5 Quality Planning and Analysis

8/8/2019 5 Quality Planning and Analysis

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QUALITY PLANNING & ANALYSIS

Assoc. Prof. Ir. Dr. Cheong Kuan Yew

School of Materials & Mineral ResourcesEngineering

Engineering Campus

Universiti Sains Malaysia


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INTRODUCTION

Scope

y Initial Planning for Quality

y Concept of Controllability

y

Automated Manufacturingy Overall Review of Manufacturing Planning

y Planning for Evaulation of Product

y Process Quality Audit

y Quality Measurement

y Continuous Improvement


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INTRODUCTION

Customer demands for:

y Higher quality

y Reduced inventories

y

Faster response time

Customer demands for:

y Higher quality

y Reduced inventories

y

Faster response time

Lean Manufacturing

Agile Competition

Impact of Technology

Lean Manufacturing

Agile Competition

Impact of Technology


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INITIAL PLANNING FOR QUALITY

Review of Product Design

Identification of Key Process Characteristics

Relative Importance of Product Characteristics

Analysis of the Process Flow Diagramy Correlation of process variables with product results

Error-Proofing the Process

y Error-proof principles (elimination, replacement,

facilitation, detection, mitigation) Plan for Neat and Clean Workplace (5S)

Validate the Measurement System

y Possible sources of variation


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POSSIBLE SOURCES OFVARIATION

Observed Process Variation

Actual Process Variation Measurement Variation

L

on -TermProcess

Variation

S ort-TermProcess

Variation

Variationue to

O erators

Variationue to

au e

Re roducibility

Re eatability

Accuracy

Stability

Lineality


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Inspection of Accuracy

Error of Measurement

y Effect of measurement error on accetance decisions.

y Bias the difference between observed average ofmeasurements and the reference value. The reference

value (accepted reference value or master value) is a

value that serves as an afreed-uopn reference for the

measured values.

Reference value

bserved average

value

bias


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Repeatability

y The variation in measurements obtained with one

measurement instrument when used several times by

an appraiser while measuring the identical

characteristic on the sam epart.

Repeatability


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Reproducibility

y The variation in the average of the measurements

made by different appraisers using the same

measuring instrument when measuring the identical

characteristic on the same part.

eproducibility

A

B

C


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Stability

y The total variation in the measurements obtained

with a measurement system on the same master or

part when measuring a single characteristic over an

extended time period

Time 2

Time 1


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Linearity

y The difference in the bias values through the

expected operating range of the gage

Reference value

bserved average value

Larger

bias

Reference value

smaller

bias


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Distinction between bias and repeatability

(precision).

y Precise but biased

y

Unbiased but not precisey Unbiased and precise


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CONCEPT OF CONTROLLABILITY: SELF

CONTROL

Knowledge of what they are

supposed to do

Knowledge of what they areactually doing (performance)

Ability and desire to regulate

the process for minimumvariation


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CONTROLLABILITYBY:

Worker Controllable

Management Controllable


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AUTOMATED MANUFACTURING

Computer-integrated manufacturing (CIM)

Computer-aided manufacturing (CAM)

Computer-aided design (CAD)

Group Technology

Flexible Manufacturing System


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OVERALL REVIEW OF MANUFACTURING

PLANNING

Production validation tests

Process qualification

Process certification


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ORGANIZING FOR QUALITY

Interaction of two systems Sociotechnical

Systems (STSs)

y Technical System

Design, equipment, procedure

y Social System

People, roles, coaches,


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PLANNING FOR EVALUATION OF PRODUCT

Formal evaluation of product suitability for

marketplace.

y Measuring the product for conformance to

specification.

y Taking action on the nonconformance product.

y Communicating information on the disposition of

nonconformance product.

Self-inspection vs. inspection by departmental

basis.


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Criteria for Self-Inspection

y Quality the number one priority

y Mutual confidence is necessary

y

Criteria must be met (specification must be clear andacceptable)

y Process must permit assignment of clear

responsibility for decision making.


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PROCESS QUALITYAUDITS

Quality audit = an independent review conducted

to compare some aspect of quality performance

with a standard for that performance.

Process Audit, Product Audit, QualityManagement System Audit, etc

Trained Auditor

Audit Checklist


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QUALITYMEASUREMENT IN

MANUFACTURING OPERATIONS

Key processes

Subject Unit of measurement

y Quality of manufacturing output

y Quality of input to manufacturing


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MAINTAININGA FOCUS ON CONTINUOUS

IMPROVEMENT

Three types of action

y Trobleshooting

y Quality Improvement

y

Quality Planning

5 Quality Planning and Analysis

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