Total Quality Management Integration Industry 4.0.pptx

Hubungan antara TQM dengan Industry 4.0 dan bagaimana bisa kita mebuat hal tersebut terintegrasi

1. INTEGRATION TQM WITH INDUSTRI 4.0 Manufacturing Practice Total Quality Management & Industry 4.0 Presented By : Budy Ariyanto

2. Profile Education Background Diploma ( polytechnic Gajah Tunggal) Electrical Engineering Bachelor ( Swiss German University) Industrial Engineering Master ( Swiss German University) Engineering Management Name : Budy Ariyanto Email : [email protected] Address : Tangerang Mobile Phone : [phone] Experience PT. Gajah Tunggal Tbk - Leader of Production Process ( 2015 – 2018) PT. Gajah Tunggal Tbk - Head of Section Process Improvement (2018 – 2022) PT. Gajah Tunggal Tbk - Sub Department Head Implementation Process ( 2022 – Now)

3. CONTENT : Overview ( Manufacturing & Quality) TQM ( Total Quality Management) Definition & Philosophy, Historical, Development of Quality Management, Quality Management Principles, Quality Management Challenges Industry 4.0 Definition & Evolution of Industry, Advanced Manufacturing System, Manufacturing Industry 4.0, View of Manufacturing 4.0 How The Total Quality Management Approach Can Be Integrated With The Concept Of Industry 4.0 Traditional Quality & Quality 4.0, TQM integration with industry 4.0 (Aspect & Desc), Some Ways 4.0 Support TQM Advantages Of Integration Quality Management with Industry 4.0 & . Challenges of integrating TQM with Industry 4.0 Learning Objective

4. Quality as a delivered performance or result is the degree to which a set of inherent characteristics fulfill requirements according to ISO 9000 definition. The business term “ quality as a discipline ” guarantees that clients will receive the highest quality products. It is your expectation as a consumer that the goods and services you buy will live up to your standards Overview o Price o Function o Level of Service o Time o Location Requirements Include: Definition of Quality :

5. Overview Manufacturing is the process of transforming raw materials or components into finished products Variation Process/Product the differences or deviations in a product or process from its intended or target state. It's a natural occurrence in manufacturing due to various factors like material inconsistencies, machine wear, or human error Manufacturing Manufacturing and Quality :

6. Overview Variation in manufacturing refers to the differences or deviations in a product or process from its intended or target state. It's a natural occurrence in manufacturing due to various factors like material inconsistencies , machine wear , or human error Accuracy and Precision: Accuracy is a measure of correctness while precision is a measure of exactness Variation Manufacturing : Low Accuracy Low Precision Low Accuracy High Precision High Accuracy Low Precision High Accuracy High Precision

7. Total Quality Management Management system for a customer focused organization that involves all employees in continuous improvement of all aspects of the organization to establish a customer’s goodwill and value-for-money reputation. Total Quality Management Philosophy:

8. Total Quality Management Development of Quality Management : Interconnectivity Integration Big Data

9. Total Quality Management QMP 1 –CUSTOMER FOCUS QMP 2 –LEADERSHIP QMP 3 –ENGAGEMENT OF PEOPLE QMP 4 – PROCESS APPROACH QMP 5 – IMPROVEMENT QMP 6 – EVIDENCE-BASED DECISION MAKING QMP 7 –RELATIONSHIP MANAGEMENT 7 PRINCIPLES OF QUALITY MANAGEMENT (QMPS) :

10. Total Quality Management Define Quality Goals – Set Clear, Measurable Objective Establish QMS – Create Structure & Process Document Procedure – SOP, Work Instruction Train Staff – Build Quality Awareness Implement Process – Follow Document Method Monitor Performance – Data, Target, Track Key Matrics Audit – Check Compliance & Gaps Correct Issue – Fix & Prevention Improve – Refine Process Continuously Quality Management Process Implementations :

11. Total Quality Management Lack of Leadership – Weak top Management Support Poor Communication – Info Gaps & Misunderstanding Inconsistent Process – Process Variation Insufficient Training – Skill and Knowledge Gaps Resistance to Change – Pushback on New Initiative Weak Document – Affects Traceability & Control Low Customer Focus – Misaligned with Customer Needs Supplier Issues – Poor Input Quality Control Bad Corrective Actions – Problem Keep Recurring No Improvement Culture – No drive for Better Quality Quality Management Challenges :

12. Industry 4.0 The 4th Industrial Revolution is leading the Intelligent Information Society the Digital Transformation, its advance Technologies. Development Industry 4.0 Internet of Things Cloud Computing Big data Artificial Intelligence Mobile Robotic/Automations

13. Industry 4.0 Robotics Autonomy Productivity Sensors Traceability Predictability 3D Printing Scrap Elimination -Customization Cloud Computing Big Data Cyber Security Advanced Manufacturing System :

14. Industry 4.0 Smart Manufacturing is the intelligent real time orchestration and synchronized of business, Physicall and digital processes within factories and across the entire value chain. Resource and process are automated, integrated, monitored and continuously evaluated based on available information as close to real time as possible Manufacturing Industry 4.0 : Process People Technology Industry Manufacture 4.0 MESA International.

15. Industry 4.0 View of Manufacturing 4.0 :

16. TQM & Industry 4.0 Integrated Approach Traditional Quality & Quality 4.0 : - Connected Process - Big Data Analytic - Big Data - Edge Device - Connected - Management System - Analytics - Data - Connectivity - Collaboration - Competency - Leadership - Culture People Technology Process Cross Functional Traditional Data Traditional Analytic Mental Individual

17. TQM & Industry 4.0 Integrated Approach Aspect Description Definition TQM is a management philosophy focused on continuous improvement, customer satisfaction, and employee involvement. Industry 4.0 represents the fourth industrial revolution, integrating smart technologies for automation and data exchange. Objectives   TQM aims at achieving quality excellence, reducing defects, and meeting customer expectations. Industry 4.0 aims at creating smart, interconnected systems for enhanced productivity, automation, and decision making. Data-Driven Decision Making TQM relies on data for analysis and decision making to improve processes. Industry 4.0 leverages real-time data from connected devices and sensors for intelligent decision-making . Technology Integration TQM integrates quality management tools. Industry 4.0 integrates technologies like loT , Al, machine learning, and cyber-physical systems for seamless connectivitv and automation Process Optimization TQM focuses on optimizing existing processes. Industry 4.0 enables the redesign of entire value chains through digitalization and interconnected processes. Customer-Centric Approach TQM emphasizes meeting customer needs and expectations. lndustry4.0 facilitates customization and personalization through data-driven insights and flexible manufacturing. Employee Involvement TQM encourages employee participation in decision making. lndustry4.0 involves employees in the implementation and maintenance of smart technologies. fostering a culture of innovation. Quality Monitoring TQM employs statistical process control and quality audits. Industry 4.0 utilizes sensors and real-time monitoring to ensure quality throughout the production process. Supply Chain Integration TQM seeks collaboration \\1th suppliers for quality improvement. Industry 4.0 integrates the entire supply chain through digital Platformsenhancing transparency and responsiveness Continuous Improvement TQM promotes a culture of continuous improvement Industry 4.0 facilitates adaptive processes and continuous learning through focdback loops and data analytics.

18. Some Ways Industry 4.0 Support TQM Enhanced Data Collection and Analysis IoT devices and big data analytics provide real-time data, enabling more precise monitoring and control of processes, which is essential for TQM TRADITIONAL DATA BIG DATA Volume ( Low To High) Variety Structured ( Low to High ) Variety Semi-Structured ( Low to High ) Variety Un-Structured ( Low to High ) Velocity ( Low to High ) Data Accuracy ( Low to High ) Transparency( Low to High )

19. Some Ways Industry 4.0 Support TQM Predictive Maintenance and Quality Control: AI and ML algorithms can predict equipment failures and defects, reducing downtime and ensuring higher quality standards

20. Some Ways Industry 4.0 Support TQM Improved Process Optimization: Advanced robotics and automation can streamline processes, reduce variability, and enhance productivity while maintaining high quality.

21. Some Ways Industry 4.0 Support TQM Real-Time Feedback and Continuous Improvement CPS and cloud computing facilitate real-time feedback loops, enabling rapid response to quality issues and continuous improvement.

22. Some Ways Industry 4.0 Support TQM Collaboration and Communication: Digital platforms and tools enhance communication and collaboration across all levels of the organization, aligning with TQM's emphasis on total employee involvement and effective communication

23. Advantages & Challenges of integrating TQM with Industry 4.0 Advantages Challenges Improved quality integration Data security Operational efficiency Skills gaps and workforce training deficiencies Data-driven decision making Complexity and compatibility of integration Enhanced customer satisfaction Resistance to change Agile and adaptable processes Initial implementation costs Cost reduction and waste automation Overemphasis on technology Innovation and product development Employee involvement in the process