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Books > Professional & Technical > Mechanical engineering & materials > Production engineering > Industrial quality control
Many scientists and technologists would like to carry out their own statistical analyses without reference to a professional statistician. Often, however, they have no knowledge of statistics or otherwise do not know how to apply it to research and development problems. The first edition of Statistics in Research and Development was written for these people. The second edition brings the book up-to-date.
All measurements are subject to error because no quantity can be
known exactly; hence, any measurement has a probability of lying
within a certain range. The more precise the measurement, the
smaller the range of uncertainty. Uncertainty, Calibration and
Probability is a comprehensive treatment of the statistics and
methods of estimating these calibration uncertainties.
Illustrates the use of systems such as in-process control, quality auditing, and specifications, stressing a troubleshooting, cost-effective approach to product packaging for maximized early lead time to the customer. Addressing the needs of the pharmaceutical industry, the approaches supplied are l
If your goal is 100% zero defects, here is the book for you -- a completely illustrated guide to poka-yoke (mistake-proofing) for supervisors and shop-floor workers. Many poka-yoke ideas come from line workers and are implemented with the help of engineering staff or tooling or machine specialists. The result is better product quality and greater participation by workers in efforts to improve your processes, your products, and your company as a whole. The first section of the book uses a simple, illustrated format to summarize many of the concepts and main features of poka-yoke. The second section shows 240 examples of poka-yoke improvements implemented in Japanese plants. The book:
Use Poka-yoke in study groups as a model for your improvement efforts. It may be your single most important step toward eliminating defects completely. (For an industrial engineering perspective on how source inspection and poka-yoke can work together to reduce defects to zero, see Shigeo Shingo's Zero Quality Control.)
When humans are well, they are in a state where body, mind, and spirit are holistically integrated, and, as a result, are healthy, happy, and resilient. The same can be said for a thriving business. Industrial and Manufacturing Wellness: The Complete Guide to Successful Enterprise Asset Management explains how to use reliability engineering principles to design and build companies that are robust, reliable, self-improving, integrated business systems best suited for achieving optimal results. Written by asset management expert Mike Sondalini, creator and author of The Plant Wellness Way, this revolutionary work goes beyond basic plant management. Instead, it reveals a completely new way to engineer and implement business processes and work flow strategies that deliver overall operational excellence. The author introduces risk management, decision-making methods that prove the worth or not of a change before it is initiated in the organization, thus protecting a company from making the wrong choices. His universally applicable process improvement concepts empower readers to take a system-wide approach that can be repeated infinitely to deliver maximum success. Features Presents the first reliability engineering-based design and business process management solution. Includes a complete methodology to deliver enterprise asset management, plant maintenance, and equipment reliability. Shows how to maximize production uptime while minimizing costs and, uniquely, how to sustain those improvements. Incorporates the ISO 55001 framework in re-engineering business processes for operational success. Uses tips to reduce business processes to the fewest, simplest, quickest, safest, and most productive solutions. "Mike created what could basically be referred to as an ISO55001 implementation manual, with a big picture holistic engineering reliability approach to asset management. You will be surprised how he did that while also expanding on his existing 'Plant Wellness Way' methodology in just 286 pages! I also like how he emphasized throughout the book, attention to life cycle cost. Something that has been lacking in our industry. A must-read in today's world." -Don Fitchett, Business Industrial Network (BIN95.com)"Mike Sondalini's new book Industrial and Manufacturing Wellness is one of the best in our field that I have seen." -Len Bradshaw, Editor of Asset Management and Maintenance Journal(AMMJ)Mike Sondalini, MBA, CP Eng., is an expert in information and knowledge management, risk management and elimination, quality management systems, asset management, and operational excellence and reliability engineering. His immersion in these areas led him to create "The Plant Wellness Way," a life cycle asset management methodology. He subsequently coined the term "Industrial and Manufacturing Wellness" to depict a holistic, business-wide system of reliability. Introduction Reliability of Work, Processes, and Machines The Physics of Failure Variability in Outcomes Preventing Life-Cycle Risks Process 1-Identify Business and Operational Risks Asset Management For Plant Wellness Operating Equipment Risk Assessment Process 2-Order Risks by Importance Removing Risks And Raising Reliability Chance Reduction Risk Management Selecting Reliability Strategy Process 3-Numerate Risk Elimination Options The Accuracy-Controlled Enterprise Precision Maintenance Skills and Standards Process 4-Introduce Risk Control Solutions Reliability Growth Measuring to Improve Performance The Chance of Success Process 5-Control Operational Processes Failure Root Cause Prevention Change Management for Workplace Innovation Plant Wellness Index Process 6-Synthesize Ideas to Continuously Improve Bibliography Index
This is a comprehensive, user-friendly and hands-on book that is a single source of reference of tools and techniques for all quality practitioners. Implementing Six Sigma and Lean covers the basics of how to manage for consistently high quality and gives good coverage of both simple tools and advanced techniques which can be used in all businesses. This book provides guidance on how to use these tools for different situations such as new start-up companies, stalled projects and the constant achievement of high quality in well-established quality regimes. Case studies are included that encourage the reader to respond in a practical situations and provide a good learning resource for courses. There are summaries of key elements and questions with exercises at the end of each chapter.
Although regularly introducing new products or services is the lifeblood of most industries, bringing them to market can be fraught with peril. Timing, cost, and quality all play important roles in a successful product launch and avoiding expensive - often in more than just dollars - recalls and redesigns. Quality Assurance: Applying Methodologies for Launching New Products, Services, and Customer Satisfaction details continual improvement (CI), a proven process for avoiding common problems and creating customer satisfaction. The book explores the three fundamental approaches required to create a truly CI culture in any organization: a) consistent philosophy of improvement by management, b) receptive organizational culture, and c) the entire culture of the organization must be willing to make decisions based on measurement and data. It outlines the seven principles: research/plan, assure, explain, prioritize, demonstrate, confirm, and show. However, as with CI itself, this attitude must be incorporated into the processes of any organization and create products or services for the market place that will delight customers rather than just satisfying them. Time and cost constraints are the biggest culprits here, not any one person's lack of due diligence. When this happens, organizations must look at the bigger picture internally and identify it as a system problem. Based on the author's 35 years of experience, this book covers the essential items for doing the right thing the first time especially during launching a good product and/or service to the customer. It identifies key indicators and methodologies that will help you attain excellent performance, delivery, and cost with both the customer and supplier. In other words, by following these methodologies and indicators, the job will get done right the first time.
The Routledge Handbook of Communication Disorders provides an update on key issues and research in the clinical application of the speech, language and hearing sciences in both children and adults. Focusing on areas of cutting edge research, this "Handbook" showcases we know about communication disorders, and their assessment and treatment. It emphasizes the application of theory to clinical practice throughout, and is arranged by the four key bases of communication impairments:
The "Handbook "ends with an integrative section, which looks at innovative ways of working across domains to arrive at novel assessment and treatment ideas. It is an important reference work for researchers, students and practitioners working in communication science and speech and language therapy.
The process of discovery in science and technology may require investigation of a large number of features, such as factors, genes or molecules. In Screening, designed experiments and statistical analyses of the resulting data sets are used to identify efficiently the few features that determine key properties of the system under study. This book brings together accounts by leading international experts that are essential reading for those working in fields such as industrial quality improvement, engineering research and development, genetic and medical screening, drug discovery, and computer simulation of manufacturing systems or economic models. Our aim is to promote cross-fertilization of ideas and methods through detailed explanations, a variety of examples and extensive references. Topics cover both physical and computer simulated experiments. They include screening methods for detecting factors that affect the value of a response or its variability, and for choosing between various different response models. Screening for disease in blood samples, for genes linked to a disease and for new compounds in the search for effective drugs are also described. Statistical techniques include Bayesian and frequentist methods of data analysis, algorithmic methods for both the design and analysis of experiments, and the construction of fractional factorial designs and orthogonal arrays. The material is accessible to graduate and research statisticians, and to engineers and chemists with a working knowledge of statistical ideas and techniques. It will be of interest to practitioners and researchers who wish to learn about useful methodologies from within their own areaas well as methodologies that can be translated from one area to another.
As projects become more complex and the project teams are more geographically and culturally dispersed, so strong, trusting relationships come to the fore. Trust provides the security that enables project teams to work together effectively, even when they face project-threatening problems and challenges. Because today's team members work virtually as much by choice as by geographic necessity, business leaders must understand how team relationships such as trust, cross-divisional projects, and how offshore team participation are all positively motivated by a solid quality assurance program. Offering real world solutions, Trust in Virtual Teams provides a clear view of how virtual projects can succeed, and how quality assurance compliments and promotes effective organizational design and project management to build solid trust relationships. Dr Wise combines the latest research in virtual team trust with simple and proven quality methods. He builds upon more than 20 years of experience in quality and project work to guide team managers in creating high performing project teams. Our understanding of the role human factors play in project performance and project resilience continues to grow. As it does, so does our need to address the behaviors and culture that enable good performance. Tom Wise's book is a thoughtful and pragmatic guide to help project teams and managers do just that.
The book is written for anyone who wants to design experiments, carry them out, and analyze the results. The authors provide a clear-cut, practical approach to designing experiments in any discipline and explain the general principles upon which such design is based. The reader then can apply these theories to any specific problem in his own work. No advanced mathematics is needed to utilize Design of Experiments - the necessary statistical concepts and briefly reviewed in the first two chapters. Subsequent chapters explain why and how the design of experiments in an intrinsic part of the scientific method, what problems will be encountered by the researcher in setting up his experiment and how to deal with them, and how to accurately analyze the result in terms of the sample taken and the method used. Each chapter includes problems encountered in specific fields so that the reader can test himself on his comprehension of the material. The diversity of the applications that these problems encompass also allows the reader to grasp the basic principles that unite the statistical approach to experiment design. Researchers and students in engineering, agriculture, pharmacy, veterinary science, chemistry, biology, the social; sciences, statistics, mathematics, or any other field that requires the design, solution, and analysis of problems will find this book absolutely indispensable.
This text provides the practising engineer with a review of the current techniques and applications of machine control. The control of machines is essential in the manufacturing process in order to produce products with more speed, efficiency and accuracy. The range of machinery dependent upon control by a dedicated computer is very broad, encompassing sheet metal feeding machines, operating at a few cycles per minute to textile machines, some parts of which rotate at a hundred thousand revolutions per minute.
As a society, we tend to reward problem solvers, rather than those who prevent problems at their source. In other words, we focus on after-the-fact occurrences (appraisal activities) instead of trying to eliminate these occurrences (preventing activities). Discussing and evaluating the core requirements of quality efficiency and improvement, 10 Essentials for High Performance Quality in the 21st Century proposes an approach to help shift the paradigm of quality from appraisal mode to preventing mode. Identifying 10 steps readers can follow to optimize the quality of products and improve customer satisfaction, the book explains the rationale behind each of the steps in separate chapters. It addresses specific quality issues in six different sectors of the economy and provides statistics, tables, and figures from various organizations that support the need for a paradigm shift. Outlining a systematic process to guide your organization along the path toward improvement, the book covers risk and quality, multicultural management, empowerment, error analysis, team building, advanced quality planning, and quality operating systems. The accompanying downloadable resources provide tips and tools to help you implement all the necessary improvement initiatives under the umbrella of quality.
In an era of intense competition where plant operating efficiencies must be maximized, downtime due to machinery failure has become more costly. To cut operating costs and increase revenues, industries have an urgent need to predict fault progression and remaining lifespan of industrial machines, processes, and systems. An engineer who mounts an acoustic sensor onto a spindle motor wants to know when the ball bearings will wear out without having to halt the ongoing milling processes. A scientist working on sensor networks wants to know which sensors are redundant and can be pruned off to save operational and computational overheads. These scenarios illustrate a need for new and unified perspectives in system analysis and design for engineering applications. Intelligent Diagnosis and Prognosis of Industrial Networked Systems proposes linear mathematical tool sets that can be applied to realistic engineering systems. The book offers an overview of the fundamentals of vectors, matrices, and linear systems theory required for intelligent diagnosis and prognosis of industrial networked systems. Building on this theory, it then develops automated mathematical machineries and formal decision software tools for real-world applications. The book includes portable tool sets for many industrial applications, including:
The book also proposes future directions for intelligent diagnosis and prognosis in energy-efficient manufacturing, life cycle assessment, and systems of systems architecture. Written in a concise and accessible style, it presents tools that are mathematically rigorous but not involved. Bridging academia, research, and industry, this reference supplies the know-how for engineers and managers making decisions about equipment maintenance, as well as researchers and students in the field.
Considering that the biggest machines that do the most work are made up of smaller machines and components, it becomes obvious that when a large machine breaks, it is normally due to small components acting antagonistically. Detailing a time-tested method for increasing productivity and lowering operational costs, Spend Analysis and Specification Development Using Failure Interpretation explains how to establish performance-based procurement specifications for the components, devices, and items that contribute the most to operational downtime and repair/replacement costs. The book emphasizes the critical need to perform both spend and failure analysis in order to develop a procurement document, which will ultimately reduce overall costs. Accompanied by downloadable resources with helpful material such as, specification checklists, case study worksheets, form letters, and return on investment (ROI) worksheets that you can customize to your needs, the text discusses how to: Identify the products that will cost the most if they fail Develop performance-based procurement specifications to reduce direct and indirect costs Examine cost analysis as it relates to operations, maintenance, and production Determine effective criteria based on properties, test results, and standards for each operation Written by an industry expert with decades of experience giving seminars, training customers and associates, and authoring numerous papers and articles, the text provides the real-world understanding of the influential components and materials' physical properties needed to engage in effective failure and spend analysis. It addresses product submission and monitoring and includes helpful tools so you can immediately get started on conducting your own cost-saving analysis.
Quality Analysis of Additively Manufactured Metals: Simulation Approaches, Processes, and Microstructure Properties provides readers with a firm understanding of the failure and fatigue processes of additively manufactured metals. With a focus on computational methods, the book analyzes the process-microstructure-property relationship of these metals and how it affects their quality while also providing numerical, analytical, and experimental data for material design and investigation optimization. It outlines basic additive manufacturing processes for metals, strategies for modeling the microstructural features of metals and how these features differ based on the manufacturing process, and more. Improvement of additively manufactured metals through predictive simulation methods and microdamage and micro-failure in quasi-static and cyclic loading scenarios are covered, as are topology optimization methods and residual stress analysis techniques. The book concludes with a section featuring case studies looking at additively manufactured metals in automotive, biomedical and aerospace settings.
Today, multi-functional materials such as piezoelectric/ferroelectric ceramics, magneto-strictive and shape memory alloys are gaining increasing applications as sensors, actuators or smart composite materials systems for emerging high tech areas. The stable performance and reliability of these smart components under complex service loads is of paramount practical importance. However, most multi-functional materials suffer from various mechanical and/or electro-magnetical degra-dation mechanisms as fatigue, damage and fracture. Therefore, this exciting topic has become a challenge to intensive international research, provoking the interdisciplinary approach between solid mechanics, materials science and physics. This book summarizes the outcome of the above mentioned IUTAM-symposium, assembling contributions by leading scientists in this area. Particularly, the following topics have been addressed: (1) Development of computational methods for coupled electromechanical field analysis, especially extended, adaptive and multi-level finite elements. (2) Constitutive modeling of non-linear smart material behavior with coupled electric, magnetic, thermal and mechanical fields, primarily based on micro-mechanical models. (3) Investigations of fracture and fatigue in piezoelectric and ferroelectric ceramics by means of process zone modeling, phase field simulation and configurational mechanics. (4) Reliability and durability of sensors and actuators under in service loading by alternating mechanical, electrical and thermal fields. (5) Experimental methods to measure fracture strength and to investigate fatigue crack growth in ferroelectric materials under electromechanical loading. (6) New ferroelectric materials, compounds and composites with enhanced strain capabilities.
This book presents a collection of real cases from industrial practices that production system and quality managers implement to ensure a high quality as well as a low cost in products. This book is divided in sections that are focused on: * The quality and philosophies implemented to production systems; starting from the product design as well as from the supply system. * The principal statistical techniques applied to the quality assurance (statistical quality control, analysis of tests and failure, quality function deployment, accelerated life tests, among others), the process of gathering information, its validation, its reliability process, and techniques for data analysis. * The techniques applied to the integration of human resources in the process of quality assurance, such as managers and operators' participation, training, and training processes. * Use of information and communications technologies, software, and programs implemented to guarantee the quality of the products in the production systems. ISO standards and policies that are used for quality management and monitoring.
Richard Bellmann developed a theory of dynamic programming which is for many reasons still in the center of great interest. The authors present a new approach in the ?eld of the optimization and multi-objective control of time-discrete systems which is closely related to the work of Richard Bellmann. They develop their own concept and their extension to the optimization and multi-objective control of time-discrete systems as well as to dynamic networks and multilayered structures are very stimulating for further research. Di?erent perspectives of discrete control and optimal dynamic ?ow problems on networks are treated and characterized. Together with the algorithmic solutions a framework of multi-objective control problems is - rived. The conclusion with a real world example underlines the necessity and - portance of their theoretic framework. As they come back to the classical Bellmann concept of dynamic programming they stress and honor his basic concept without debase their own work. Multilayereddecisionprocessesaspartofthedesignandanalysisofcomplexsystems and networks will be essential in many ways and ?elds in the future.
Complexity in automation- and safety systems in railway as well as automotive applications are dominated more and more by formal description means, methods and tools. Formal techniques provide next to correctness and integrity checkups - especially for safety relevant systems - the possibility to model, prove, simulate and check the specification of the system as well as to generate the system implementations. Requirements of the CENELEC- and IEC-Standards on formal techniques, particularly with regard to the handling of safety analysis, are to be treated in FORMS/FORMAT 2010. The main focus lies on topics facing formal techniques for railway applications and intelligent transportation systems as well as for automotive applications. Gained findings, experiences and also difficulties associated with the handling of the subject matter as well as description means and tools are to be shown.
The book provides background information about technical solutions, processes and methodology to develop future automated mobility solutions. Beginning from the legal requirements as the minimum tolerable risk level of the society, the book provides state-of-the-art risk-management methodologies. The system engineering approach based on todays engineering best practices enhanced by principles derived from cybernetics. The approach derived from the typical behaviour of a human driver in public road traffic to a cybernetical based system engineering approach. Beyond the system engineering approach, a common behaviour model for the operational domain will show aspects how to extend the system engineering model with principles of cybernetics. The role and the human factors of road traffic participants and drivers of motor vehicles are identified and several viewpoints for different observers show how such mixed traffic scenarios could be assessed and optimised. The influence of the changing mobility demands of the society and the resulting changes to the origination of producer, owner, driver and supplier show aspects for future liability and risk share option for new supply chains. Examples from various industries provide some well-proven engineering principles how to adapt those for the future mobility for the benefit of the users. The aim of the book is to raise awareness that the safety provided by a product, a means of transport or a system up to an entire traffic system depends on the capabilities of the various actors. In addition to the driver and passengers, there are also other road users, maintenance personnel and service providers, who must have certain abilities to act safely in traffic. These are also the capabilities of the organisation, not only the organisation that develops or brings the product to market, but also the organisation that is responsible for the operation and the whole lifecycle of the products. The book is for people who want to get involved in the mobility of the future. People, that have ideas to become a player who want to help shape the future mobility of society and who want to bring responsible solutions for users into the market.
This second edition details all productivity and quality methodologies, principles and techniques, and demonstrates how they interact in the three phases of the productivity and quality management triangle (PQMT): measurement, control and evaluation; planning and analysis; and improvement and monitoring. This edition features material on practical strategies for implementing quality programmes, balancing productivity and quality results , resolving quality problems and empowering employees.
Demonstrates How To Perform FMEAs Step-by-Step Originally designed to address safety concerns, Failure Mode and Effect Analysis (FMEA) is now used throughout the industry to prevent a wide range of process and product problems. Useful in both product design and manufacturing, FMEA can identify improvements early when product and process changes are relatively easy and inexpensive to make. Updated to include changes reflected in ISO/TX-16949:2002 standards and 2008 AIAG guidelines, The Basics of FMEA, Second Edition continues to provide the expert advice needed to help shorten the learning curve for FMEA teams to conduct effective and efficient FMEAs, even if it is their very first one. Includes Ready-to-Use Worksheet Templates Using a manufacturing case study, readers learn step-by-step how to use FMEAs to assess, evaluate, and prioritize areas of risk, and then to implement the actions needed to reduce risks to an acceptable level. It shows the steps needed to ferret out potential problems and prevent making inferior products that could endanger public and worker safety and compromise profits as well as the future of all stakeholders. Although engineers have typically analyzed processes and products for potential failures, the FMEA process standardizes the approach and establishes a common language that nontechnical as well as technical employees can use at all levels. Unlike other improvement tools, FMEA does not require complicated statistics. However, they require a full commitment to quality and a willingness to take a team approach that involves all stakeholders.
"Real-time Systems Quality of Service" examines the attainability of efficiency, economy, and ease of use, which make up the quality of service of technologically advanced products. "Real-time Systems Quality of Service" reviews the state of the art in quality of service evaluation for real-time systems. It gives a classification of the relevant parameters for quality of service evaluation and also determines the critical points in the design and development process of real-time systems where performance criteria should be applied or checked. Then, software development and certification standards are assessed, and finally the authors elaborate on how the suggested criteria should be applied to the design, development, and certification process of real-time systems. "Real-time Systems Quality of Service" will guide researchers and postgraduates in embedded and real-time systems through the process of introducing quality of service parameters into real-time systems. |
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