Quality development Antti Salonen

Transcription

1 Quality development Antti Salonen

2 What is Quality? Quality means those features of products which meet customer needs and thereby provide customer satisfaction. Quality means freedom from deficiencies.

3 Two types of deficiensies Design related Manufacturing related

4 Manufacturing related deficiensies Faulty raw material Poor material handling Faulty machines Human errors

5 Process improvement Process quality Deviations! Upper limit Lower limit Time

6 Process improvement Process quality Time

7 Process improvement Process quality Time

8 7QC The seven basic tools of quality The Ishikawa diagram The Check sheet The Control chart The Histogram The Pareto chart The Scatter diagram Stratification

9 7QC: The Ishikawa diagram Management Man Method Machine Main problem Material Environment Measurement system

10 7QC: The Check sheet

11 7QC: The Control chart

12 7QC: The Histogram

13 7QC: The Pareto chart Short Småstopp stops KB w Quantity Antal Stegbalk Station

14 7QC: The Scatter diagram How do you set the line? Linear regression!

15 7QC: Stratification

16 Why do machines produce defects?

17 Common machine related problems Wear and tear Vibrations and movements Missadjustments and poor handling Environmental disturbances

18 Quality maintenance (TPM)

19 Quality maintenance (TPM) Phase 1 Phase 2 Phase 3 Phase 4 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 6 Perform PM-analysis 7 Eliminate all factors, contributing to defects 8 State operating conditions and optimize the equipment and change-over procedures 9 Identify defects 10 Restore or improve 11 Evaluate standard levels and determine which components to monitor 12 Determine the condition for defect free production 13 Reduce the number of points for inspection 14 Specify standard values for the inspection points 15 Make a draft for a quality matrix 16 Evaluate the content of the inspection standard 17 Evaluate and adjust the standards and inspection points through trend analysis

20 Advanced concepts for Quality development Design Of Experiments Multiple factor analysis PM-analysis Geometry measurement (tooling machines)

21 Design Of Experiments (+) Temperature C (+) (-) (-) Concentration B (-) Catalyst A (+)

22 Design Of Experiments

23 PM-analysis Physical analysis Cons-tuent condi-ons Primary 4M Secondary 4M Established op-mal condi-ons Abnormali-es Suggested improvements Step 2 Step 3 Step 4.1 Step 4.2 Step 5 Step 6 Steps 7 and 8 The distance (A) varies 3: The posieon 3:1 The gripper don't pull the Locking rolls are worn Max 3mm deterioraeon OK! Not presented between the edge (B) of of the pipe pipe to the right length the cucng tool and the varies end posieon (C) of the pipe Too low force in the locking piston Minimum 80 N Too low Oil on the locking rolls No oil Oil present High amount of oil on the pipes No oil Oil present The pipe is misaligned in the frame The pipe should run smooth Resistance Debri in the steering mechanism Absolute clean Not clean High flexibility in frame Max 30 N on inner tube To high force Debri on the door Absolute clean Doesn't grip because of resistance in Not clean gripper mechanism No resistance Some resistance 3:2 The gripper doesn't move the right distance Play in slewing bracket Max 2mm play Play exists Loose bracket Air pressure too low Fastened Pressure 5KPa Loose OK (if enough) 3:3 The posieon of the tube changes a[er the gripper has released The pipe bounce on the door No Bounce Not evaluated! Skew pipe is pulled up Max skewness 0.1mm/100mm Skewness occurs Resistance in the locking mechanism No resistance Some resistance makes it pull the pipe Pipe bounce when the cu]er posieons too late Wear/grades on the top of the door Cu]er should posieon when pipe is released Occasionaly No wear or grades Damaged!

24 Machine geometry

25 Machine geometry

26 Ball bar meassuring

27 Ball bar meassuring

28 What is Quality? Quality means those features of products which meet customer needs 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.

29 Practical advice Use the 7QC tools Use multiple data sources Your own observations The operators statements Compare these Formal instructions etc. Ask the quality deepartment