FACULTY OF ENGINEERING
Department of Mechatronics Engineering
IE 344 | Course Introduction and Application Information
| Course Name |
Cost of Quality
|
|
Code
|
Semester
|
Theory
(hour/week) |
Application/Lab
(hour/week) |
Local Credits
|
ECTS
|
|
IE 344
|
Fall/Spring
|
3
|
0
|
3
|
5
|
| Prerequisites |
None
|
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| Course Language |
English
|
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| Course Type |
Service Course
|
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| Course Level |
First Cycle
|
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| Mode of Delivery | - | |||||
| Teaching Methods and Techniques of the Course | - | |||||
| Course Coordinator | ||||||
| Course Lecturer(s) | ||||||
| Assistant(s) | - | |||||
| Course Objectives | Prime objective is to gain insight for calculating the real loss (waste) due to quality failures. To gain some experience to produce proactive measures against internal & external quality failures and resultant losses. To gain some insight to find and calculate the hidden failure costs. |
| Learning Outcomes |
The students who succeeded in this course;
|
| Course Description | In competitive business life, realizing the recognition of quality costs provides the cost reduction, optimum loss-to-profit ratio and increase profitability. In this course it is aimed to explain the theoretical steps of defining, determining, classifying, calculating, evaluating the quality costs by putting the targets and determining the cost reduction works by continuous improvement, demonstrating the application methods and presenting practical studies with examples. |
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Core Courses | |
| Major Area Courses | ||
| Supportive Courses | ||
| Media and Management Skills Courses | ||
| Transferable Skill Courses |
WEEKLY SUBJECTS AND RELATED PREPARATION STUDIES
| Week | Subjects | Related Preparation |
| 1 | Kick off, Introduction, Review of Basic Quality Descriptions • Meaning of quality, standard, process, prevention, correction, improvement, failure definition, Pareto, PDCA, customer satisfaction etc.), • The necessity of quality management systems, quality and cost relation, evaluation of quality cost concept, course content, • Wishes and expectations. | Part1 presentations for basic quality terms |
| 2 | a)Quality management structure and cost relation b)Quality Cost (QCo) concept • Quality Cost history, • Target of QCo system, hidden costs in quality, • QCo’s place in Total Quality Management, ISO 9000, VDA 6.1 Quality Management System. | Campanella, J., Principles of Quality Costs, ASQ Press, third edition, Unit 1 a) Part1 presentations b) Part 2 presentation |
| 3 | Quality Cost (QCo) concept • Quality Cost history, • Target of QCo system, hidden costs in quality, • QCo’s place in Total Quality Management, ISO 9000, VDA 6.1 Quality Management System. | Campanella, J., Principles of Quality Costs, ASQ Press, third edition, Unit 1 Part 2 presentation |
| 4 | Quality Cost (QCo) system clasification: • Quality cost categories, • Quality cost elements, • Study in class • Quality cost bases (Trend analysis, improvement activities). | Campanella, J., Principles of Quality Costs, ASQ Press, third edition, Unit 2 Part 3 presentation |
| 5 | Quality Cost (QC) system classification ( con’t) • Quality cost categories, • Quality cost elements, • Quality cost bases (Trend analysis, improvement activities). | Campanella, J., Principles of Quality Costs, ASQ Press, third edition, Unit 2 Part 3 presentation |
| 6 | • Quality cost system classification – process approach • What is process approach ? • Process description with Turtle diagram • Process cost calculation • Conformity and nonconformity cost • Studies in class. | Campanella, J., Principles of Quality Costs, ASQ Press, third edition Unit 2 Part4 presentation |
| 7 | Midterm – 1 hr Quality cost program implementation: • How to implement, • Involvement of top management • Pilot Program, • Quality Cost Education (or training?), • Internal Quality Cost procedure, • Quality Cost data collection and analysis. | Campanella, J., Principles of Quality Costs, ASQ Press, third edition Unit 3 Part 5 presentation |
| 8 | Quality cost program implementation ( con’ t): • How to implement, • Involvement of top management • Pilot Program, • Quality Cost Education (or training?), • Internal Quality Cost procedure, Quality Cost data collection and analysis. Studies in class | Campanella, J., Principles of Quality Costs, ASQ Press, third edition Unit 3 Part 5 presentation |
| 9 | Quality cost program implementation and Project studies Quality Cost data collection and analysis. Activity based quality cost calculation, preparation of cost calculation table Project studies start up and content description | Campanella, J., Principles of Quality Costs, ASQ Press, third edition Pg 188-204 Project Content file |
| 10 | Quality Improvement and Quality Cost reduction: • Finding of problematic areas, • Quality Cost analysis (Trend, Pareto analysis), • Team approach, • Team based problem solving, • Cost reduction by cooperation with suppliers, • The relationship between customer satisfaction and quality cost. | Campanella, J., Principles of Quality Costs, ASQ Press, third edition Unit 5 |
| 11 | Supplier Quality Cost: • Supplier selection, • Supplier ranking, • Choice of the quality control methods • Supplier quality cost (hidden cost), • Application of quality cost to supplier control, • Supplier cost reduction activities | Uğur Naci, KOSGEB Tedarikçi ilişkileri, Ankara Eğitim Merkezi Yayın No: 39 Juran’s Quality Control handbook, Section 15 |
| 12 | Case studies examples • The Banc One Quality Cost Process flow, • Quality Cost Report review, • RESs CoSQ model | Campanella, J., Principles of Quality Costs, ASQ Press, third edition Unit 6 |
| 13 | Case studies examples • The Banc One Quality Cost Process flow, • Quality Cost Report review, • RESs CoSQ model | Campanella, J., Principles of Quality Costs, ASQ Press, third edition Unit 6 |
| 14 | Basic Financial Concepts: • Prime cost, • Overhead cost, • Cost of goods produces, • Cost of goods sold, • Revenue and Profit, • Balance Tables. | Campanella, J., Principles of Quality Costs, ASQ Press, third edition Appendix A |
| 15 | Problem Solving techniques and 8D Method Problem description, root cause analysis, Fish bone diagram, cause and effect analysis, pareto, 5 times why, KT analysis, 8D steps, lessons learned, organizational learning, creating company memory | Part 8 Presentations case studies in class |
| 16 | Project Presentations, General Course Review, questions and answers, closing the lecture, wishes and improvement areas discussion | Project files |
| Course Notes/Textbooks | Textbook: Campanella, J., Principles of Quality Costs, ASQ Press, Third edition |
| Suggested Readings/Materials |
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EVALUATION SYSTEM
| Semester Activities | Number | Weigthing |
| Participation |
1
|
5
|
| Laboratory / Application | ||
| Field Work | ||
| Quizzes / Studio Critiques |
4
|
15
|
| Portfolio | ||
| Homework / Assignments |
1
|
10
|
| Presentation / Jury | ||
| Project |
1
|
15
|
| Seminar / Workshop | ||
| Oral Exams | ||
| Midterm |
1
|
20
|
| Final Exam |
1
|
35
|
| Total |
| Weighting of Semester Activities on the Final Grade |
65
|
|
| Weighting of End-of-Semester Activities on the Final Grade |
35
|
|
| Total |
ECTS / WORKLOAD TABLE
| Semester Activities | Number | Duration (Hours) | Workload |
|---|---|---|---|
| Theoretical Course Hours (Including exam week: 16 x total hours) |
16
|
3
|
48
|
| Laboratory / Application Hours (Including exam week: '.16.' x total hours) |
16
|
0
|
|
| Study Hours Out of Class |
15
|
3
|
45
|
| Field Work |
0
|
||
| Quizzes / Studio Critiques |
4
|
0
|
|
| Portfolio |
0
|
||
| Homework / Assignments |
2
|
4
|
8
|
| Presentation / Jury |
0
|
||
| Project |
1
|
14
|
14
|
| Seminar / Workshop |
0
|
||
| Oral Exam |
0
|
||
| Midterms |
1
|
15
|
15
|
| Final Exam |
1
|
20
|
20
|
| Total |
150
|
COURSE LEARNING OUTCOMES AND PROGRAM QUALIFICATIONS RELATIONSHIP
|
#
|
Program Competencies/Outcomes |
* Contribution Level
|
||||
|
1
|
2
|
3
|
4
|
5
|
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| 1 | To have knowledge in Mathematics, science, physics knowledge based on mathematics; mathematics with multiple variables, differential equations, statistics, optimization and linear algebra; to be able to use theoretical and applied knowledge in complex engineering problems |
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| 2 | To be able to identify, define, formulate, and solve complex mechatronics engineering problems; to be able to select and apply appropriate analysis and modeling methods for this purpose. |
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| 3 | To be able to design a complex electromechanical system, process, device or product with sensor, actuator, control, hardware, and software to meet specific requirements under realistic constraints and conditions; to be able to apply modern design methods for this purpose. |
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| 4 | To be able to develop, select and use modern techniques and tools necessary for the analysis and solution of complex problems encountered in Mechatronics Engineering applications; to be able to use information technologies effectively. |
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| 5 | To be able to design, conduct experiments, collect data, analyze and interpret results for investigating Mechatronics Engineering problems. |
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| 6 | To be able to work effectively in Mechatronics Engineering disciplinary and multidisciplinary teams; to be able to work individually. |
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| 7 | To be able to communicate effectively in Turkish, both in oral and written forms; to be able to author and comprehend written reports, to be able to prepare design and implementation reports, to present effectively, to be able to give and receive clear and comprehensible instructions. |
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| 8 | To have knowledge about global and social impact of engineering practices on health, environment, and safety; to have knowledge about contemporary issues as they pertain to engineering; to be aware of the legal ramifications of engineering solutions. |
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| 9 | To be aware of ethical behavior, professional and ethical responsibility; information on standards used in engineering applications. |
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| 10 | To have knowledge about industrial practices such as project management, risk management and change management; to have awareness of entrepreneurship and innovation; to have knowledge about sustainable development. |
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| 11 | Using a foreign language, he collects information about Mechatronics Engineering and communicates with his colleagues. ("European Language Portfolio Global Scale", Level B1) |
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| 12 | To be able to use the second foreign language at intermediate level. |
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| 13 | To recognize the need for lifelong learning; to be able to access information; to be able to follow developments in science and technology; to be able to relate the knowledge accumulated throughout the human history to Mechatronics Engineering. |
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*1 Lowest, 2 Low, 3 Average, 4 High, 5 Highest
