- Asst. Prof. Dr. Gökhan İZBIRAK
Supervisor Mohammad Khanjani Student
Application of Measurement System Analysis at the ABC Company
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Application of Measurement System Analysis at the ABC Company Asst. - - PowerPoint PPT Presentation
Application of Measurement System Analysis at the ABC Company Asst. Prof. Dr. Gkhan ZBIRAK Supervisor Mohammad Khanjani Student 1 the purpose of this thesis Critical Part ISO 9001, ISO 14001, OHSAS 18001 Quality Planning 1 Miner
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ISO 9001, ISO 14001, OHSAS 18001
1 Quality Planning
Miner non- conformit y
PART Average 5 4 3 2 1 8.0 7.5 7.0 6.5 6.0 O PERA TO R 1 2 OPERATOR * PART Interaction Gage R&R (Xbar/R) for D12
The performance level The need, requirements or expectation Time
S t a n d a r d
the degree to which a set of fundamental characteristics fulfils a need or expectation that is stated, generally implied or obligatory
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USL LSL
Target Japan United States
$
Japan US
Cost of Guarantee
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Automotive International Action Group
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Sampling
Control
Supply Chain Management Supply Chain Quality Management (SCQM) 11920-1960 Internal Organization 1960-1980 Internal Organization 1980-1990
1990-present All supply channel members and mostly internal organization 2004-present All supply channel members and mostly external organization Programs Years Focus
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Control Sheet Control Sheet Control Sheet Control Sheet Control Sheet Control Sheet Control Sheet Control Sheet
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PLAN DO STUDY ACT PLAN DO STUDY ACT PLAN DO STUDY ACT 1- ANALYZE THE PROCESS
doing?
control
2- MAINTAIN THE PROCESS
performance.
variation and act upon it. 3- Improve the process
Understand common cause variation.
variation
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Actual process variation Observed process variation Production gage variation 18
2 2
3 , 3 min
d R d R pk
LSL X X USL C
2
6
d R p
LSL USL C
19 6
p
C 1
pk
C
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Repeatability
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2
p p
TV R GR & %GR&R = 100
2 2
GR &R = nr ity repeatabil d X range
2 2 2
15 . 5 Reproducibility =
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15 . 5 d R Repeatability GR&R Percentage Measurement system Less than 10% Acceptable 10% to 30% May be acceptable based on importance Of application, gage cost, etc. More than 30% Unacceptable-measurement System needs improvement
R GR V p &
ndc = 1.41
the characteristic behavior define the safety or regular requirements if not, it is not accepted),
2 2
&
p
V R R TV
24 %GR&R Actual process Cp Observed process Cp 10 2.0 1.96 30 2.0 1.71 60 2.0 1.2
ijl ij j i ijl
R PO O P y ) (
E
MS ity repeatabil 15 . 5 bn MS MS ility reproducib
AB A
15 . 5 abn Y bn Y SS
a i i A 2 1 2 ..)
(
abn Y an Y SS
b j i B 2 1 2 . . )
(
B A b j ij a i AB
SS SS abn Y n Y SS
2 1 2 . 1
) ( abn Y Y SS
b j n k ijk a i T 2 1 1 2 1
B A AB T E
SS SS SS SS SS n MS MS I
E AB
15 . 5
2 2 2
& I ility reproducib ity repeatabil R R an MS MS V
AB A P
15 . 5 25
R D UCLR
4
R D LCLR
3
R A X UCLX
2
R A X LCL X
2
2
6
d R g
LSL USL C
2 2
3 , 3 min
d R d R gk
LSL X X USL C 26
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Organization Structure Project Characteristic
Functional Weak Matrix Balanced Matrix Strong Matrix Projectized Project Manager’s Authority Little or None Limited Low to Moderate Moderate To High High to Almost Total Resource availability Little or None Limited Low to Moderate Moderate To High High to Almost Total Who controls the Project budget Functional Manager Functional Manager Mixed Project Manager Project Manager Project Manger’s Role Part-time Part-time Full-time Full-time Full-time Project Management Administrative Staff Part-time Part-time Part-time Full-time Full-time
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ISO 9001: Requirement 7.3.1 (see Appendix A). In some case, the stages of the design and development review, verification and validation has not been covered as consequently. ISO 9001: Requirement 4.1 (see Appendix A). Defined measures for engineering and design process are not sufficient for effective monitoring and measuring of the quality parameters. ISO 9001: Requirement 8.4 (see Appendix A). In some cases, the data records of the ABC company have not been utilizing to identifying improvement opportunity properly. ISO 14001: Requirement 4.3.1 (see Appendix A). In some cases, the ABC company has not been considering the environmental aspects and related potential risk requirements in the product planning stage.
Continual improvement of the quality management system
Managemen t responsibility Measurement, analysis, and improvement Resource managemen t Product realizatio n
Customer s
Requirem ents Inp ut
Customer s
Satisfact ion
Outp ut Produ ct
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Source DF SS MS F P PART 4 0.0049200 0.0012300 0.18053 0.937 OPERATOR 1 0.0000300 0.0000300 0.00440 0.950 Part * Operator 4 0.0272533 0.0068133 9.92233 0.000* Repeatability 20 0.0137333 0.0006867 Total 29 0.0459367
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PART Average 5 4 3 2 1 8.0 7.5 7.0 6.5 6.0
O PERA TO R 1 2
OPERATOR * PART Interaction Gage R&R (Xbar/R) for D1
PART Average 5 4 3 2 1 6.2 6.0 5.8 5.6 5.4 5.2 5.0 4.8
OPERATOR 1 2
OPERATOR * PART Interaction Gage R&R (Xbar/R) for D2 OPERATOR 2 1 8 7 6 5 4
D1 by OPERATOR
Gage R&R (Xbar/R) for D1
OPERATOR 2 1 6.5 6.0 5.5 5.0 4.5 4.0 3.5 3.0
D2 by OPERATOR Gage R&R (Xbar/R) for D2
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OPERATOR 2 1 5.975 5.950 5.925 5.900 5.875 5.850 5.825 5.800
D3 by OPERATOR
Gage R&R (Xbar/R) for D3
OPERATOR 2 1 6.5 6.0 5.5 5.0 4.5 4.0
D4 by OPERATOR
Gage R&R (Xbar/R) for D4 PART Average 5 4 3 2 1 5.92 5.90 5.88 5.86 5.84 5.82
O PERA TO R 1 2
OPERATOR * PART Interaction
Gage R&R (Xbar/R) for D3
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PART Average 5 4 3 2 1 5.0 4.8 4.6 4.4 4.2 4.0
O PERA TO R 1 2
OPERATOR * PART Interaction
Gage R&R (Xbar/R) for D4
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(one qualified operator, and one master part in interval times)
Sample Mean 10 9 8 7 6 5 4 3 2 1 5.57 5.56 5.55 _ _ X=5.5604 UCL=5.57285 LCL=5.54795 Sample Range 10 9 8 7 6 5 4 3 2 1 0.04 0.02 0.00 _ R=0.02158 UCL=0.04563 LCL=0 Sample Values 10 8 6 4 2 5.56 5.54 5.52 5.58 5.57 5.56 5.55 5.54 5.53 5.52 5.58 5.56 5.54 5.52
Within Overall Specs
Within StDev 0.00928 C p 21.56 C pk 1.42 C C pk 21.56 O v erall StDev 0.00952 Pp 21.02 Ppk 1.39 C pm *
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Process Capability Sixpack of master D2
Xbar Chart R Chart Last 10 Subgroups Capability Histogram Normal Prob Plot A D: 4.342, P: < 0.005 Capability Plot Sample Mean 10 9 8 7 6 5 4 3 2 1 4.41 4.40 4.39 _ _ X=4.4006 UCL=4.41376 LCL=4.38744 Sample Range 10 9 8 7 6 5 4 3 2 1 0.04 0.02 0.00 _ R=0.02281 UCL=0.04824 LCL=0 Sample Values 10 8 6 4 2 4.42 4.40 4.38 4.42 4.41 4.40 4.39 4.38 4.425 4.410 4.395 4.380
Within Overall Specs
Within StDev 0.00981 C p 20.39 C pk 6.78 C C pk 20.39 O v erall StDev 0.01044 Pp 19.17 Ppk 6.37 C pm *
Process Capability Sixpack of master D4
Xbar Chart R Chart Last 10 Subgroups Capability Histogram Normal Prob Plot A D: 1.893, P: < 0.005 Capability Plot
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Characteristic Specification Ranking & Source Instrument & Resolution Study date GR&R Action plan # Thickness 4+,- 0.1 A FMEA#035 Micrometer 0.01 26.2.2009 60% 02 Diameter 6+,- 0.5 B SPC(2.2.2009) Caliper 0.1 26.2.2009 29% 03
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Does customer feedback suggest control plan changes? Are operating And SPC procedures sufficient to make control plan work? Are preventive process actions identified? Is the quality system Ford approved? Have characteristics for sensitive process been identified for SPC? Can control charts for variables be Used on all key characteristics? Is the process ready for sign-off ? Is 100% inspection required? Does the plan have customer concurrency? Can product be manufactured, Assembled, and tested? Are engineering changes required?
Q101 quality system Feasibility analysis
Can causes of field plant concerns be monitored? Manufacturing control plan
Process potential study
Process sign-off
Are process changes needed to improve feasibility? Job # 1 Ford Motor Company Never-ending improvement Has a launch Team been Identified? Was the process FMEA used to develop Process sheets? Quality planning team Supplier quality assistance Supplier or customer product engineering Warranty responsible activity
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