| Topic : Ensuring Successful Process Control Systems |
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Activity:
490 views;
last activity : 08 17 2010 05:29:49 +0000
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Using Control Charts
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PROCESS MAPPING
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PFC (Process Flow charts/Diagram)
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Root cause analysis
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Six Sigma
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Ensuring repeatability, accuracy & process capability of machines
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CTQ
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tracking each step
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TRACEABILITY
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How process control can be eliminated or rduced significantly
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More on Control Charts
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Study the process well & Use high level commonsense..
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utilizing advance process control system
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By following SOPs
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At the heart of manufacturing process technology is a graph called a control chart. Control charts are used by operators on the shop floor to help identify when corrective actions are required. Control limits, or decision limits, clearly indicate when corrective action is needed and, conversely, when it is not. |
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Hello Mr.Steger, though a very good sigma will result in a good Cp but its shift will result in an inferior Cpk. Instead a not so good sigma with a distribution about a mean may result in good Cpk. May be I am wrong but as far as the spread is reasonably well within the specified limits ,Cpk is the one which should be watched.
Just one additional: everybody know what is Cp/Cpk, Have You ever tried Cpm ? Also known as the Taguchi capability index.
Cpm is a variant of the Cp and Cpk capability indexes. If sigma is very very good but Your distribution is shifted Cp is showing very good results and even Cpk as well (because of very good sigma), but can we accept it ? Check the formula here:http://www.iaeng.org/publication/WCE2008/WCE2008_pp1188-1192.pdf
See the "C" process on the page 2 & 3. (Fig. 1. and Table 1)
Let's assume this example: target=0, mean=8, sigma=0.5 USL=10, LSL=-10, Cp=6.7, Cpk=1.3, Cpm=0.41http://picasaweb.google.com/andras.steger/CpCpkVsCpm#5444974167921611058
hello Isha, to make any manufacturing process a zero defect process, i think proper and complete FMEA/QMEA should be done along with various cross functional teams to foresee failures/problems.when once this is done and still if the particular manufacturing step is not consistent enough to bring down negative of FPY,then we have to look Cp/CpK of that particular process and rectify if not.taking any process according to control plan will give good results.SPC's also will help for critical dimensions.bringing Xbar of any process as much as near to the middle will give ultimate desired output.
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Good question Isha...Process mapping provides the good parameters to monitor and control...if done and implemented properly and effectively.
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Very true Raj....you have mentioned the core implementation of process mapping
Thanks for support
For any implementation of process control techniques the very basic tool which could be used is 'Value Stream Mapping(VSM)' otherwise called 'Material & Information flow diagram' as called by Toyota.This VSM identifies each resource in the process & seggragates it according to bottlenecks & Non-bottlenecks.This also helps to identify the material flow and the dependancies between the tasks.After devloping this any process control techniques like 6 sigma, control charts can be used for independent resources which would form an integrated control & monitoring system and thereby process control can be improved on a day-to-day basis.
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I agree with Isha.......we can introduce the Process Flow Charts inline with Control charts from First operation to last operation in manufacturing industry.
Further KAN-BAN,TGR&TGW (things going right or wrong), 5s etc. similar quality managment tool automatically introduce w.r.t to process flow charts.
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first we did proceess flow chart, then we have to check and then we have to take call on that
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One of the ways is to implement Root Cause Analysis. This identifies the basis deviation, errors and corrective measures that need to be taken to correct the process systems, including work methods and procedures. The topic is vast for me to give all the details in this section. Interested people can contact me at vplawat@gmail.com |
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Six Sigma, is a data driven technique which helps in reducing errors in the manufacturing industry... |
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Scheduled validation of accuracy of machine axis. Calibration of encoders , attention to backlash & errors in gear trains, ball bar checks etc., will automatically lead to quality production. Similarly on the raw material side, proper hardness , surface finish, steel free of inclusions, excessive carbides etc., will lead to consistent product quality . |
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Dear All, I just pondering over about Your suggestions which are very comprehensive. I want add TWO more :-). Step 0: before You create whatever control about the processes You have to identify the CTQs (input CTQ is much more better). Step -1: Have You heard about manufacturing (not assembly) PFMEA ? Regards, Andras Steger (Six Sigma & Lean Expert) |
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Yes CTQ(Critical To Quality), knowing this areas as whats accuracy ur costumer meed it can be in microns like what in required in toolroom. or it can in surface fininsh like in plastic molds.
CTQ areas highlited in drawing followed by various station level inspection points may finally lead to zero errors. actually we should think who actaully is going to work on the machine ,not we we made the design we made the inspection points , we made the process sheet but untill unless a shop suppervisor will not get in contact with the machine operator and inform about the CTQ ares and tell him how the precausion should be taken no manufacturing shop will be the Zero error shop...
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Actually purpose of qualified supervisory/manager keep track of each step of production not only for quality but also how to improve production (by improving working skill of worker or automation system) It is only possible by discussing fist with worker/operator for there views/ideas then with supervisors/mangers .It should be done practically not by sitting in office/by seeing the production/defect record on graphs /pc |
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NOW THE LATEST PROCESS CONTROL IS USING TRACEABILITY IDENTIFICATIONS .THE SYSTEMS LIKE CONBON, WHICH IS JAPANESE WAY OF METHOD AND MORE FAMILIAR IN MASS PRODUCTION AUTOMOBILE INDUSTRIES. TOYOTO IS USING THIS CONBON .BAR CODE SENSING IS VERY SENSITIVE WAY TO CONTROL PROCESS AND IS MOSTLY USED IN ASSEMBLY SECTIONS .IT MAINTAIN ZERO ERROR WHILE PROCESS IS RUNNING . THIS IS FAMILIAR WITH NISSAN |
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I would like to share some of my views
We should aim for achieving a process conditions that does not produce bad quality. A Process that produces consistent good quality continuously. Controls become redundant. Question of disposal of defective product does not arise. Even, if it is not totally eliminated, it gets minimized to a very low level.
This task is difficult but not impossible. It can be achieved by continuously doing design of experiment using Taguchi’s methodology. |
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If you are interested to know more about control check out the below video of a free webinar on what Six Sigma Black Belts don't know about control charts http://rec1.dimdim.com/view/
Cheers...neil |
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Study the process in deep,implement effective operating system contineusly...Continues implementation followed by contineus study will give good result. Dont apply,6Sigma,and other systems blindly... |
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APC system utilizes advanced computer system and interacts with various no of parameters and control with distributed system.
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when we talked about process control, autometically we talk about certain steps which needs to be perfom sequencly. And I think SOPs are the best tools for this |
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