| Topic : Ensuring Successful Process Control Systems |
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Activity:
180 views;
last activity : 07 06 2010 20:18:09 +0000
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By using effective SPC
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Customer/ consumer needs and specifications should be set as standards to be achieved'
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exhaustive testing
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Getting feedback from consumers...
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Test conditions may not satisfy in reality.
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Designing for test conditions
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Use only reliable, thoroughly tested technology
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Avoiding cutting corners
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Statistical process control (SPC) involves using statistical techniques to measure and analyze the variation in processes. Most often used for manufacturing processes, the intent of SPC is to monitor product quality and maintain processes to fixed targets. Statistical quality control refers to using statistical techniques for measuring and improving the quality of processes and includes SPC in addition to other techniques, such as sampling plans, experimental design, variation reduction, process capability analysis, and process improvement plans. |
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I agree Ms. Mridula, but, what after post production and post sales. I think this is a healthy trend which is starting off lately. Let it be a design change or a defective material used in production, instead of leaving the customers to mend for themselves, the company is willing to come forward to replace the defective component or change its design.
In software production, a similar process/procedure is layed by the SEI when organisations are accessed for CMM. The highest level stipulates that the organization should be willing to take responsibility and replace or take corrective actions to remove the defect. Even though, the same rules cannot be applied to Manufacturing, similar actions can be tried to lay down a strong and healthy policy.
I am not sure which methodology either Toyota or Honda is following.
Implement Q M S in all seriousness this automatically includes aplying S P C, customer feedback, comprehensive testing etc etc. The mistake occurs when seemingly small errors from design acceptance to material testing are taken lightly and whence these accumulate, become a serious issue. Yet it is only companies with reputation who undertake recalls, most Indian companies are still seen putting best efforts towards, shoving the problem under the carpet. Weak consumer actions are fully capitalised.
You've rather covered or zeroed down onto the management/technical aspect as such Mridula; of course would also dearly look into the finished / end product (stringent QC check) under extreme conditions to sum it up...
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1. Read carefully all the specifications of the customer 2. Understand them and clear all doubts before manufacture. 3. Plan the process control steps in detail 4. Make no compromises during each of these stages of Inspection & Control 5. Make sure adequate & calibrated instrumentation is connected and in working order to give correct data for control purposes 6. Make sure that customer specifications are fully met at each stage 7. Make sure that the QA team is fully qualified and equipped to do the PC 8. The QA team should directly report to the CEO's office and not the manufacturing head |
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to much automation is the problem as electronic circuits / devices have their own validity period after which they tend to malfunction. So proper validiation and replacement program should be followed.
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organizations should test their products exhaustively before turning them out in the market. It is just not acceptable that systems like brakes and accelerators (fundamental controls in a car) have problems. |
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This might be a way for preventing Recalls.Because only the consumer can tell the real thing about the product.How they feel about that product.This can help the manufacturers to prevent recalls and rethink the whole process. |
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Testing in labs may not give complete results. Actual road tests may result in problem areas, some of which normally has to be fixed. Before any product is released in the market, it has to undergo actual road test for a considerable time. In the absence of any unforeseen test conditions for the performance tests, such recalls may be a solution for improvement of the quality and performance of the product. |
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Yes it can be done like most of the softwares are tested, like "Win7" was given for some of Microsoft's members for trial use seven or eight months before its official launching and after overcoming all the drawbacks it was launched in market.Though softwares and automobiles are different products, yet it can help.Trial and Error Method is best method to improve anything. The only thing to make it simple.
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Well trial and error is one method, but if something like a break or an accelerator fails the results could be fatal. This is where six sigma methodology should be brought in. One has to really think through all the failure modes. FMEA would help in solving most of the critical problems. The product development should follow Design for six sigma methodology. |
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Manufacturing organisations should use only reliable & thoroughly tested technology which actually meets the basic needs of customers.Just because using an advanced technology for its name would only create problems.Competition in market doesnt mean that the company should go in for advanced technology.Excess testing will not help when the testing technology itself has some flaws in it.Hence manufacturing organisations should go in hand with the right technology.Both in testing as well as feautures in the product. |
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Avoiding cutting corners and taking quality control seriously could be a solution to recalls. Overall, recalls might not be bad thing after all. It is a genuine acceptance of errors in the manufacturing or design process that need to be corrected and the companies take the responsibility for that. Much better, than those unscrupulous manufacturers who deliberately push sub-standard products into the market and refuse to take responsibility for product performance later trying to save money on both the occasions. |
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