Computer Integrated

Manufacturing
(CIM)
Lecturer: VU VAN PHONG

Dr. Van-Phong Vu-Department of Automatic Control

Contents of Chapter 7

 7.1 Overview
 7.2 Process Variability and Process Capability
 7.3 Statistical Process Control
 7.4 Six Sigma

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Overview

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Overview

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Overview
 quality control (QC):
 Detecting poor quality in manufactured products
 Taking corrective action to eliminate it.
 Traditional QC:
Only inspecting the product and its components, and deciding
whether the dimensions and other features conformed to design
specifications
Satsify specification--> ship to customer, do not satisfy rework
or dispose
 The modern QC: broader scope of activities that are accomplished
throughout the enterprise, not just by the inspection department

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Overview
 Aspects of Quality:
 Product features:
 characteristics of a product includes the functional and aesthetic
features of the product
 Provide satisfaction to the customer
 Defines its grade, Level in the market at which the product is
aimed

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Overview
 Aspects of Quality:
 Freedom from deficiencies
 product does what it is supposed to do (within the limitations of
its design features) and that it is absent of defects and out- of-
tolerance conditions
 Achieving freedom from defi- ciencies means producing the
product in conformance with design specifications

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Overview
 Aspects of Quality:

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Overview
 Traditional Quality Control
 Focused on inspection
 sampling and statistical methods (statistical quality control )
 Two statistical sampling methods of statistical quality control:
A control chart: graphical technique
statistics on one or more part or product characteristics of
interest
Checking the behaving normally or abnormally.

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Overview
 Traditional Quality Control
Acceptance sampling: statistical technique,
sample drawn from a batch of parts is inspected
decision is made whether to accept or reject the batch on the
basis of the quality of the sample
Acceptance sampling used for
(1) verifying quality of raw materials received from a vendor,
(2) deciding whether or not to ship a batch of parts or
products to a customer,
(3) (3) inspecting parts between steps in a manufacturing
sequence.
Dr. Van-Phong Vu-Department of Automatic Control
7.1 Overview
 Modern Quality Control
 Total quality management (TQM)
 three main objectives:
(1) achieving customer satisfaction,
(2) continuously improving
(3) involving the entire workforce

Dr. Van-Phong Vu-Department of Automatic Control

7.2 Process Variability and
Process Capability

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Process Variability and Process Capability

 Process Variability
 Random variations result from intrinsic variability in the
process, no mat- ter how well designed or well controlled it is
 Random variations cannot be avoided;
 caused by factors such as inherent human variability from one
operation cycle to the next, minor variations in raw materials,
and machine vibration
 Assignable variations indicate an exception from normal
operating conditions.
 operator mistakes, defective raw materials, tool failures, and
equipment malfunctions.

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Process Variability and Process Capability

 Process Variability
 Random variations result from intrinsic variability in the
process, no mat- ter how well designed or well controlled it is
 Random variations cannot be avoided;
 caused by factors such as inherent human variability from one
operation cycle to the next, minor variations in raw materials,
and machine vibration
 Assignable variations indicate an exception from normal
operating conditions.
 operator mistakes, defective raw materials, tool failures, and
equipment malfunctions.

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Process Variability and Process Capability

 Process Variability
 Random variations result from intrinsic variability in the
process, no mat- ter how well designed or well controlled it is
 Random variations cannot be avoided;
 caused by factors such as inherent human variability from one
operation cycle to the next, minor variations in raw materials,
and machine vibration
 Assignable variations indicate an exception from normal
operating conditions.
 operator mistakes, defective raw materials, tool failures, and
equipment malfunctions.

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Process Variability and Process Capability

 Process Capability and Tolerances

 Process Capability

PC = process capability

Assumption:
(1) the output is normally distributed
(2) steady-state operation has been achieved and the
process is in statistical control
Dr. Van-Phong Vu-Department of Automatic Control
7.1 Process Variability and Process Capability

 Process Capability and Tolerances

process capability of a given manufacturing operation
is not always known
Process mean and standard deviation estimated from
the sample average and the sample standard deviation

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Process Variability and Process
Capability
 Sample average

 Standard deviation

 Process variablility

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Process Variability and Process Capability

 Process Capability and Tolerances

Tolerances are specified as being equal to process
capability, the upper and lower boundaries of this range
define the natural tolerance limits
Process capability index: Ratio of the specified
tolerance range relative to the process capability

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Process Variability and Process Capability

 Process Capability and Tolerances

Process capability index

Dr. Van-Phong Vu-Department of Automatic Control

7.1 Process Variability and Process Capability

 Process Capability and Tolerances

Process capability index

Dr. Van-Phong Vu-Department of Automatic Control

7.3 STATISTICAL PROCESS
CONTROL

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control

Statistical process control (SPC) involves the use of various
methods to measure and analyze a process.
The overall objectives of SPC
Improve the quality of the process output
Reduce process variability and achieve process stability
Solve processing problems

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 control charts
 histograms
 Pareto charts
 check sheets,
 defect concentration diagrams
 scatter diagrams
 cause-and- effect diagrams

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Control Charts

Graphical technique in which The chart consists of three horizontal lines

statistics computed from mea- • a center line (CL),
sured values of a certain • a lower control limit (LCL), and
process output characteristic • an upper control limit (UCL)
(e.g., part dimension) are
plotted over time

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Control Charts

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Control Charts
center line is usually set at the
nominal design value of the part
or product characteristic of
interest

the upper and lower control

limits are generally set at +-3
standard deviations of the
nominal value

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Role of Control Chart
 sample value does fall outside these limits
 ==> process is out of control
 Investigation to determine the reason
  appropriate corrective action is taken to eliminate
the condition

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Two principal types of control charts for variables :
 x-bar chart: plot the average measured value of a certain quality
characteristic for each of a series of samples
 R chart: R chart plots the range of each sample

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Control Charts for Attributes:
 Control charts for attributes monitor the fraction defect rate or the
number of defects in the sample as the plotted statistic
 Two principal types of control charts for attributes:
 the p chart, which plots the fraction defect rate in successive
samples
 c chart, which plots the number of defects, flaws, or other
nonconformities per sample


Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 pi is the ratio of the number of nonconforming or defective items
di over the number of units in the sample n

 mean value

 Lower and upper

standard deviation
Dr. Van-Phong Vu-Department of Automatic Control
7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 The c chart (c for count): the number of defects in the sample is
plotted over time

c = number of quality defects found during final inspection, or

the sample

 Control Limit

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Historgram: a statistical graph consisting of bars representing different
values or ranges of values, in which the length of each bar is proportional
to the frequency or relative frequency of the value or range

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Pareto Chart:

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Check Sheets: A check sheet is a data- gathering tool generally used
in the preliminary stages of the study of a quality problem

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Cause-and-Effect Diagrams

Dr. Van-Phong Vu-Department of Automatic Control

7.3 Statistical Process Control

 Statistical process control tools

 Cause-and-Effect Diagrams

Dr. Van-Phong Vu-Department of Automatic Control