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 |  موضوع: كتاب Tool and Manufacturing Engineers Handbook - Volume VII - Continuous Improvement الإثنين 27 يونيو 2022, 3:42 pm | |
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Tool and Manufacturing Engineers Handbook - Volume VII - Continuous Improvement
FOURTH EDITION
A reference book for manufacturing engineers, managers, and technicians
Ramon Bakerjian, CMfgE
Handbook Editor
Philip Mitchell, CMfgT
Staff Editor
Produced under the supervision of the SME Reference Publications Committee in cooperation with the SME Technical Divisions
و المحتوى كما يلي :
CONTENTS
VOLUME VII-CONTINUOUS IMPROVEMENT
Symbols and Abbreviations . xi
Continuous Improvement . 1.1
Total Quality Management 2-1
Continuous Improvement Teams . 3-1
Continuous Improvement and Training 4-1
Implementing Continuous Improvement . 5-1
Supplier Involvement in Continuous Process Improvement Efforts . 6-1
Benchmarking 7-1
Activity-Based Costing . 8-1
Deming, Juran and Taguchi . 10-1
Process Appraisal . 11-1
The Role of IS0 9000 in Continuous Improvement 12-1
The Baldrige Criteria as a Self-Assessment Tool 13-1
General Productivity Improvement .14-1
Total Productive Maintenance . 15-1
Machining . 16-1
Forming . 17-1
Finishing 18-1
Assembly 19-1
Accident Prevention and Continuous Improvement 20-1
Continuous Improvement and Just-in-Time 9-1
Index . 1-1
ixSYMBOLS AND
ABBREVIATIONS
The following is a list of symbols and abbreviations in general use throughout this volume. Supplementary and/or derived units, symbols,
and abbreviations that are pectrliw to specific subject matter are listed within chapters.
A-B
ABC
ABM
ABS
ABX
AC
ADA
AFAQ
AFNOR
AIAG
ANOVA
ANSI
ANSI/ASQC
Q90 series
APQC
AQAP-1
ARP
ASME
ASQC
ASTM
AWS
BEST
BOM
BPR
BSI
BTU
Activity-based costing
Activity-based management
Anti-braking system
Activity-based information
Alternating current
Americans with Disabilities Act
Association Francaise pour L’Assurance de la
Qualite
Association francaise de normalization
Automotive Industry Action Group
Analysis of variance
American National Standards Institute
US equivalent of the ISO 9000 series
American Productivity and Quality Center
Allied Quality Assurance Publication I
Activity-requirement planning
American Society of Mechanical Engineers
American Society for Quality Control
American Society for Testing and Materials
American Welding Society
Burr, Edge, and Surface conditioning
Technology division of SME
Bill of materials
Business process reengineering
British Standards Institute
British thermal unit
C-D-E
C&E
CAM-I
CARC
CASCO
CASE
CBN
CBT
CCT
CD
CDCF
CDT
CE
CED
CEN
CENENLEC
CI
Cause and effect (diagram)
Computer-Aided Manufacturing-International
Chemical agent resistant coating
Committee for Conformity Assessment
Conformity Assessment System Evaluation
Program
Cubic boron nitride
Computer-based training
Competitive cycle time
Committee draft
Continuous dress creep-feed
Cumulative trauma disorder
Mark European Community Mark
Cathodic electrodeposition
European Committee for Standardization
European Committee for Electrotechnical
Standardization
Continuous improvement
CIE
CIM
CIP
CIUG
cm
CM
CMM
CMMS
CNC
CPI
CPSC
CTD
CVD
DC
DESC
DFARS DOD
DFM
DHHS
DIN
DIS
DITI
DOC
DOD
DOE
DOT
DRF
EAC
EC
ECC
ECN
EDA
EDI
EEA
EFTA
EN 29000
series
EN
ENV
EOQ
EOQ
EOTA
EOTC
EPA
EQNET
Computer-integrated enterprise
Computer-integrated manufacturing
Continuous improvement process, continuous
improvement program
Continuous improvement users group
centimeter
Cell manufacturing
Coordinate measuring machine
Computerized maintenance management
systems
Computer numerical control
Corrugated plate interceptors
Consumer Product Safety Commission
Regulations, U.S. GovemmentProduct Safety
Cumulative trauma disorders
Chemical vaporized deposition
Direct current
Defense Electronics Supply Center, DOD
Federal Acquisition Regulation Supplement
Design for manufacturability
Department of Health and Human Services
Deutsches Institute fur Normung
Draft International Standard
Department of Trade and Industry (UK)
Department of Commerce
Department of Defense
Department of Energy
Department of Transportation
Data reference frame
European Accreditation of Certification
European Community
Engineering change control
Engineering change notice
Economic Development Administration
Electronic Data Interchange
European Economic Area
European Free Trade Association
European equivalent of 1S0 9000
European Norm of Standard
European Pre-standards
European Organization for Quality
Economic order quantity
European Organization for Technical
Approvals
European Organization for Testing and
Certification
Environmental Protection Agency
European Network for Quality System
Assessment and Certification
xiEQS European Committed for Quality System
Assessment and Certification
ETA European Technical Approval
ETSI European Telecommunications Standards
Institute
EVOP Evolutionary optimization
F-G-H-l-J-K
FAA
FAR
FDA
FMCA
FMEA
FOD
FTA
FY
GMP
gm
GNP
GPa
GRR
GSA
GT
HAZ
HD
HLVP
HP
HSM
HSS
ID
IEC
in.
IQA
1s0
ISO/TC176
ISR
JAZ
JIT
JSA
kg
kN
kPa
LAN
lb(s)
LPS
MAU
MBNQA
MBO
MIL SPECS
mm
MOU
MP
MPa
MRA
MRP
MSDS
Federal Aviation Administration
Federal Acquisition Adminstration
Food and Drug Administration
Failure mode and critical analysis
Failure mode and effects analysis
Foreign object damage
Fault tree analysis
Fiscal year
Good Manufacturing Practice Guidelines
(FDA)
gram
Gross national product
Gigapascal
Gage repeatability and reproducibility
General Services Administration
Group technology
Heat affected zone
Harmonized document
High-volume, low pressure
Hewlett-Packard
High speed machining
High speed steel
Inner diameter
International Electrotechnical Commission
inch
Institute for Quality Assurance
International Standards Organization
International Standards Organization Technical
Committee 176
Initial sample runs
Japanese Certification Organization
Just-in-time
Job safety analysis
kilogram
kilonewton
kilopascal
L-M-N-O
Local area network
pound(s)
Lean production systems
Medium access units
Malcomb Baldrige National Quality Award
Management by objective
U.S. Government Military Specifications
millimeter
Memorandum of Understanding
Master performer
Megapascal
Mutual Recognition Agreement
Material requirements planning
Material Safety Data Sheets
MTC
MTM
NAC-QS
NACCB
NATO
NCSCI
NEMA
NFPA
NIST
NRC
NVCASE
NVLAP
OD
OEE
OEM
OJT
ONA
OSHA
Manufacturing technology centers
Motion and time methods
Comite National pour L’accreditation des
Organisms de Certification
National Accreditation Council for
Certification Bodies (Belgium)
North Atlantic Treaty Organization
National Center for Standards and
Certification Information
National Electrical Manufacturer’s Association
National Fire Protection Association
National Institute of Standards and
Technology
Nuclear Regulatory Commission
National Voluntary Conformity Assessment
System Evaluation
National Voluntary Laboratory Accreditation
Program
Outer diameter
Overall equipment effectiveness
Original equipment manufacturer
On-the-job (training)
Orbital nozzle assembly
Occupational Safety and Health
Administration
P-Q-R-S-T
PAS
Pc
PCD
Pcs
PDCA
PDF
PDSA
PLC
PM
PPE
PPH
ppm
PPM
PTS
PVD
QCO
QFD
QIS
QIT
QML
QPL
QSR
RAB
RCRA
RF
RFDC
rms
ROI
RPN
RVC
SAE
Sc
Scc
Performance appraisal system
Personal computer
Polycristalline diamonds
Plain carbon steels
Plan-do-check-act
Probability density function
Plan-do-study-act
Programmable logic controller
Preventive maintenance
Personal protective equipment
Parts per hour
Parts per million
Parts per minute
Performance to schedule
Physical vaporized deposition
Quick change over
Quality function deployment
Quality information system
Quality improvement team
Qualified manufacturers list
Qualified products lists
Quality System Registrar
Registrar Accreditation Board
Resource Conservation and Recovery Act
Radio frequency
Radio Frequency Data Communications
Root mean square
Return on investment
Revolution per minute
Risk priority number
Raad Voor de Certificate (Holland)
Society of Automotive Engineers
Subcommittee
Standards Council of Canada
xiiSEM Scanning electron microscopy
SIMS
SM
SME
SMED
SMT
SOP
SPC
SQC
TAAC
TC
TCM
TEI
TMU
TOC
TPM
TQM
TTT
Scanning ion mass spectroscopy
Synchronous manufacturing
Subject matter expert
Single minute exchange dies
Self managed team
Standard operating procedure
Statistical process control
Statistical process control
Tmde Adustment Assistance Centers
Technical Committee
Total change management
Total employee involvement
Time measurement unit
Theory of constraints
Total preventive maintenance
Total quality management
Total team trainers
u-v-w-x-Y-z
UL Underwriters Laboratories
UPC Universal product code
Voc Volatile organic compounds
WBS Work breakdown structure
Wc Workman’s compensation
WCM World class manufacturing
WD Working draft
WG Working group
SYMBOLS
Alpha
Approximately equal to
Beta
Degree
Greater than
Greater than or equal to
Less than
Less than or equal to
Mu
Omega
Percent
Plus or minus
Sigma (summation)
INDEX
cathodic tank, 18-I6 (Fig. 18-3)
cure, 18-17
dry-film lubricant, 18-19
on tubular products, 18-20
organic, 18-14
specifications, 18-15
testing, 18-20
to replace other finishes, 18-17, 18-19,
ultrafiltration, 18-17
18-20
Electronic Data Interchange, 14-23
Ergonomics, 20-4, 20-7 (Fig. 20-2)
guidelines, 20-4
material handling tasks, 20-5
workplace design, 20-7, 20-8 (Table 20- I),
redesign, 20-6
20- 13, 20-20 (Fig. 20-20j
Employee involvement, 3-8 (Fig. 3-6)
management, 18-3
materials, 18-2
methods, 18-2
money and manpower, 18-1
paint, 18-4
power brushes, 18-29
pretreatment, 18-4
quality control, 18-22
surface improvement, 18-33
system variables, 18-8 (Table 18- I )
Fishbone diagrams, 1- 1 1
Flow diagram, 10-12 (Fig. 10-I), 10-14
Flowcharts, 5-6 (Fig. 5-21, 19-16 (Fig. 19-1I ) ,
FMEA, see: Failure Mode and Effects
Forming, 17-1
(Fig. 10-5)
19-12 (Fig. 19-9)
Analysis
limit diagram, 17-9 (Fig. 17-4)
F
Facility layout, 20-13, 20-14 (Figs. 20-8 and
20-9), 20- 18 (Fig. 20- 16) see also Workplace
design
aisle design, 20-23
by computer, 20-23
material flow, 20-14, 20-15 (Fig. 20-lo),
20-16 (Fig. 20-1 1 and 20-12), 20-17
(Fig. 20-13 through 20-15)
analysis 20- 16, 20- 18 (Fig. 20- 16),
20-19 (Fig. 20-17 and 20-18), 20-20
(Fig. 20-19)
planning, 20- 13
responsibility, 20-3
space requirements, 20-23
types, 20- 13
important machining parameters, 16-6
machine tool aspects, 16-6
setup and workholding aspects, 16-6
process planning aspect, 16-6
work material condition, 16-6
value-added concept, 16-6,
Factors affecting process quality, 16-6
Failure Mode and Effects Analysis, 1-12,
14-35, 19-7 (Fig. 19-3)
forms, 14-38
guidelines, 14-38
mechanics, 14-37
process, 14-39
purpose, 14-35
recommendations, 14-38
vocabulary, 14-36
Fasteners
hook and loop, 19-51, 19-52 (Fig. 19-54,
19-55j
improvements, 19-52, 19-53 (Fig.
materials, 19-53
19-56, 19-57)
Feeders, 19-19
bowls, 19-20 (Fig. 19-14), 19-21
(Fig. 19-15>,19-22 (Fig. 19-16), 19-24,
19-25 (Fig. 19-27), 19-26 (Fig. 19-29)
tooling, 19-21
centrifugal, 19-24
hoppers. 19-26
muff ling, 19-25
orientation, 19-22, 19-23 (Fig. 19-17
through 19-26), 19-26 (Fig. 19-28)
selecting, 19-20
stands, 19-26
autodeposition, 18-43
deburring and surface conditioning, 18-41
electrocoating, 18-14
honing, 18-35
induction heating, 18-27
machinery, 18-3
Finishing, 18-1
G
Geometric control, 14-4 (Fig. 14-3), 14-6
(Fig. 14-5), 14-12 (Fig. 14-10)
H
Histograms, 1-12, 10-16 (Fig. 10-7)
History of continuous improvement, 1-3
Honing, 18-35
abrasive selection, 18-35
bore errors, 18-36 (Fig. 18- 13)
cross-hatch pattern, 18-36
cutting pressure versus cost, 18-38
fluids, 18-38
honed and bored cylinder, 18-36
machine selection, 18-39, 18-40 (Fig.
spindle speed, 18-35, 18-37 (Fig. 18- 16)
statistical proccss control, 18-39
stock removal rate, 18-37 (Table 18-5);
18-38 (Table I8-7), 18-40 (Table 18-10)
surface finish, 18-37, 18-39 (Table 18-9),
18-40 (Fig. 18-19)
time required, 18-38 (Table 18-6)
(Table 18-8)
(Fig. 18-14 and 18-15)
18-21), 18-41 (Fig. 18-22, 18-23, 18-24)
Hook and loop fasteners, see Fasteners
House of quality, 2-12 (Fig. 2-8)
I
Implementing continuous improvement, 5-1
assuring success, 1-13
communication, 5- 17
cultural change, 5-16, 5-17 (Fig. 5-8)
flawed approaches, 5-16
flowcharts, 5-6 (Fig. 5-2)
issues and traps, 5-15
management behavior, 5- 18
planning, 5- 1
checklist, 5-7 (Fig. 5-3)
organizational issues, 5-7
preparation, 5-4
purpose, 5-2
methodologies, 5-5
principles, 5-14 (Fig. 5-7)
recognition and rewards, 5-17
rules, 5-8
standards and measures, 5-18
strategies, 5-1 1 (Fig. 5-5)
techniques, 5-12 (Fig. 5-6)
training, 5-17
user groups, 5-18, 5-21 (Fig. 5-1 1)
benefits, 5-19
small firms, 5-19
“storyboard,” 5-20 (Fig. 5-10)
vision, mission, and values, 5-8
Importance of continuous improvement, 1-4
Induction heating, 18-24
coils, 18-27
equipment, 18-28
power supplies, 18-26
process controls, 18-26
work handling, 18-28
workstations, 18-26
recognizing process variables, 16-19
key system components, 16-I9
the grinding cycle, 16-20
types of in-process gaging systems, 16-20
gap control systems, 16-20
in-process considerations, 16-20
measuring for machining, 16-21
conceptual foundations, 12-3
effect of registration, 12-5
guidelines, I2- 10
improvement, I 2-4
In-process gaging systems, 16-19
I S 0 9000, 1-9, 12-1
documentation, 12-4
problem prevent ion, 12-5, 12-7
records, 12-4
registration, 12-9
standards, 12-2 (Table 12-1)
supplemental standards, 12-10
support for continuous improvement. 12-2
terminology, 12-4 (Table 12-2)
Interfaces machine toolicutting tool, 16-36
accurate toolholding, 16-36, 16-37
(Figs. 16-34 and 16-35)
precision clamping, 16-37, 16-38
(Figs. 16-36 and 16-37)
in-between adaptation, 16-37
J
Joints, see Brazed and soldered joints
Juran, Joseph M., 1-5, 10-11
philosophy, 10-1I
identifying customers, 10-13
quality control, 10-12
quality improvement, 10-12
system components, 10-14 (Fig. 10-4)
(Fig. 10-2)
Just-in-Time, 9-1
elements of, 9-2
human/people issues, 9-5
implementation, 9-7
organization issues, 9-6
technical issues, 9-3
U-line layout, 9-4 (Fig, 9-2)
scheduling, 9-6 (Fig. 9-4)
K
Kaizen, 1-6
Kinematic control, 14-4 (Fig. 14-4)
1
Laser processing, 16-54
(Fig. 16-53)
autofocus, 16-54 (Fig. 16-52), 16-55
part programming, 16-55
coordination of beam characteristics and
positioning systems, 16-55 (Fig. 16-54)
orbital nozzle assembly, 16-56 (Fig. 16-55)
use of inert gases, 16-56
welding-laminar barrier inerting, 16-56
(Fig. 16-56)
1-2INDEX
cutting-high pressure inert assist, 16-56
Laser welding, see Welding
Machining coolants, 16-57
improving quality and productivity through
filter media selection criteria, 16-57
filter media physical properties, 16-57
filter media manufacturing process characteristics, 16-57, 16-58 (Fig. 16-57),
16-58 (Fig. 16-58), 16-59 (Fig. 16-59)
filter media composition characteristics,
16-59, 16-61 (Fig. 16-60)
evaluating filter media, 16-60, 16-62 (Fig.
16-61), 16-63 (Figs. 16-62 and 63)
comparative study sequence, 16-62
statistical analysis of evaluation results,
16-62, 16-65 (Fig. 16-64), 16-66
(Figs. 16-65 and 66)
sludge evacuation to eliminate coolant
wastes, 16-64, 16-69 (Fig. 16-67)
on site clean up of small volumes of oily
wastes, 16-68
filter media selection, 16-57
Machining centers, 14-32 (Fig. 14-17), 14-33
Macro design, 8-25 (Fig. 8-31)
Maintenance, 15-1 , 20-3I
Management, 14-18
(Fig. 14-18), 14-33 (Fig. 14-19)
see also Total Productive Maintenance
constraint-based, 14-19
global versus local, 14-18
scheduling, 14-22, 14-26, 14-34
Manufacturing Resource Planning I1
flowchart, 19-12 (Fig. 19-19)
Material flow, 20-14, 20-15 (Fig. 20-lo),
(Fig. 14-20)
20-16 (Figs. 20-1 1 and 20-12), 20,16, 20-17
(Fig. 20-13 through 20-15)
analyzing, 20-16, 20-18 (Fig. 20-16),
20- I9 (Fig. 20-I7 and 20-18), 20-20
(Fig. 20-19)
evaluation chart, 20-22 (Fig. 20-23)
From-to chart, 20-21 (Fig. 20-21)
patterns, 20-26 (Fig. 20-29)
relationship chart, 20-24 (Fig. 20-25)
diagrams, 20-25 (Figs. 20-26 and
20-27), 20-26 (Fig. 20-28)
Mechanisms for continuous improvement,
12-5, 12-6 (Fig. 12-3)
contract review, 12-7
corrective action, 12-6
design control, 12-8
handling, storage, packaging, 12-8
inspection and test, 12-8
internal quality system audits, 12-7
management review, I 2-7
process control, 12-6
training, 12-8
Metal stamping, 17-I
automation, 17-4
blanking operations, 17-1
equipment selection, 17-I
lubrication, 17-2
miscellaneous considerations, 17-8
press, die, and operator protection, 17-7
production rate, 17-6 (Fig. 17-3)
quick die change, 17-3
rolling bolster operations, 17-5 (Fig. 17-2)
strip utilization, 17-2 (Fig. 17-1)
MRP I1 see Manufacturing Resource
Planning I1
Need for further advancement, 16-49
high speed machining, 16-49
interfaces machine toolkutting tool, 16-50
cutting tool material, 16-52, 16-53 (Fig.
(Fig. 16-50)
16-51)
0
Optimization, 14-19 (Fig. 14-14)
Optimizing processes and parameters, 16-38
single step-machining, 16-38
one pass-machining, 16-39, 16-40
(Figs. 16-38 and 16-39)
proactive finetuning, 16-39, 16-41
(Fig. 16-40)
Overall equipment effectiveness, 19-11
(Fig. 19-8)
P
~ ~ _ _ _ _ _
Paint and Painting, 18-4
conveyor loading, 18-9 (Table I8-2), 18-13
efficiency, 18-7
electrostatic, 18-10 (Fig. 18-1), 18-11
(Fig. 18-2)
environmental concerns, 18-7
film testing, 18-20
hose volume, 18-12 (Table 18-3)
improvement, 18-6
performance characteristics, 18-22, 18-24
pretreatment, 18-4
quality control 18-22
quality assurance, 18-22, 18-24
system analysis, 18-8
variables, 18-8 (Table I8- I )
systems, 18-6
testing, 18-20, 18-24 (Table 18-4)
waste minimization, 18-7
(Table 18-4)
Parts feeders, see Feeders
Performance indicators, 7-5 (Fig. 7-3)
Performance monitoring, 1 1-4
Plan-do-check-act cycle, 1-5, 1-6
Planning, 5- I
Power brushes, 18-29
abrasive-filled nylon, 18-31
advantages, 18-29
applications, 18-30 (Fig. 18-5)
compared to abrasive wheel, 18-32
(Fig. 18-11)
design, 18-29
performance variables, 18-32 (Fig. 18-10)
recommended surface speeds, 18-32
types, 18-29, 18-30 (Fig. 18-6)
when to use, 18-31
wire, 18-30, 18-31 (Fig. 18-7, Fig. 18-8)
Practices of continuous improvement, 1-5
best practices, 1-8, 7-1
plan-do-check-act cycle, 1-5, 1-6
Juran approach, 1-5
Kaizen, 1-6, 1-8
Taguchi approach, 1-7
Press forging, 19-36
components, 19-36
hydraulic clamping, 19-37, 19-38
measurement, 1 1-6
(Fig. 18-9)
(Figs. 19-37, 19-38), 19-40 (Figs. 19-39,
19-40), 19-41 (Fig. 19-41), 19-42
(Fig. 19-42)
improving precision, 19-41, 19-42
(Figs. 19-43, 19-44), 19-44 (Figs. 19-45,
19-46), 19-45 (19-47), 19-46 (Figs.
quick change tool system, 19-36, 19-37
(Figs. 19-35, 19-36), 19-39, 19-43
(Fig. 19-44)
19-48, 19-49)
Preventive maintenance, 14-28
Probability, 10-17 (Fig. 10-8)
Problems
Problem solving, 19-8 (Fig. 19-5)
Process Appraisal, 11-1
cause and effect diagram, 11-7 (Fig. 11-7)
complexity, 11-8
correcting problems, 11-5
factors, 11-4 (Fig. 11-4)
innovation, 11-8, 11-9 (Fig. 11-8)
integration, 11-1 1
management support, I 1-1 1
measurement, I 1-6
model, 11-2 (Fig. 11-1)
monitoring performance, 1 1-4
optimization, 11-9
production, 1 1-3 (Fig. 1 1-2)
understanding, 1 1-2
universal factors, 1 1-4 (Fig. 1 1-3)
viewpoint, 11-1
waste, 11-8
correcting and preventing, 11-5
Process development, 19-1, I 9-2 (Fig. 19-1)
Process Capability Index, 19-4 (Fig. 19-2)
Process chart, 20-20 (Fig. 20-19)
Process improvement opportunities, 6-7
Process improvement pointers, 16-7
machining aspects, 16-7
machine tool aspects, 16-7
setup and workholding aspects, 16-7
process planning aspect, 16-8
work material condition, 16-8
value-added concept, 16-8, 16-9 (Fig. 16-
6), 16-10 (Fig. 16-7), 16-11 (Fig. 16-8),
16-12 (Fig. 16-9), 16-13 (Fig. 16-10),
16-14 (Fig. 16-1I ) , 16-15 (Figs. 16-12
and 16-13)
Process re-engineering, 8-22 (Fig. 8-29), 8-27
Product definition, 14-1, 14-7
Focus, 14-4
Implementation, 14-9
(Fig. 8-33)
Product realization cycle, 12-3 (Fig. 12-1)
Productivity, 14-1
Project management, 1- 13
Q
QFD, See: Quality Function Deployment
Quality
improvement, 10-12
planning for, 10-7
program maturity, 15-2 (Fig. 15-1)
benefits, 18-24
service report, 18-25 (Fig. 18-4)
Quality assurance programs, 18-22
Quality Assurance Standards, 12-2, (see also
Quality by design, 14-25
Quality control, 5-10 (Fig. 5-4), 10-12, 10-15
tools, 2-10 (Fig. 2-6), 2-1 1 (Fig. 2-7),
ISO-9000)
(Fig. 10-6)
2- 12 (Fig. 2-8)
Quality cost, see: Cost of Quality
Quality Function Deployment, 1-12, 6-7, 19-9
Quality system requirement, 12-4 (Fig. 12-2)
Quick die change, 17-3
(Fig. 19-6)
1-3INQEX
Recognition and reward, 5-17
Re-correcting, 14-21
Refined tooling modules, 16-32,16-33
(Fig. 16-29),16-34(Figs. 16-30and 16-31)
modular design, 16-32
toolbody, 16-35(Fig. 16-32),16-36
(Fig. 16-33)
Risk, 14-35(Fig. 14-21),14-38
S
Safety, 17-7,20-1, 20-3, 20-43;see also
Accidents
falls, 20-43
hazard elimination, 20-45
housekeeping, 20-33
Job Safety Analysis, 20-34,20-37
(Fig. 20-34)
benefits, 20-36
procedures, 20-36
layout planning, 20-13
lockoutitagout, 20-36,20-38(Fig. 20-35)
loss control, 20-39
machines, 20-30,20-3I , 20-33
20-34(Fig. 20-33)
guards, 20-31 , 20-32(Fig. 20-32),
tips, 20-33
planning checklists, 20-25,20-27
(Fig. 20-30),20-29(Fig. 20-31)
policies, 20-45
product safety, 20-39
audits, 20-42
communications, 20-40
recalls, 20-41
protective equipment, 20-33, 20-44, 20-44
(Table 20-2)
enforcing use, 20-45
inspection and maintenance, 20-45
selecting, 20-45
training, 20-45
Scattergrams, 1- I 2
Self-assessment, 13-I (see also Baldrige
National Quality Award)
lessons learned, 13-14
perspectives, 13-16
uses of, 13-3
consensus, I3-13
dekelop next steps, 13-14
develop and define expectations, 13-13
drafting the Baldrige application, 13-13
feedback, 13-14
opportunities for improvement, 13-14
review, 13-13
scoring, 13-13
site visit, 13-14
training in evaluation processes, 13-I3
versus continuous improvement, 13-12
applications, 14-33
extended to suppliers, 14-28
for scheduling, 14-34(Fig. 14-20)
getting started, 14-34
history, 14-32
in decision making, 14-31
in process control, 14-28
limitat ions, 14-27
machining centers, 14-32(Fig. 14-17),
Shop floor management, 14-18,14-30,14-40
Soldering, see Brazed and soldered joints
SPC, see: Statistical Process Control
Standards, 14-1,14-10(Fig. 14-9),14-30
Simulation, 14-24,14-24(Table 14-1)
14-33(Fig. 14-18),14-33(Fig. 14-19)
(Fig. 14-22)
ANSI Y14.5M,14-1
Standards and measures, 5-I8
Statistical Process Control, 18-39
Stringent finish requirements, 16-42
tight tolerances, smooth surface finishes,
16-42(Fig. 16-41),16-43(Fig. 16-42),
16-44(Fig. 16-43),16-45(Fig. 16-44)
six sigma and cPk-manufacturing, 16-45
(Fig. 16-45),16-46(Fig. 16-46),16-47
(Fig. 16-47),16-48(Fig. 16-48)
first part/good part, zero defectproduction, 16-46,16-48(Fig. 16-49)
Suppliers, 6-1
certification, 6-1, 6-2(Fig. 6-l),6-4
contract, 6-6
evaluation criteria, 6-3(Fig. 6-2)
performance, 6-3
reducing the number, 6-6
support, 6-6
visits, 6-3
choosing a method, 18-33
finishing stone, 18-34(Fig. 18-12)
(Fig. 6-3),6-7
Surface improvement technology, 18-33
System of profound knowledge, 10-8
T
Taguchi, Genichi, 1-7,1-9,10-14
quality control processes, 10-15 (Fig. 10-6)
reduction of variability, 10-14
formation and growth, 3-4,3-5 (Fig. 3-5)
paradigm, 3-I
performance, 3-6
Teams and teamwork, 3-1
cultural integration, 3-I2
diagnosis, 3-7,3-9(Fig. 3-8)
direction, 3-10, 3-10(Fig. 3-9)
improvement, 3-7,3-9 (Fig. 3-7)
redesign, 3-11 , 3-11 (Fig. 3-10)
review and recycle, 3-12
support structure, 3-12
requirements, 3-1
Tools of continuous improvement, I - 11
benchmarking, 1- 13,7-1, 8-24
capability studies, 1 - 12
checksheets, 1-12
control chart, 1 - 1 1
design of experiments, 1-12
failure mode and effects analysis, 1- 12
fishbone diagrams, 1- I I
histograms, 1-12
project management, 1-I3
Quality Function Deployment, 1- 12
scattergrams, I - 12
equipment effectiveness, 15-4
Total Productive Maintenance, 15-1
calculation, 15-5 (Fig. 15-3),15-6
(Fig. 15-41
measuring, 15-4
overall, 15-4
inspection forms, 15-7(Fig. 15-5), 15-9
planning, 15-6
stages, 15-3 (Fig. 15-2)
training, 15-9
history, 2-1
philosophy, 2-8
responses, 2-4
Total Quality Management, 2-1, I9-I 2
American, 2-4
crossfunctional management, 2-5
Japanese, 2-4
Deming’s 14points, 2-14(Table 2-4)
quality control tools, 2-10(Fig. 2-6),2-11
techniques, 2-9 (Table 2-2),2-13 (Table
(Fig. 2-7),2-12(Fig. 2-8)
2-3)
tools, 2-10(Fig. 2-6),2-11 (Fig. 2-7),
2-12(Fig. 2-8)
technology, 2-8
Total quality organization, 3-1
Tolerance refinement, 14-10 (Fig. 14-8)
TPM, see: Total Productive Maintenance
TQM, see: Total Quality Management
Training, 4-1,5-17
analysis, 4-8
capturing data, 4-8 (Fig. 4-5)
key roles, 4-8
purpose, 4-8
as a result of CI, 4-2
best approach, 4-3
costs, 4-5 (Fig. 4-2)
levels of learning, 4-4(Fig. 4-1)
delivery strategies, 4-6 (Table 4-2)
design, 4-9
development, 4-6,4-9
levels of improvement, 4-2
pilot-test, 4-10
products, 4-1
project planning, 4-7
key roles, 4-7
revision and release, 4-10
to support C1 efforts, 4-5
u
Unification of quality, time, and cost data,
User groups, 5-18
8-31
v
Variability reduction, 10-4
Vision, mission, and values, 5-8
w
Waste, 9-2, 9-3 (Fig. 9-1), 11-8
minimization, 18-7
Waste elimination, 14-24
extended to suppliers, 14-28
opportunities for improvement, 14-25
laser, 19-45,19-47(Fig. 19-50),19-48,
19-49(Fig. 19-51),19-50(Fig. 19-52)
material considerations, 19-47
optimizing, 19-48
seam welds, 19-51 (Fig. 19-53)
workholding technologies for continuous
advantages of preset workholding, toolWelding, 19-45
Workholding, 16-12
improvement, 16-12
holding, and part registration to reduce
setup time, 16-16
Workplace design, 20-7,20-8(Table 20-I),
20-13,20-20(Fig. 20-20), 20-21 (Fig. 20-
22), 20-23(Fig. 20-24);see also facility layout
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