advanced manufacturing systems design © 2000 john w. nazemetz lecture 10 topic : shop floor support...
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Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design
© 2000 © 2000 John W. NazemetzJohn W. Nazemetz
Lecture 10 Topic :Lecture 10 Topic : Shop Floor Shop Floor Support SystemsSupport Systems
Segment A Topic:Segment A Topic: Automatic Guided Automatic Guided Vehicles - ConceptsVehicles - Concepts
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 2
ADVANCED ADVANCED MANUFACTURING MANUFACTURING SYSTEMS DESIGNSYSTEMS DESIGN
Shop Floor SupportShop Floor Support
Automated Guided Vehicles - Automated Guided Vehicles - ConceptsConcepts
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 3
OverviewOverview
• Overview of Material Handling Overview of Material Handling SystemsSystems
• Automated Guided VehiclesAutomated Guided Vehicles– Components– Types– Guidance– Routing and Control– System Design
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 4
Material Handling Material Handling Overview (1) Overview (1)
• ConceptConcept– Best Material Handling is No Material
Handling• Except for Delivery to Customer, Material
Handling Adds No Value to Product• Can be 10 to 80% of Cost of Product
• GoalGoal– Least Cost Delivery of Undamaged
Material in a Timely Manner
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 5
Material Handling Material Handling Overview (2) Overview (2)
• In–Plant MovementIn–Plant Movement– On Machines/Equipment (NC)– Within and/or Between Cells/Machines
• Fixed Path (Conveyors, Robots)• Variable Path (AGVs, Forktrucks)• Interface of Handling System and Equipment• Location Information and Control System• Hoists/Assists
– Between Floor and Storage (WIP, Finished)• Location Information, Status, and Control
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 6
Material Handling Material Handling Overview (3) Overview (3)
• Outside of Plant MovementOutside of Plant Movement– Between Suppliers, Subcontractors
• Generally Longer Distances• Unit Loads for Efficiency• Time Delays, Variance in Receipt Time
– Between Plant and Customer• Generally Longer Distances• Multiple Destinations, Amounts to Move• Multiple Modes (Truck, Rail, Air, …)
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 7
Material Handling and Material Handling and Storage Principles (1) Storage Principles (1)
• Orientation PrincipleOrientation Principle– Facilitate Next Operation
• Planning PrinciplePlanning Principle– Establish Plan, Contingencies
• Systems PrincipleSystems Principle– Integrate into Rational System
• Unit Load PrincipleUnit Load Principle– Always transport is Largest Load
Possible
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 8
Material Handling and Material Handling and Storage Principles (2) Storage Principles (2)
• Space Utilization PrincipleSpace Utilization Principle– Use All (Cubic) Space
• Standardization PrincipleStandardization Principle– Maximize Similarity of Solutions
• Ergonomic PrincipleErgonomic Principle– Make Human Compatible
• Energy PrincipleEnergy Principle– Minimize Energy (Potential/Kinetic)
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 9
Material Handling and Material Handling and Storage Principles (3) Storage Principles (3)
• Ecology PrincipleEcology Principle– Minimize Environmental Impact
• Mechanization PrincipleMechanization Principle– Mechanize Wherever Possible
• FlexibilityFlexibility– Use Equipment Across Part Families
• Simplification PrincipleSimplification Principle– Eliminate/Simplify/Reduce
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 10
Material Handling and Material Handling and Storage Principles (4) Storage Principles (4)
• Gravity PrincipleGravity Principle– Use Gravity (Cheap!) Whenever
Possible
• Safety PrincipleSafety Principle– Meet Codes, Capture Experience
• Computerization PrincipleComputerization Principle– Use Automation Wherever Applicable
• System Flow PrincipleSystem Flow Principle– Integrate Data and Material Flow
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 11
Material Handling and Material Handling and Storage Principles (5) Storage Principles (5)
• Layout PrincipleLayout Principle– Synchronize Processing and Layout
• Cost PrincipleCost Principle– Investigate Alternatives
• Maintenance PrincipleMaintenance Principle– Ability/Cost to Service and Maintain
• Obsolescence PrincipleObsolescence Principle– Long Range Life Cycle Plan
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 12
Automatic Guided Automatic Guided Vehicles (AGV’s) Vehicles (AGV’s)
• ConceptsConcepts– Utilization
• Idle Labor = Problem (Wait for Delivery or Wait to Deliver)
• Idle Equipment = Cost• Equipment Cost -> Spread over Multiple
Shifts
– Control -- Sequence/Discipline– Automatic “Knowledge” of Location– Conveying with Less Bulk/Blockage
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 13
AGV’s - ComponentsAGV’s - Components• Components (Same as All Mat’l Components (Same as All Mat’l
Handl.)Handl.)– The Vehicle
• Device and Power System
– The Path• Routing and Alternatives
– Control Unit• Monitor and Control Vehicle and Path• Collision Avoidance/Reroute
– The Computer/Info System Interface• Link to Rest of Production System/World
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 14
AGV’s – Types/GuidanceAGV’s – Types/Guidance
• TypesTypes– Towing– Unit Load– Pallet Truck– Fork Truck– Light Load– Assembly Line
• GuidanceGuidance– Wire– Optical– Inertial– Infrared– Laser– Teaching
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 15
AGV’s – System AGV’s – System Analysis Analysis (1)(1)
• Vehicle Design and SelectionVehicle Design and Selection– Size/Cost/Maintenance– Height/Load/Width/– Maneuverability/ Interface/Off-Path
• Path/Vehicle Design ConsiderationsPath/Vehicle Design Considerations– Unidirectional, Bi-directional, Branches– Loading/Unloading, Variety of Load– Safety/Clearances
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 16
AGV’s – System AGV’s – System AnalysisAnalysis (2) (2)
• Number of VehiclesNumber of Vehicles– Analytical (p. 274 Singh)
• Single Cycle (Empty, Loaded Travel Percentage)
• Multiple Cycle (Probabilistic)
– Simulation– Breakdown/Replacement
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 17
AGV’s – Analysis (1)AGV’s – Analysis (1)
• PathPath– Routing/Flow of Product– Type of Guidepath/Vehicle– Location of Pickup/Dropoff Points– Storage/Buffer Locations
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 18
AGV’s – Analysis (2)AGV’s – Analysis (2)• Number of VehiclesNumber of Vehicles
– Distances Between Points– To/From Volume Between Points
• Recycling/Returns• Alternate Branches
– Required Deliveries/Hour– Loading and Unloading Time– Vehicle Travel Speed– Traffic Factor– Operation concept (Single/Bi-
Directional – One Cart per Path Segment)
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 19
AGV’s – ExampleAGV’s – Example
• Will Show Next SegmentWill Show Next Segment
Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design
© 2000 © 2000 John W. NazemetzJohn W. Nazemetz
Lecture 10 Topic :Lecture 10 Topic : Shop Floor Shop Floor Support SystemsSupport Systems
Segment A Topic:Segment A Topic: Automated Guided Automated Guided Vehicles - ConceptsVehicles - Concepts
END OF SEGMENT END OF SEGMENT
Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design
© 2000 © 2000 John W. NazemetzJohn W. Nazemetz
Lecture 10 Topic :Lecture 10 Topic : Shop Floor Shop Floor Support SystemsSupport Systems
Segment B Topic:Segment B Topic: Automated Guided Automated Guided Vehicles – Example, ASRS Vehicles – Example, ASRS
SystemsSystems
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 22
ADVANCED ADVANCED MANUFACTURING MANUFACTURING SYSTEMS DESIGNSYSTEMS DESIGN
Shop Floor SupportShop Floor Support
Automated Guided Vehicles – Automated Guided Vehicles – ExampleExample
Automated Storage and Automated Storage and RetrievalRetrieval
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 23
OverviewOverview• AGV Design ExampleAGV Design Example
• Automated Storage and Retrieval Automated Storage and Retrieval SystemsSystems– Principles and Concepts– Design and Analysis
• AGV and ASRS RationalizationAGV and ASRS Rationalization
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 24
AGV’s – Example Def’nAGV’s – Example Def’n
• Primarily “Straight Line” Flow with Primarily “Straight Line” Flow with Rework ReturnsRework Returns
• RoutingRouting– Whse -> A -> B -> C -> D -> Whse– A and B are Machining– C and D are Assembly
• LoadLoad– 100 Units Per Hour
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 25
AGV’s – Example LayoutAGV’s – Example Layout
Warehouse
AB
C
D
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 26
AGV’s – Example Flows AGV’s – Example Flows (1)(1)
Warehouse
AB
C
D
100
10
100100
8
50150
12
150
100
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 27
AGV’s – Example AGV’s – Example VolumesVolumes
. To. To
From From ..
AA BB CC DD WhseWhse
WhseWhse 100100 5050 100100
AA -- 100100
BB 1010 -- 100100
CC 88 -- 150150
DD 1212 -- 150150
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 28
AGV’s – Assumed PathAGV’s – Assumed Path
Warehouse
A
B
C
D
100100
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 29
AGV’s – Path Volumes AGV’s – Path Volumes (Unidirectional)(Unidirectional)
. . ToTo
From From . .
AA BB CC DD WhseWhse
WhseWhse 100100 5050 100100
AA -- 100100
BB 1010 -- 100100
CC 88 -- 150150
DD 1212 -- 150150W -> AW -> A (110)+8+(50+12)+(100)=2(110)+8+(50+12)+(100)=2
808000
A -> BA -> B 0+108+62+100=2720+108+62+100=272 88
B -> CB -> C 10+0+162+100 = 27210+0+162+100 = 272 88
C -> DC -> D 10+8+(100+150) = 26810+8+(100+150) = 268 1212
D -> WD -> W 10+8+12+150 = 18010+8+12+150 = 180 100100
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 30
AGV’s – Path VolumesAGV’s – Path Volumes (Bi-directional) (Bi-directional)
. . ToTo
From From . .
AA BB CC DD WhseWhse
WhseWhse 100100 5050 100100
AA -- 100100
BB 1010 -- 100100
CC 88 -- 150150
DD 1212 -- 150150W <-> AW <-> A (100)+ (0) + (50) + (100) = 250 (100)+ (0) + (50) + (100) = 250
+12+12
A <-> BA <-> B 10+ (100) + (50) + (100) = 260 +10 10+ (100) + (50) + (100) = 260 +10 + + 22
B <-> CB <-> C 0 + 8+ (50+100) + (100) = 258 + 8 0 + 8+ (50+100) + (100) = 258 + 8 + + 44
C <-> DC <-> D 0 + 0 + 12+ (100+150 ) = 262 +12 *0 + 0 + 12+ (100+150 ) = 262 +12 *
D <-> WD <-> W 0+0+0+0+ 0+0+0+0+ 150 150 = 150 = 150 + + 112112
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 31
AGV’s – AnalysisAGV’s – Analysis• Measure of PerformanceMeasure of Performance
– Number of Vehicles Needed
vD
TvD
TN
N
eh
d
f
hourdeliveriesvehicles
60
/
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 32
AGV’s – SensitivityAGV’s – Sensitivity• Different PathsDifferent Paths
– Dedicated Loops– Different Equipment Positions– Different Vehicles
• Loads/Speeds
– Different Traffic Factors • Higher for Bi-directional, Larger Segments
– Breakdowns
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 33
Automatic Storage And Automatic Storage And Retrieval Systems (1)Retrieval Systems (1)
• ConceptsConcepts– Space Efficiency – Utility Savings (Lights, Heat, ...)– Knowledge of Location– Safety (Elimination of Labor)– Zoned Storage– Distributed/Multiple Locations of Items
• Breakdown of System• Rsponse Time
– Less Breakage, Pilferage
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 34
Automatic Storage And Automatic Storage And Retrieval Systems (2)Retrieval Systems (2)
• TerminologyTerminology– Storage Volume/Cube
• Space of Warehouse
– Bay• Vertical Column of Storage Locations
– Row• Series of Bays (One Side of Aisle)
– Aisle• Space Between Rows
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 35
Automatic Storage And Automatic Storage And Retrieval Systems (3)Retrieval Systems (3)
• TerminologyTerminology– Storage Racks
• Structure comprising storage locations, bays, and rows
– Storage/Retrieval Unit• Machine capable of storing/retrieving items
from storage locations
– Input Output Stations• Area/Equipment at end of aisles that
interfaces with factory floor distribution and receiving system
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 36
Automatic Storage And Automatic Storage And Retrieval Systems (4)Retrieval Systems (4)
• TerminologyTerminology– Storage Modules/Bins
• Media for holding parts in a storage location
– Pick-up and Delivery Stations• Same as Input-Output Stations
– Transfer Stations• End of Aisle Equipment Used to effect
transfer of parts between rows (Same as Pick-up and Delivery/Input-Output Stations)
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 37
Automatic Storage And Automatic Storage And Retrieval Systems (5)Retrieval Systems (5)
• Why Use ?Why Use ?– Space Efficiency (Height/Cube)
• No Need to Allocate Space so Human can Remember Location/Find
– Improved Inventory Management• Accuracy of Counts• Knowledge of Location(s)• Aging/Security
– Quick Storage/Retrieval– Eliminate Manual Operations– Interface with Other Automated
Systems
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 38
Automatic Storage And Automatic Storage And Retrieval Systems (6)Retrieval Systems (6)
• TypesTypes– Unit Load– Mini-Load
• Location Precision• Must be in Trays, Standard Containers
– Person on Board• Kitting• Small Items
– Deep Lane– Automated Item
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 39
Automatic Storage And Automatic Storage And Retrieval Systems (7)Retrieval Systems (7)
• Design, Modeling, and AnalysisDesign, Modeling, and Analysis– Minimize Number of Spaces
• Dedicated Storage– Contamination/Special Requirements
• “Random” Storage– Rules applied so not Totally random
– Maximize Throughput/$• Single Cycle• Dual Cycle• Number of Aisles vs. Response Time
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 40
ASRS Design (1)ASRS Design (1)
• Determine Load/Storage Bin SizesDetermine Load/Storage Bin Sizes– Distribution of Sizes (Unit Multiples)
• Determine Number of Each Size Determine Number of Each Size NeededNeeded– Dedicated
• Sum of Maximum Needed in Any Period
– Random• Maximum Aggregate, Any Period
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 41
ASRS Design (2)ASRS Design (2)
• Determine Number of Determine Number of Store/Retrieve Needed per HourStore/Retrieve Needed per Hour
• Determine Number/Length of Rows Determine Number/Length of Rows and Baysand Bays– Base on Random or Dedicated Storage– Available Footprint Restrictions– Common Sense
• Maximum Practical Length– Cycle Time– Available Height
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 42
ASRS Design (3)ASRS Design (3)
• Determine Cycle TimesDetermine Cycle Times– Dependant on
• Aisle Length/Height, Ratio• Size/Number of Storage Locations• S/R Speed
– Single Cycle• Only Stores or Only Retrieves per cycle
– Dual Cycle• Stores and Retrieves (after store) each cycle
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 43
ASRS Design (4)ASRS Design (4)
• Determine Cycle TimesDetermine Cycle Times
heightspacestorageofnumberm
baysofnumbern
where
chmH
clnL
/___
__
)(
)(
1
2
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 44
ASRS Design (5)ASRS Design (5)
• Determine Cycle TimesDetermine Cycle Times
VelocityVerticalV
VelocityHorizontalV
where
VHt
VLt
v
h
vv
hh
_
_
/
/
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 45
ASRS Design (6)ASRS Design (6)
• Determine Cycle TimesDetermine Cycle Times
DepositorPickupforTimeTpd
TtTtQ
ttT
Where
TQ
TT
vh
vh
pdsc
____
)/,/min(
),max(
2)13(
2
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 46
ASRS Design (7)ASRS Design (7)
• Determine Cycle TimesDetermine Cycle Times
DepositorPickupforTimeTpd
TtTtQ
ttT
Where
TQQT
T
vh
vh
pddc
____
)/,/min(
),max(
4)1540(30
32
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 47
ASRS Design (8)ASRS Design (8)
• Assess AlternativesAssess Alternatives– Vary Length/Height– Vary Single/Dual Command
Cycles/Ratio– Calculate System Cost for Various
Configurations– Select “Best”
• Expandability• Match to Other Automated Systems
Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design
© 2000 © 2000 John W. NazemetzJohn W. Nazemetz
Lecture 10 Topic :Lecture 10 Topic : Shop Floor Shop Floor Support SystemsSupport Systems
Segment B Topic:Segment B Topic: AGV Example and AGV Example and ASRSASRS
END OF SEGMENTEND OF SEGMENT
Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design
© 2000 © 2000 John W. NazemetzJohn W. Nazemetz
Lecture 10 Topic :Lecture 10 Topic : Shop Floor Shop Floor Support SystemsSupport Systems
Segment C Topic:Segment C Topic: Quality Assurance Quality Assurance
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 50
ADVANCED ADVANCED MANUFACTURING MANUFACTURING SYSTEMS DESIGNSYSTEMS DESIGN
Shop Floor SupportShop Floor Support
Quality Assurance/EngineeringQuality Assurance/Engineering
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 51
OverviewOverview• Defining QualityDefining Quality
– Meaning– Dimensions– Costs
• Taguchi Loss FunctionTaguchi Loss Function• Failure Mode and AnalysisFailure Mode and Analysis• Control ChartsControl Charts• Anticipatory Quality ControlAnticipatory Quality Control
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 52
Defining QualityDefining Quality
• ““The totality of features and The totality of features and characteristics of a product or characteristics of a product or service that bear on its ability to service that bear on its ability to satisfy a given need”satisfy a given need”
ANSI/ASQC Standard A3-1987
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 53
Dimensions of Quality Dimensions of Quality (1)(1)
• Dimensions (All Products Subsets Dimensions (All Products Subsets of)of)– Performance
• Job it Does
– Features• Secondary Characteristics
– Time• Time to Receive/Time to Use
– Reliability• Meant Time to Failure
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 54
Dimensions of Quality Dimensions of Quality (2)(2)
• Dimensions (All Products Subsets of)Dimensions (All Products Subsets of)– Durability
• Amount of (Ab)Use to Maintenance or Repair
– Uniformity• Variation between Instances
– Consistency/Accuracy• Specifications Conformance
– Serviceability• Response to Complaints/Ability for Owner
Service
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 55
Dimensions of Quality Dimensions of Quality (3)(3)
• Dimensions (All Products Subsets Dimensions (All Products Subsets of)of)– Aesthetics
• Psychological/Sensual Appeal
– Personal Interface• People to People Interaction Quality
– Harmlessness• To User, To Environment
– Perceived Quality• Purchaser Perception/Inference
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 56
Costs of Quality (1)Costs of Quality (1)• Prevention CostsPrevention Costs
– Avoiding Costs of Failure/Degraded Performance
• Appraisal CostsAppraisal Costs– Cost of Measurement/Testing to Assure
Quality
• Internal Failure CostsInternal Failure Costs– Cost of Scrapping/Repairing Defects
prior to Customer Receipt of Product
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 57
Costs of Quality (2)Costs of Quality (2)External Failure CostsExternal Failure Costs
– Cost of Repairing/Replacing Defects after Customer Receipt of Produc t
– Suits for Damages as a Result of Lack of Merchantability
• Life Cycle CostsLife Cycle Costs– Designing Quality In Products, Processes– Quality Production– Quality Maintenance/Repair– Disposal
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 58
Taguchi Loss Function Taguchi Loss Function (1)(1)
• ConceptConcept– Loss increases with deviation from
Target Value (Quadratically)– Nominal is Best:
valuetT
productofsticscharacteriqualityy
tcoefficienLossqualityk
Where
TykyL
_targe
___
__
)()( 2
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 59
Taguchi Loss Function Taguchi Loss Function (2)(2)
• ConceptConcept– Loss increases with deviation from
Target Value (Quadratically)– Smaller is Better:
valuetT
productofsticscharacteriqualityy
tcoefficienLossqualityk
Where
ykyL
_targe
___
__
)()( 2
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 60
Taguchi Loss Function Taguchi Loss Function (3)(3)
• ConceptConcept– Loss increases with deviation from
Target Value (Quadratically)– Larger is Better:
valuetT
productofsticscharacteriqualityy
tcoefficienLossqualityk
Where
ykyL
_targe
___
__
)1()(
2
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 61
Taguchi Loss Function Taguchi Loss Function (4)(4)
• ConceptConcept– Average Loss can be Determined Based
on Target, Functional Limits, and Variation
– Based on Average Loss• Different Processes can be Evaluated• Different Definitions of Functional Limits
can be Explored
– Controllable, Uncontrollable, Noise Factors
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 62
Failure Mode AnalysisFailure Mode Analysis
• ConceptConcept– Recognize and evaluate potential
failure modes and effects• Mode -- Occurrence/Severity/Detection
– Identify actions that can eliminate or reduce the chance of potential failure occurring
– Document the process
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 63
Control Charts (1)Control Charts (1)
• AttributesAttributes– X bar and R– P charts
• Use to Identify Unlikely EventsUse to Identify Unlikely Events– Presume Process Has Changed
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 64
Control Charts (2)Control Charts (2)
• Record Out-of-Control Record Out-of-Control Events/CausesEvents/Causes– Histograms– Pareto Charts– Cause and Effect Diagrams– Scatter Diagram
Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 65
Anticipatory Quality Anticipatory Quality ControlControl
• ““Look Ahead Control Charts”Look Ahead Control Charts”– Results not Random, Autocorrelated
UCL
LCL
Mean
x x x xx
x x x xx
x x x xx
x x x xx
Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design
© 2000 © 2000 John W. NazemetzJohn W. Nazemetz
Lecture 10 Topic :Lecture 10 Topic : Shop Floor Shop Floor Support SystemsSupport Systems
Segment C Topic:Segment C Topic: Quality Assurance Quality Assurance
END OF SEGMENT END OF SEGMENT
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