quality development 2016asn190411ahm -...
TRANSCRIPT
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2019-04-11 Industrial Process Development PPU413Anders Hellström based on 2016 Antti Salonen and Anders Fundin 2018
Quality development
What is Quality?
“Quality” means those features of products which meetcustomer needs and thereby provide customer satisfaction.
“Quality” means freedom from deficiencies.
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Two types of deficiensies
Design related
Manufacturingrelated
It is in the market we are judged by the Customer, we want to have a good reputation and we want the customer to chose us again and again.Just a short example of proud presentation: Customer satisfaction, Atlas Copco global 1:43 min eng ” We want to understand our customers and more importantly what their problems are - so we can help them solve them. Learn about how we do business”:
https://www.youtube.com/watch?v=q0J7_ZcnGXI
Over all Quality system
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• Faulty raw material• Poor material handling• Faulty machines• Human errors
Manufacturing related deficiensies
The Normal Distribution
The 3 Sigma mentality means 2700 defectives per million!
LowerSpec.Limit
UpperSpec.Limit
-1 +1
y 1 = 68.26%
+2-2
y 2 = 95.44%
-3 +3
y 3 = 99.73%
y(Target)
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The 6 Sigma Metric
-6 -5 -4 -3 -2 -1 y +1 +2 +3 +4 +5 +6
LowerSpecification
Limit
UpperSpecification
Limit
Normal DistributionCentred on Target
6 99.999999999 0.002
5 99.99994 0.6
4 99.9937 63
SpecificationLimit
Percent within Specification(Centred Distribution)
Defects Per Million(Centred Distribution)
3 99.73 2700
Process improvement
Process quality
Time
Deviations!
Upper limit
Lower limit
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Process improvement
Process quality
Time
7QC
1. The Ishikawa diagram2. The Check sheet3. The Control chart4. The Histogram5. The Pareto chart6. The Scatter diagram7. Stratification
The seven basic tools of quality
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7QC: The Ishikawa diagram
Mainproblem
Man Method Machine
Material Environment Measurementsystem
Management
7QC: The Check sheet
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7QC: The Control chart
7QC: The Histogram
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7QC: The Pareto chart
Småstopp KB w603
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Clip aboout Pareto analysis and how to use Excel for it, 5 min: https://www.youtube.com/watch?v=SDzBkjo8Qeo
7QC: The Scatter diagram How do youset the line?
Linear regression!
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7QC: Stratification
Why do machinesproduce defects?
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Common machine related problems
● Wear and tear
● Vibrations and movements
● Missadjustments
● Poor handling
● Environmental disturbances
Operational quality improvement
Six sigma (Operational)
Quality maintenance (TPM)
Total Quality Management (TQM)
A clip 1 min about variation and the customers choice:https://www.youtube.com/watch?v=T1-Dz2chgYc
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Operational Six Sigma• Six Sigma is a systematic aproach to Process Improvement,
using statistical tools, in order to reduce variability and eliminatedefects.
• Operational Six Sigma focuses on the reduction of variation in manufacturing processes
• Usually involve physical transformations of materials or parts
• Used in order to meet a combination of dimensional and performance requirements
• Common performance metrics include ppm (defective), yield, process capability indexes, scrap etc. Clip 7 min on SixSigma and process capbility: https://projectmanagers.org/definition/preliminary-process-capability-index/
Six sigma
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Process yield
Q99.8%
Q99.9%
Q99.7%
Q99.6%
The resulting process yield:
0.998 x 0.999 x 0.997 x 0.996 = 0.990
In other words, 1 defect per 100 produced units!
Quality maintenance (TPM)
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Quality maintenance (TPM)
Phase 1: Preparation
1. Control of quality standards and parameters
2. Study where the quality defects appear
3. Choose a pilot equipment for the implementation of quality maintenance
4. Check functions, operations and setup procedures of the equipment
5. Restore the condition of the equipment
Advanced concepts for Process Quality development
• Design Of Experiments Multiple factoranalysis
• PM-analysis
• Geometry measurement (tooling machines)
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Design Of Experiments
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Temperature C
Catalyst A
Concentration B
Design Of Experiments
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Machine geometry
Machine geometry
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Ball bar meassuring
Ball bar measuring
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What is Quality?
“Quality” means those features of products which meet customerneeds and thereby provide customer satisfaction.
Higher quality in this sense usually “costs more.”
“Quality” means freedom from deficiencies.
In this sense, higher quality usually “costs less.”
Practical advice
• Use the 7QC tools• Use multiple data sources
• Your own observations• The operators’ statements Compare these• Formal instructions etc.
• Ask the quality department