardize, Sustain).
(Rated: High).

An overview of Design For Quality, Assembly, Disassembly, KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE.
(Rated: Medium; nevertheless many students did not know what this meant, so we'll discuss these methods)

The role of Quality Standards and Quality Circles.
(Rated: High)

A real-world TQM challenge, based on a virtual tour of an existing facility.
(Rated: High)

JIT and Kanban (Lean) production control methods for design, manufacturing, assembly and service quality Improvement.
(Rated: High)

TQM tools.
(Rated: Very High)

How the learned methods and tools fit together, and how we can integrate them for specific applications.
(Rated: Very High)

TQM team management methods and issues. TQM in the automotive, aerospace, food, service, medical, and other TQM standards re-visited.
(Rated: High).

Quality ethics. Enterprise -wide quality leadership, implementation and management methods.
(Rated: Very High).

Globalization issues.
(Rated: Medium)

TQM cultural issues; Conflict in the workplace, and how TQM methods and principles can help to avoid them.
(Rated: High)

Continuous improvement methods and cases.
(Rated: Very High)

TQM project presentation skills.
(Rated: High).

Industrial and R&D Case studies for every topic (as listed above).
(Two groups have emerged: one rated Very High, the other one Medium)

Any other topic you would like to cover? Please explain.
(Received none, meaning, that the class is happy with the offered topics)


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