pat a framework for excellence
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PAT A FRAMEWORK FOR EXCELLENCE. By Timothy Leistikow ASQ FD&C DIVISION 22. October 2004. PAT Goals. Risk Management. Current Technology. Manufacturing Innovation. Characterization of “Future State” of manufacturing . Quality ensured through effective & efficient processes - PowerPoint PPT PresentationTRANSCRIPT
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PAT
A FRAMEWORK FOR EXCELLENCE
ByTimothy Leistikow
ASQ FD&C DIVISION22. October 2004
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PAT Goals
Risk Management
CurrentTechnology
Manufacturing Innovation
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Characterization of “Future State” of manufacturing
• Quality ensured through effective & efficient processes
• Recognizing the capability of process control strategies to mitigate risk of poor quality
• Product & process specifications based on formulation and process factors
• Continuous real time quality assurance
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Characterization of “Future State” of manufacturing
• Quality ensured through effective & efficient processes
• Recognizing the capability of process control strategies to mitigate risk of poor quality
• Product & process specifications based on formulation and process factors
• Continuous real time quality assurance
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Process Efficiency and Effectivity
Basic Process Functions?Process Failures?
Failure Effect on Process and Product?Process controls?
Control Effectivity?
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Assessing Process Effectivity and Efficiency
• Functional Block Diagram• Failure Modes and Effects Analysis• Characteristics Matrix• Design of Experiments • Dynamic Control Planning
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Characterization of “Future State” of manufacturing
• Quality ensured through effective & efficient processes
• Recognizing the capability of process control strategies to mitigate risk of poor quality
• Product & process specifications based on formulation and process factors
• Continuous real time quality assurance
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Process Control Strategies
FMEA PFMEA
EMEA
Product Process
Human Error
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Process FMEA & EMEA
• Indicates risks to process output quality
• Documents process control rationale
• Shows effects of process variation on product quality
• Prioritizes Continuous Improvement effort
• Indicates risk areas due to human error
• Provides direction for Poka – yoke applications
• Reveals Management induced errors
• Continuous Improvement format for operators
Equipment Error Modes Analysis
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People Processes Gap AnalysisPeople Processes Matrix
SYSTEMMaintenance Operations Materials
Formal SOP 325SOP 156
SOP 958SOP 639
SOP 187
Informal SkillsManualsEnvironment
SkillsEquipment KnowledgeEnvironment
SkillsIT SystemKnowledge
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EMEA paradigm shift
• Errors aren’t caused by “bad” personnel• It’s “good” people having bad results
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EMEA Process
The greatest discovery of my generation is that human beings can alter their lives by altering their attitudes of mind.
William James
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Characterization of “Future State” of manufacturing
• Quality ensured through effective & efficient processes
• Recognizing the capability of process control strategies to mitigate risk of poor quality
• Product & process specifications based on formulation and process factors
• Continuous real time quality assurance
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Characteristics MatrixAutomotive Application
• C = Characteristic is used for clamping• L = Characteristic used for locating• X = Characteristic changed at operation
DimNo
Description
Tolerance
Operations05 10 20 30
1 ID +/- .01 X C X2 Face +/- .001 X C C4 OD +/- .005 X
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Characteristics Matrix Paradigm Shift Example
• X = characteristic affected by operation – see process flow diagram
• S = Characteristic must be stable• NC = Characteristic not controlled
Charact.Descript
Tol. Operation number / Capability10 Cpk 20 Cpk 30 Cpk
H20 PH PH 6-8
X 1.56 S 1.44 S 1.0
H20 Temp
+/- 1 deg
NC 0.9 NC 0.9 X 2.0
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Measurement Capability Studies
• Use of DOE to assess measurement capability
• Measure capability as a ratio of variation to process/product tolerance (% tolerance)
• Typical requirement – 6 sigma can be no more than 30% of tolerance
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Characterization of “Future State” of manufacturing
• Quality ensured through effective & efficient processes
• Recognizing the capability of process control strategies to mitigate risk of poor quality
• Product & process specifications based on formulation and process factors
• Continuous real time quality assurance
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Continuous Real Time
• Measuring the characteristic• Creating the signal• Interpreting the signal• The response
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Line of sight
Clean Room4
6
Continuous Real Time Feedback
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Line of sight
Clean Room
Continuous Real Time Feedback
Operator instructions
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Operator Feedback
The real problem is not whether machines think but whether men do. – -- B. F. Skinner
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Manufacturing Innovation
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Innovation in manufacturingCustomer Satisfaction
New
Materials
New
Processes
New
Skills
Customer
Satisfaction
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Manufacturing Innovation Benchmarking
Automotive Quality Planning
Advanced Product Planning and Control Plan Process (APQP)
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Advanced Product Quality Planning and Control Plan (APQP)
• PLAN – DO – STUDY – ACT (Cycle of continuous improvement)
• Organizes reviews of elements that affect quality
• Identifies risks to product quality • Reveals critical paths and efficiency
problems
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Goal of Product Planning Cycle
The APQP cycle
Upfront planningDocuments the experience from one program
Applies acquired knowledge to the next program
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Learning from the past
• Experience is the name every one gives his mistakes. – -- Elbert Hubbard
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Common ToolsLoss of knowledge
•Computers -DOS operating systems
• Maybe 20% of current windows users know how to operate.
10-30 years ago
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How tools have changed
There is no reason for any individual to have a computer in his home.
– -- Kenneth H. Olson, President of DEC, Convention of the World Future Society, 1977
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“Success is meeting customer needs in a timely manner at a cost that represents
value”
• Timing of elements for Quality Planning• Simultaneous engineering
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Quality Planning Sequences Planning
Product Design andDevelopment
Process Design and Development
Validation Activities
Production
Launch
Feedback Assessment & Corrective Action
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Planning Program
• Things gone wrong reports• Things gone right reports• Capability indicators• Problem resolution reports• Customer returns/rejections
• Product Goals• Reliability and Quality
Goals• Preliminary Process Flow
Chart• Preliminary listing of
Product and Process Characteristics
• Product Assurance Plan
Inputs Outputs
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Quality Planning Sequences Planning
Product Design andDevelopment
Process Design and Development
Validation Activities
Production
Launch
Feedback Assessment & Corrective Action
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Product Design & Development
• Design for manufacturability
• Design reviews• Product Specifications• Material
Specifications
• New tooling and facilities requirements
• Gages/Testing requirements
• Prototype Control Plan• Special Product and
Process Control Characteristics
Design Outputs Advanced Quality Planning
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Product Design & Development
• Identifying special Product and Process Characteristics
• Identification of testing and gauging requirements
• New equipment requirements
Design Review Process APQP Team
Concurrent Engineering
Design of ExperimentsVariation of Product
Design FMEA’sDesign for manufacturability
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Design FMEA
• Aids in identifying controls needed to reduce variation of product
• Indicates where risk elements to Product Quality may exist
• Provides an open format for listing continuous improvement tasks
• Provides a knowledge base for identifying root causes.
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Quality Planning Sequences Planning
Product Design andDevelopment
Process Design and Development
Validation Activities
Production
Launch
Feedback Assessement & Corrective Action
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Process Design and Development
• Packaging Standards• Process Flow Charts• Measurement Systems Analysis Plan• Process FMEA’s• Process Instructions• Characteristics Matrix
OUTPUTS
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FMEA & EMEA Supporting Analyses
• Functional Block Diagrams• Characteristics Matrix• Process Flow Charts• Design of Experiments• Cause and Effect Diagrams• Capability Studies (Process)• Capability Studies (Measurement Process)
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Quality Planning Sequences Planning
Product Design andDevelopment
Process Design and Development
Validation Activities
Production
Launch
Feedback Assessment & Corrective Action
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Feedback Assessment & Corrective Action
• Documentation of Variation sources affecting Product Quality (Risks)
• Identification of critical path items affecting Delivery and Product Quality (Risks)
• Continuous Improvement– Lessons learned during APQAP Project– Elements requiring further optimization– Elements requiring reduction in variation
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Successful Risk Managementis based on
• Recognizing what can go wrong• Determining the probability of occurrence• Determining the severity of occurrence
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• What we anticipate seldom occurs: but what we least expect generally happens. – -- Benjamin Disraeli
Final thoughts