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Manufacturing Systems
Quality Management – Pareto Analysis
Dry Joint
Oversolder
Not Soldered
Wrong Placement
Faulty Comp
PCB fault
Causes of poor soldering
Des.Error
Heat Damage
Quality Management – Pareto Analysis
Quality Management – Pareto Analysis
140
120
100
80
60
40
20
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Quality Management – Pareto Analysis
Cumulative plot is made of all of the causes
80% caused by two problems
120
87
80 80
60 60
40
20
in
t r ed
t nt r e e
o de er en ne rr
o ag g
J l m po E n an
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Dr er So la om gn
Ov ot P C e si C
B t D
N ng ty D P ea
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W F
Statistical Process Control
How?
•Measure a small proportion of the produced items (sample)
•Use X-bar and R Charts to see if process is in control
•Conclude the quality characteristics of the whole process
Normal Distribution
120
100
80
60 Series1
40
20
0
1.525
1.55
1.65
1.675
1.75
1.825
1.85
1.575
1.625
1.7
1.725
1.775
1.8
1.875
1.6
1.5 1.525 1.55 1.575 1.6 1.625 1.65 1.675 1.7 1.725 1.75 1.775 1.8 1.825 1.85
60
50
40
30
20
10
1.5 1.511.52 1.53 1.54 1.55 1.56 1.57 1.58 1.59 1.6 1.611.62 1.63 1.64 1.65 1.66 1.67 1.68 1.69 1.7 1.711.72 1.73 1.74 1.75 1.76 1.77 1.78 1.79 1.8 1.811.82 1.83 1.84 1.85 1.86 1.87
60
50
40
30
20
10
0
Normal Distribution
60
50
40
30
20
10
( y1 y ) 2 ( y2 y ) 2 ....( yn y ) 2
N
SIGMA = 0.73
Normal Distribution
215 220
218
214
216
214 214
212
210
210
208
206
204
202
200
1 2 3 4 5 6 7
Control Charts – X-bar Charts
4. Calculate UCL and LCL
4.2
σsample 2.42 degrees
3
220
218
216
214
212
210
208
206
204
202
200
1 2 3 4 5 6 7
UCL = 218.27
LCL = 203.72
Control Charts – X-bar Charts
220
215
210
205
200
195
1 2 3 4 5 6 7
220
215
210
205
200
195
1 2 3 4 5 6 7
230
225
220
215
210
205
200
1 2 3 4 5 6 7
All data points are all above the process mean. This
suggests some non-random influence on the process that
should be investigated.
Control Charts – Range Charts
4 0 2.28
LCL = D3 x Raverage 5 0 2.11
6 0 2.00
7 0.08 1.92
8 0.14 1.86
9 0.18 1.82
UCL = 2.57 x 13 10 0.22 1.78
= 33.41 degrees 11 0.26 1.74
LCL = 0 x 13
= 0 degrees
Control Charts – Range Charts
35 UCL
30
25
20
15 R average
10
5
LCL
0
1 2 3 4 5 6 7
Process Capability
If Cp =1
•Process is capable
•i.e. 99.97% of the natural variation of the process will be
within the acceptable limits
Process Capability Index
If Cp > 1
•Process is capable.
•i.e. very few defects will be found – less than three per
thousand, often much less
Process Capability Index
If Cp <1
Size of Sample?
Sufficient to allow accurate assessment of process
•More – does not improve accuracy
•Less – reduced confidence in result
Sampling
Size of Sample
2
z
s
e
S = sample size
e = acceptable error - as a proportion of std. deviation
z = number relating to degree of confidence in the result
Confidence Value for z
99% 2.58
95% 1.96
90% 1.64
80% 1.28
Sampling
Therefore s = 384.16
Sigma = 10g
Result:
95% confident average weight of all
packets of sugar 994 g 1016 g
QC, QA and TQM
Quality Control:
• emerged during the 1940s and 1950s
• increase profit and reduce cost by the inspection of product
quality.
• inspect components after manufacture
• reject or rework any defective components
Disadvantages:
• just detects non-conforming products
• does not prevent defects happening
• wastage of material and time on scrapped and reworked
parts inspection process not foolproof
• possibility of non-conforming parts being shipped by
mistake
QC, QA and TQM
Quality Assurance
• Set up a quality system
• documented approach to all procedures and processes that
affect quality
• prevention and inspection is a large part of the process
• all aspects of the production process are involved
• system accredited using international standards
QC, QA and TQM
Previous
process Number of
components