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Zero Defect Man.
30-11-2016 09:21  |  Zero Defect Manufacturing
aFraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh J_LEAPT)bDepartment of Chemical, Materials and Industrial Production Engineering, University of Naples Federico II, Piazzale Tecchio 80, Naples 80125, Italy Available online 26 April 2015 In the cutting zone of a machining process, several variables are influenced by process conditions: cutting force, vibrations, temperature, acoustic emission, power absorption. Some variables, useful for process monitoring, can be measured by sensors installed on the machine tool. However, when assessing a particular process variable, a single sensory source may not be able to meet all the requirements. A solution is sensor data fusion, the purpose of which is to combine sensory information from disparate sources so t...

12-09-2016 09:53  |  Zero Defect Manufacturing
Abstract One of the most significant advances in the development of computer science, information and communication technologies is represented by the cyber-physical systems (CPS). They are systems of collaborating computational entities which are in intensive connection with the surrounding physical world and its on-going processes, providing and using, at the same time, data-accessing and data-processing services available on the Internet. Cyber-physical production systems (CPPS), relying on the latest, and the foreseeable further developments of computer science, information and communication technologies on one hand, and of manufacturing science and technology, on the other, may lead to the 4th industrial revolution, frequently noted as Industrie 4.0. The paper underlines that there a...

12-09-2016 08:37  |  Zero Defect Manufacturing
The Toyota Production System (TPS), also known as the Lean management system (Lean), is already helping health care organizations provide high-quality, low-cost care, and it promises to do far more. However, the potential benefits of TPS/Lean are endangered by a failure of many to understand it. For example, Pamela Hartzband and Jerome Groopman claimed in a recent article that TPS/Lean was a direct descendant of “The Principles of Scientific Management,” a monograph published by Frederick Winslow Taylor in 1911 that described his theory of workers in manufacturing processes. Equating Taylorism and TPS could not be further from the truth. Hartzband and Groopman go on to state that the principles of TPS, as applied to create near zero defects in manufacturing, don’t work when caring f...

12-09-2016 08:31  |  Zero Defect Manufacturing
NEW DELHI: Just weeks after the high-profile launch of Startup India, the Centre is looking at rolling out yet another major initiative, dubbed ZED, which was first mentioned by Prime Minister Narendra Modi in his 2014 Independence Day speech and yet again last week. The acronym stands for zero defect, zero effect (on the environment) — high quality manufacturing that's also green. Expected to be launched in March, the programme is to be widely discussed at Make in India week next month. Officials said the initiative is meant to raise quality levels in the unregulated micro small and medium enterprises (MSME) sector, the engine of growth for the Indian economy, driving almost 38% of the nation's GDP and employing 110 million Indians. It's thereby seen as a cornerstone of the flagship Mak...

12-09-2016 08:24  |  Zero Defect Manufacturing
IMG - Ensuring zero defects on internally threaded fasteners - Aerospace Manufacturing and Design High-speed sorting technologies, including vision-based hole and thread detection, are making traditional methods obsolete.It is critical to inspect formed metal fasteners used in aerospace to ensure zero defects whether for safety, mission-critical performance, or to optimize the manufacturing process. Conventional methods to do this exist, such as sorting mechanically for size or hand sorting with optical comparators. Yet traditionally, it has been difficult to inspect internal threads for tiny defects such as chips, tears, weld spatter, or short or missing threads. Inspecting the vertical walls of a fastener hole and its threads is difficult for the human eye due to their small size, as well as lighting and viewing issues. Not only is such an inspection process slow, labor intensive, an...

12-09-2016 08:14  |  Zero Defect Manufacturing
IMG - How To Tackle Supplier Quality Management in the GEC Meeting It’s no secret that suppliers have become increasingly vital to quality and organizational success. Increases in outsourcing, globalization, and product complexity are three long-term drivers that have increased the role of suppliers as well as the assumption of increased supplier-generated risk. Click here to speak with Dan LNS Research has published research on this important topic for several years, both to identify important Supplier Quality Management (SQM) trends and considerations as well as to determine best practices. These topics will be further explored in our upcoming Quality Global Executive Council meeting on Tuesday, March 15 at 1:00 pm EDT. We’re excited to welcome our guest speaker, Michael Bennett, GSM Systems Analyst for Nexteer Automotive. Michael has been integr...

23-08-2016 12:27  |  Zero Defect Manufacturing
Journal of Quality in Maintenance Engineering, Volume 22, Issue 4, October 2016. Purpose This paper analyses the effects of condition-based maintenance based on unscheduled maintenance delays that were caused by ATA chapter 21 (air conditioning). The goal is to show the introduction of condition monitoring in aircraft systems Design/methodology/approach The research was done using the Airbus In-Service database to analyse the delay causes, delay length and to check if they are easy to detect via condition monitoring or not. These results were then combined with delay costs. Findings Analysis shows that about 80% of the maintenance actions that cause departure delays can be prevented when additional sensors are introduced. With already existing sensors it is possible to avoid about 20% of t...

18-06-2016 04:29  |  Zero Defect Manufacturing
Opens overlay Antje Zoesch, Dr. rer. nat. a, Opens overlay Thomas Wiener, Dipl.-Inf. b, Opens overlay Michael Kuhl, Dr. Ing. b,⁎,Michael.kuhl@iwu.fraunhofer.de aimq-Ingenieurbetrieb GmbH, Gewerbering 30, 08451 Crimmitschau, GermanybFraunhofer IWU Chemnitz, Reichenhainer Str. 88, 09126 Chemnitz, Germany Available online 2 July 2015 The progressive automation and consistent rationalization in production of automotive components requires the use of new sheet materials as well as innovations in press and tool technologies. Sheet metal forming is getting more and more complex. Thus several structural defects like thinning, cracks and creases as well as geometrical imprecisions due to spring back may occur. At the same time, consumer demands are rising concerning product quality and val...

18-06-2016 04:29  |  Zero Defect Manufacturing
A volume in Woodhead Publishing Series in Composites Science and Engineering 2016, Pages 377–390 Edited By Ramesh Talreja and Janis Varna Abstract Traditional damage and failure analysis of composite materials has been on homogenized solids without defects. In recent years, it has been possible to observe and characterize defects induced by manufacturing. This fact, and the need to understand the effects of defects for possible cost reduction, has given impetus to studies of damage and failure with account of defects. This chapter will review some of these studies, giving illustrative results. A comprehensive multiscale failure analysis scheme incorporating manufacturing defects will then be described. Keywords Composite failure; Damage; Failure analysis; Manufacturing defects...

07-06-2016 09:02  |  Zero Defect Manufacturing
aPolitecnico di Milano, Mechanical Engineering Department, Via la Masa, 1, 20156, Milano, ItalybInstitute for Control Engineering of Machine Tools and Manufacturing Units (ISW), Seidenstraße 36, 70174 Stuttgart, Germany Received 16 February 2015, Accepted 19 February 2015, Available online 30 September 2015 Electric mobility is an emerging industrial sector that requires innovative quality control methods as common manufacturing and testing methods of combustion engines cannot be transferred directly to electric motors. This paper presents new solutions for the quantitative evaluation of quality-oriented rotor assembly strategies in electric drive production systems. The proposed methods assist the analysis of productivity and quality performance of two different assembly strategi...

04-06-2016 01:00  |  Zero Defect Manufacturing
Abstract In remanufacturing industries, inventory is significant because remanufacturing industries includes the stock of recycled products, stock of components (parts) after disassembly and refurbishing operation, stock of new parts purchased from manufacturers and stock of remanufactured products. Therefore, current research presents an approach to search an appropriate inventory policy for single product with multi-components for a third party remanufacturing company cooperated with the original equipment manufacturer (OEM). The third party for remanufacturing working in close cooperation with the OEM (such as dealer) can acquire the regional protection rules and can gain the technical support from the OEM. A general mathematical model is developed to describe the multiple components an...

15-02-2016 14:12  |  Zero Defect Manufacturing
IMG - Zero Defects - Strategy Training from MindTools.com Getting It Right First Time © iStockphotoAWSeebaran Use this philosophy to improve quality. How much do quality failures cost your company? Quality defects have significant costs associated with them – some of the most obvious being money, time, resources, and lost reputation. And programs to eliminate quality defects can be expensive and time consuming. So, do you insist on eliminating defects entirely no matter the cost? Or, do you accept that a certain, albeit very small, percentage of defects is acceptable, and just accept the costs and learn to live with them? One of the most influential ideas about this was the notion of "zero defects." This phrase was coined by Philip Crosby in his 1979 book titled, "Quality is Free." His position was that where there are zero defects, there a...

14-02-2016 19:41  |  Zero Defect Manufacturing
Page 1 Procedia CIRP 33 ( 2015 ) 357 – 363Available online at www.sciencedirect.comScienceDirect2212-8271 © 2014 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license(http://creativecommons.org/licenses/by-nc-nd/4.0/).Selection and peer-review under responsibility of the International Scientific Committee of “9th CIRP ICME Conference”doi: 10.1016/j.procir.2015.06.0829th CIRP Conference on Intelligent Computation in Manufacturing Engineering - CIRP ICME '14An Approximate Analytical Method to Evaluate the Performance of Multi-Product Assembly Manufacturing SystemsMarcello Colledania, Andrea Rattia, Chanaka Senanayakeb*aDepartment of Mechanical Engineering, Politecnico di Milano, 20156, Milano, ItalybDepartment of Production Engineering, ...

14-02-2016 18:38  |  Zero Defect Manufacturing
Publication date: 16 June 2016 Source:European Journal of Operational Research, Volume 251, Issue 3 Author(s): Adam Kołacz, Przemysław Grzegorzewski We propose an axiomatic definition of a dispersion measure that could be applied for any finite sample of k-dimensional real observations. Next we introduce a taxonomy of the dispersion measures based on the possible behavior of these measures with respect to new upcoming observations. This way we get two classes of unstable and absorptive dispersion measures. We examine their properties and illustrate them by examples. We also consider a relationship between multidimensional dispersion measures and multidistances. Moreover, we examine new interesting properties of some well-known dispersion measures for one-dimensional data like the interqu...

09-02-2016 15:31  |  Zero Defect Manufacturing
With the world economy becoming unpredictable, it has become a necessity for businesses to relook at the way they do business. The world has become competitive and companies that aim to become profitable have seen the need to find ways to improve efficiencies and increase productivity to stay relevant. There has been an adoption of strategies that are aimed at improving the efficiencies in companies such as Total Productive Maintenance (TPM). The strategy is aimed at improving equipment efficiencies and increase productivity through the transfer of certain skills from maintenance personnel to operators. The aim is that the operators perform some of the activities that the maintenance people used to do and they do the more complex tasks. By transferring these skills to operators there is co...

05-02-2016 17:14  |  Zero Defect Manufacturing
At Tesla Motors, we depend on everybody to be as creative and productive as possible. Part of the power of the 3DEXPERIENCE platform (‘Target Zero Defect’) is its ability to allow everybody involved in the product development process to focus on being creative and productive rather than focusing on the process and tools. The ability of the 3DEXPERIENCE platform to handle the complexity both in our product and our process as we move forward is very important. Its ability to unify multiple organizations under one banner and bring them all together within a common solution will help us immeasurably going forward. Paul Lomangino Engineering Tools Director, Tesla Motors

05-02-2016 17:08  |  Zero Defect Manufacturing
Highlights • An optimal sampling plan is developed for incoming inspections in assembly lines. • Inspection sample sizes are chosen to minimize all quality related costs. • A three-step procedure is developed to efficiently solve larger size problems. • The optimization model provides insightful implications for quality management. • The optimal inspection sampling plan builds a foundation for other advanced plans. Abstract This paper proposes a nonlinear integer program for determining an optimal plan of zero-defect, single-sampling by attributes for incoming inspections in assembly lines. Individual parts coming to an assembly line differ in the non-conforming (NC) risk, NC severity, lot size, and inspection cost-effectiveness. The proposed optimization model is a...

05-02-2016 16:48  |  Zero Defect Manufacturing
Hier finden Sie wissenschaftliche Publikationen aus den Fraunhofer-Instituten.   AbstractHighly productive and low-stock or "just-in-time" manufacturing systems require safe manufacturing also in the process chain. Starting from a systematic analysis of defects and their causes in single-product and series production, a method has been developed enabling the supervision of quality in the process chain as well as its optimization by means of a learning management system. For this, quality data collected are evaluated and represented in mathematical process models. From these data, logic patterns are derived by means of cluster analyses or statistical analyses, which provide information on the causes and the assessment of nonconformities. Based on this and with the help of high-perf...

05-02-2016 16:43  |  Zero Defect Manufacturing
IMG - The Concept of Zero Defects in Quality Management | Lean Six Sigma | Simplilearn Zero Defects – a term coined by Mr. Philip Crosby in his book “Absolutes of Quality Management” has emerged as a trending concept in quality management; Six Sigma adopting it as one of the major theories.  The concept has also faced a lot of criticism. Many say that there cannot be a state of zero defects while others have been trying to prove them wrong. Zero defects in quality management don’t mean so in its literary term but it refers to a state where waste is eliminated and defects are reduced. It means ensuring quality standards and reducing defects to the level of zero in projects. Zero Defects is not possible; why? As mentioned above, zero defects cannot be taken in literary terms because in reality, zero defects are not possible. Suppose you are developing a product and w...

01-02-2016 01:00  |  Zero Defect Manufacturing
Abstract Business processes, operational environment, variability of resources and user needs may change from time to time. An effective workflow management software system must be able to accommodate these changes. The ability to dynamically adapt to changes is a key success factor for workflow management systems. Holonic multi-agent systems (HMS) provide a flexible and reconfigurable architecture to accommodate changes based on dynamic organization and collaboration of autonomous agents. Although HMS provides a potential architecture to accommodate changes, the dynamic organization formed in HMS poses a challenge in the development of a new software development methodology to dynamically compose the services and adapt to changes as needed. This motivates us to study and propose a methodo...

25-01-2016 05:10  |  Zero Defect Manufacturing
Journal of Quality in Maintenance Engineering, Volume 22, Issue 1, March 2016. Purpose We consider a system which is a part of a complex equipment (e.g., aircraft, automobile, medical equipment, production machine, etc.), and which consists of N independent series subsystems. The purpose of this paper is to determine simultaneously the system design (reliability) and its preventive maintenance replacements periodicity which minimize the total average cost per time unit over the equipment useful life, taking into account a minimum required reliability level between consecutive replacements. Design/methodology/approach The problem is tackled in the context of reliability based design considering at the same time the burn-in of components, the warranty commitment and the maintenance strategy ...

30-11-2016 09:21  |  Zero Defect Manufacturing
A plant manager’s dream come true: machines at optimum efficiency with planned maintenance and zero defects. Is it too good to be true? In a recent blog post “SPC 2.0: How IoT Predictive Analytics Gives You Psychic Powers” I outline how SPC is a great tool for looking back at historical information to make changes in manufacturing, but if you want to get ahead, IIoT is needed to take the first steps into the world of predictive analytics to begin looking into the future of manufacturing and taking action in the present. Today, I want to take that one step further and answer the question “Is a zero-defect factory too good to be true for manufacturing?” There is a dramatic shift taking place: a move from statistical process control (SPC) usually used to reduce defects in manufact...

12-09-2016 08:35  |  Zero Defect Manufacturing
New Delhi: Maruti Suzuki India Ltd will stop offering contracts to suppliers that fail to meet its zero-defect policy as part of the nation’s largest car maker’s efforts to avoid frequent and costly vehicle recalls. “About quality, we worked in terms of percentage for two decades and then we moved to PPMs (parts per million). But now, we tell all our suppliers that PPM is no longer acceptable. Zero-defect is what we want from you. It should become a norm. Only those vendors with us will go to Gujarat who have the quality levels we want them to deliver,” said Deepak Sethi, executive director (supply chain), Maruti Suzuki India. The Gujarat plant will also cater to overseas markets, which demand very high standards, making it critical for Maruti to have top-quality vendors. “This ...

12-09-2016 08:25  |  Zero Defect Manufacturing
Johannesburg - The implementation of the latest Ford production system at its plants in Silverton, Pretoria, and Struandale, Port Elizabeth, has contributed significantly towards making Ford’s plants in South Africa among the most productive and efficient in its global manufacturing plant network. Ockert Berry, the vice-president responsible for operations at the Ford Motor Company of Southern Africa, said the system was not only streamlining production and cutting costs but also unlocking potential in employees. Berry said an indicator of the improvement by the Ford Motor Company of Southern Africa was that it took 60 hours to build a vehicle 10 years ago, but now only took 27 hours and the Silverton plant also produced more complex models than a decade ago. He added that Ford’s lat...

12-09-2016 08:20  |  Zero Defect Manufacturing
A hi-tech manufacturer recently reduced recall costs by $20M annually and reduced test cycle times by 50 percent. A fuel-injection pump manufacturer reduced pump calibration times by 30 percent. A global steel manufacturer identified up to $1.3M of annual savings once they managed to aggregate data from over 20 different sources. This is the emerging and lucrative market for advanced analytics in manufacturing operations — and we’re just at the tip of a very large iceberg. Manufacturers are constantly striving to improve their performance — and over the past 20 years — have employed innovations into their operational strategies, such as continuous improvement (Kaizen), six-sigma/statistical process control, lean synchronisation and Total Quality Management. However, there is still...

12-09-2016 08:14  |  Zero Defect Manufacturing
In the not too distant future, automakers won’t be evaluated just on the physical, safety and performance characteristics of their vehicles.  Instead incumbent and next-generation automakers will be evaluated based on the completeness of their solution along five dimensions: Electric, Autonomous, Connected, Mobility Services (EAC+MS), and Information.  We read about the progress automakers and their suppliers are making along the first four dimensions.  There is much less conversation about the fifth dimension.  In this two-part series, we will discuss the big data challenge facing the automotive industry.  The pieces are the result of my work in the industry helping corporations with their innovation and big data strategies.  The first post provides the why and makes two points: ...

15-07-2016 02:05  |  Zero Defect Manufacturing
aMontronix srl, via Caradosso 12, Milan 20123, ItalybFraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh J_LEAPT), Department of Materials and Production Engineering, University of Naples Federico II, Piazzale Tecchio 80, 80125 Naples, Italy Available online 14 October 2013 In any machining process there are many parameters which should be taken under control in order to improve the quality of production. In this paper is given an overview of possible actions which could be implemented in order to reach the goal of manufacturing zero defects parts. These methodologies are here classified based on their type of interaction with the process as indirect and direct actions. Among direct actions, a particular focus is given to monitoring systems, which are th...

18-06-2016 04:29  |  Zero Defect Manufacturing
aEuropea Microfusioni Aerospaziali(EMA), Morra de Sanctis (AV), ItalybFraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh J_LEAPT), Department of Materials and Production Engineering, University of Naples Federico II, Piazzale Tecchio 80, Naples 80125, Italy Available online 14 October 2013 The investment casting process and its key parameters are described in order to give a quite detailed knowledge of the main indicators of this production method, for its nature prone to have high costs of rework or scrap. Initially, a schematic flow of the main processes is provided; afterwards the main processes are discussed in more detailed manner with their manufacturing methods and product specifications. These concepts are indispensable to introduce the discussi...

18-06-2016 00:00  |  Zero Defect Manufacturing
Abstract The quality of post-consumer products is one of the major sources of uncertainty in disassembly systems. This paper develops a methodology to design disassembly lines under variability of the End-of-Life product quality, with the objective to maximize the profit. This decision support system helps to take decisions about the depth of disassembly and the organization of the disassembly system, depending on the pre-process measurement of the key quality characteristics of the product to be disassembled. The industrial benefits are demonstrated in a real industrial case focused on the remanufacturing of mechatronic parts in the automotive industry. CitationsCitations0 ReferencesReferences7 Data provided are for informational purposes only. Although carefully...

07-06-2016 08:59  |  Zero Defect Manufacturing
IMG - Two keys to measuring operational improvements  | Plant Engineering R. Keith Mobley, CMRP 06/02/2016 Believe it or not, tracking organizational performance is not as simple as it might sound. Many of us struggle with this dilemma, and few have determined an effective way to measure it. Our dilemma begins because the criteria that define performance vary depending on the level within the organization. For example, the organization level controls asset utilization—how the installed capacity will be used, and to a large degree, reliability. At the production-maintenance level, performance is measured as compliance to the business plan and its production schedule. Therefore, criteria used to measure performance must vary, but at the same time be consistent, so that measurements at the floor level can be rolled up to meet the criteria at the organization...

22-03-2016 14:37  |  Zero Defect Manufacturing
Using the benefits of stored knowledge By bringing these seven projects together in one eco-factory research cluster, Clean Manufacture helps European manufacturers put these new technologies and techniques into practice in their own factories. By reducing material and energy costs, introducing more efficient production lines, and reducing waste, we can build a sustainable, wealthy future for all.

14-02-2016 19:48  |  Zero Defect Manufacturing
ArticlesYou can read, print and download any of these articles FREE by registering your details with us. Once you have registered, you can return to access the articles at any time simply by entering your email address in the box opposite. Click on title to read summary of article: Back to list1. Recommended Reading. A list of recommended books and other articles that we think are worth reading. [Read article] Back to list2. Reliability Manager/Engineer Job Description. A description of tasks that a reliability manager, engineer or specialist could be expected to perform including: loss accounting, root cause failure analysis, managing the results of condition monitoring functions, overhaul/shutdown support, proactive support and facilitator/communicator. [Read article] Back to list3. Sel...

14-02-2016 19:41  |  Zero Defect Manufacturing
Page 1 Production quality performance in manufacturing systems processingdeteriorating productsMarcello Colledani (2)a,*, Andras Horvathb, Alessio AngiusbaPolitecnico di Milano, Department of Mechanical Engineering, Via la Masa, 1, 20156, Milan, ItalybUniversita ` di Torino, Department of Computer Science, Corso Svizzera 185, Torino, Italy1. Introduction, motivation and objectivesProduction quality has been proposed recently as an emergingparadigm to achieve desired service levels of conforming productsin advanced manufacturing systems, by simultaneously consider-ing quality and productivity requirements [1]. With respect tothis background, the importance of an integrated analysis ofproduction logistics, product quality and equipment maintenanceto achieve balanced manufacturing system sol...

05-02-2016 17:16  |  Zero Defect Manufacturing
IMG - Zero Defects vs. Six Sigma | Quality Digest David C. Crosby  |  04/18/2006 The differences may surprise you. Zero defects is an idea that was discovered in the early 1960s. It was articulated by Phil Crosby and first implemented at the Martin company in Orlando, Florida. Zero defects enjoyed widespread popularity until the mid 1970s, and almost every major company and their suppliers had a zero-defects program.Then quality programs such as Total Quality Management (TQM), Malcolm Baldrige, and statistical process control (SPC)—as well as the rush to ISO 9001 registration—sucked up all the oxygen, and now the zero-defects approach is practiced by only a few companies. Except for those who profit from it, zero defects is forgotten. You may find it interesting that zero defects is now very popular in China. My book is being tr...

05-02-2016 16:46  |  Zero Defect Manufacturing
1. Arumugam V, Antony J, Douglas A (2012) Observation: a lean tool for improving the effectiveness of lean six sigma. TQM J 24(3):275–287CrossRef 2. Halpin JF (1996) Zero defects: a new dimension in quality assurance. McGraw-Hill, New York 3. Crosby PB (1979) Quality is free: the art of making qualify certain. McGraw Hill, New York 4. Calvin TW (1983) Quality control techniques for “zero defects”. IEEE Trans Compon Hybrids Manuf Technol 6:323–328CrossRef 5. Calvin TW (1983) Quality control techniques for “Zero Defects”. IEEE Trans Compon Hybrids Manuf Technol 6:323–328CrossRef 6. Wang K (2007) Applying data mining to manufacturing: the nature and implications. J Intell Manuf 18(4):487–495CrossRef 7. Wang K (2005) Applied computational intelligence in intelligen...

05-02-2016 16:41  |  Zero Defect Manufacturing
Working on the IFACOM project, supported by the European Commission, the researchers are developing an advanced real-time process control system focused especially on high-precision, high-value and high-performance parts as well as custom-designed components. Combining artificial intelligence and innovative sensors, the system seeks to overcome the long-standing issue of production defects, which cost manufacturers millions of euros a year in waste, production reruns and part redesigns. “Manufacturing defects are a huge issue for the industry. In some cases, 50% of production can end up as scrap because of defects, while in some complex manufacturing lines the rate of scrap can be as high as 90%,” explains Odd Myklebust, the IFACOM coordinator at the Norwegian University of Science an...

01-02-2016 01:00  |  Zero Defect Manufacturing
Abstract This paper reviews some of the most recently reported research into novel strategies for global manufacturing systems interoperability. Such research can be categorised as addressing four broad topic areas: the sensing manufacturing enterprise; semantics and knowledge management in manufacturing; service orientation and the need for negotiation; and business interoperability. Thus we identify a spectrum of research from the management of hardware and virtual sensing devices, through the semantic interpretation of the data and information generated by these, and its utilisation to support the collaborative manufacturing network lifecycle through service oriented software, and ultimately the provision of effective business interoperability. This study includes conceptual, theoretica...

02-01-2016 08:22  |  Zero Defect Manufacturing
10.1080/0951192X.2015.1130264<br/>Jumyung Um

05-09-2015 07:58  |  Zero Defect Manufacturing
Publication date: Available online 4 September 2015 Source:CIRP Journal of Manufacturing Science and Technology Author(s): A. Cataldo, R. Scattolini, T. Tolio The energy efficiency of manufacturing systems is a topic of paramount interest, and reliable methods for modeling the energy consumption of machine tools are of fundamental importance for the design and management of production plants. For these reasons, this paper proposes a approach, named aCtuatorS Methodology (CSM), for modeling and predicting the energy behavior of discrete systems, i.e. systems where the energy consumption is mainly due to the on/off switching of the actuators governed by the control logic. CSM is then used to compute the energy consumption of the pallet transport line of a de-manufacturing pilot plant. A dyna...

12-09-2016 08:33  |  Zero Defect Manufacturing
IMG - Bosch digitized shop floor to bring change in manufacturing operations   Bosch India has initiated Industry 4.0 approach to produce two wheeler parts across India. Set to transform India into a global manufacturing hub, Bosch India has introduced class leading Industry 4.0 solutions. Bosch India, a leading user and supplier of Industry 4.0 solutions for a digitized shop floor will have the advantages of higher productivity with digitally supported continuous processes along with integrated fault management and better use of resources. It will also benefit the company where fast and efficient decision-making processes are concerned while added transparency in production along with real-time access to necessary data will be provided. Industry 4.0 solutions are time saving as it eliminates the process of manual data collection and analysis while it include...

12-09-2016 08:24  |  Zero Defect Manufacturing
IMG - 5 Ways Industry 4.0 Will Impact Machine Tools > ENGINEERING.com What will the manufacturing landscape of tomorrow look like? Will human workers be replaced by robots? Will 3D printing become the dominant production technology? Will all of our sugary treats be manufactured in Mexico? Whatever the case, Industry 4.0—the catchall term for the trend toward automation and big data in manufacturing—is coming, and manufacturers the world over are doing their best to prepare. At this year’s IMTS, leaders from Taiwan’s machine tool industry plan to unveil a series of smart manufacturing initiatives during a press conference to illustrate part of the county’s overall efforts toward Industry 4.0. Presenters will include representatives from the Taiwan Association of Machinery Industry (TAMI), the Industrial Technology Research Institute (ITRI), the e-...

12-09-2016 08:19  |  Zero Defect Manufacturing
IMG - Seven Strategies for Improving Supplier Quality Management | iBASEt For complex manufacturers, their definition of quality is predicated on how well they stay aligned with the demanding, diverse and unique requirements of their customers while staying in compliance with regulatory requirements.  Keeping the entire value chain of a business well-orchestrated and focused on supplier quality needs to start with a clear, consistent strategic plan about suppliers as co-creators of a series of product generations, not just selectively sourced from based on cost alone (Szwejczewski, Goffin, Lemke, Pfeiffer, Lohmuller, 2001).  Suppliers need to be chosen more for their orchestrated role in delivering auditable, consistently high performance, not just cost reductions alone (Szwejczewski, Goffin, Lemke, Pfeiffer, Lohmuller, 2001) Studies of successful Supplier ...

09-09-2016 01:38  |  Zero Defect Manufacturing
Highlights • We propose a novel method to improve process robustness in Industry 4.0 factories. • The method uses quantile regression to find improved process tolerance limits. • Likelihood ratio and bootstrap are used to quantify uncertainty. • The method is generic and can be applied to solve the tolerance synthesis problem. Abstract The cyber-physical systems of Industry 4.0 are expected to generate vast amount of in-process data and revolutionise the way data, knowledge and wisdom is captured and reused in manufacturing industries. The goal is to increase profits by dramatically reducing the occurrence of unexpected process results and waste. ISO9001:2015 defines risk as effect of uncertainty. In the 7Epsilon context, the risk is defined as effect of uncertainty on ...

21-06-2016 00:00  |  Zero Defect Manufacturing
Abstract Automotive suppliers are facing the challenge of continuously adapting their production targets to variable demand requirements due to the frequent introduction of new model variants, materials and assembly technologies. In this context, the profitable management of the product, process and system co-evolution is of paramount importance for the company competitiveness. In this paper, a methodology for the design and reconfiguration management of modular assembly systems is proposed. It addresses the selection of the technological modules, their integration in the assembly cell, and the reconfiguration policies to handle volume and lot size variability. The results are demonstrated in a real automotive case study. CitationsCitations0 ReferencesReferences8 ...

18-06-2016 04:29  |  Zero Defect Manufacturing
aFraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh-J_LEAPT), Department of Chemical, Materials and Industrial Production Engineering, University of Naples Federico II, P.le Tecchio 80, 80125 Naples, ItalybGF Machining Solutions, Rue du Pré-de-la-Fontaine 8, 1217 Meyrin 1 / Geneva, SwitzerlandcLaboratory for Computer-Aided Design and Production, Swiss Federal Institute of Technology (EPFL), CH-1015 Lausanne, Switzerland Available online 2 July 2015 In the framework of zero-defect manufacturing, an advanced sensor monitoring procedure aimed at detecting the process conditions leading to surface defects in Wire Electrical Discharge Machining (WEDM) is proposed. WEDM experimental tests were carried out with the employment of a multiple sensor monitoring s...

08-06-2016 08:44  |  Zero Defect Manufacturing
IMG - WMG : Research : Digital Lifecycle Management The DLM group, headed by Professor Darek Ceglarek, conducts manufacturing systems research aimed at integrating products, processes and complex services with system design to create novel closed-loop production systems for “Factories-of-the-Future,” with capabilities to self-recover from product failures and changes. The principles which guide closed-loop production systems and factories are underpinned by the fact that manufacturing processes, products and interlinked services are challenged by rapidly evolving external drivers including new materials, new regulations, new technologies, sustainability, along with services and communications systems in an intensely cost-pressured environment. Meeting these challenges demands the development for new enabling technologies which entail: ...

07-06-2016 08:58  |  Zero Defect Manufacturing
IMG - How to find value in a KPI lifecycle | Plant Engineering John Horst, Barry Ezell 05/31/2016 Key Performance Indicators (KPIs) are part of a lifecycle because KPIs are continuously defined, redefined, and are even sometimes abandoned. Explicitly defining a KPI lifecycle provides an impetus for the development of methods and tools that enhance performance.     The National Institute of Standards and Technology and Virginia Modeling, Analysis and Simulation Center have designed two methods to define KPI lifecycle: one for performing KPI set composition and the other for KPI assessment.   Both methods need to produce accurate results. But how can we know that the methods are producing accurate results—thereby, providing real value to the manufacturer? Testing, not simulation Given the nature of the models, KPI set composition and...

06-03-2016 01:00  |  Zero Defect Manufacturing
Problem: Reliability is an essential element in assessing the operational suitability of Department of Defense weapon systems. Reliability takes a prominent role in both the design and analysis of operational tests. In the current era of reduced budgets and increased reliability requirements, it is challenging to verify reliability requirements in a single test. Furthermore, all available data should be considered in order to ensure evaluations provide the most appropriate analysis of the system's reliability. Approach: This paper describes the benefits of using parametric statistical models to combine information across multiple testing events. Both frequentist and Bayesian inference techniques are employed and they are compared and contrasted to illustrate different statistical methods...

14-02-2016 19:48  |  Zero Defect Manufacturing
ArticlesYou can read, print and download any of these articles FREE by registering your details with us. Once you have registered, you can return to access the articles at any time simply by entering your email address in the box opposite. Click on title to read summary of article: Back to list1. Recommended Reading. A list of recommended books and other articles that we think are worth reading. [Read article] Back to list2. Reliability Manager/Engineer Job Description. A description of tasks that a reliability manager, engineer or specialist could be expected to perform including: loss accounting, root cause failure analysis, managing the results of condition monitoring functions, overhaul/shutdown support, proactive support and facilitator/communicator. [Read article] Back to list3. Sel...

14-02-2016 18:38  |  Zero Defect Manufacturing
Publication date: 16 June 2016 Source:European Journal of Operational Research, Volume 251, Issue 3 Author(s): Virginia L.M. Spiegler, Mohamed M. Naim, Denis R. Towill, Joakim Wikner There is a need to identify and categorise different types of nonlinearities that commonly appear in supply chain dynamics models, as well as establishing suitable methods for linearising and analysing each type of nonlinearity. In this paper simplification methods to reduce model complexity and to assist in gaining system dynamics insights are suggested. Hence, an outcome is the development of more accurate simplified linear representations of complex nonlinear supply chain models. We use the highly cited Forrester production-distribution model as a benchmark supply chain system to study nonlinear control s...

09-02-2016 15:31  |  Zero Defect Manufacturing
碩士 中興大學 高階經理人碩士在職專班 103 Modern electronic products have been changing rapidly, improving our daily life with better comfort and safety. The product reliability mostly dependent on the components used in the product. Aluminum electrolytic capacitors (Al-Ecaps),which is used for energy storage filter noise reduction, and coupling functions, are key passive components in any electronic and electrical circuits. Howerver , it is also one of the most unstable components. Therefore, how to prevent early failure is becoming an important operation strategy for Al-Ecaps manufacturers in order to expand their market share. Lean six sigma (LSS) has been applying in industries for many years. This research is to apply the LSS methodology to improve Al-Ecap failure rate...

05-02-2016 17:14  |  Zero Defect Manufacturing
IMG - Targeting Zero Defects for Manufacturers in the Automotive and Transportation Industries This paper from the analysts at CIMdata explores:   the trends and challenges faced by transportation and automotive industries the type of applications and technologies they will need to address those challenges specific solutions to address the issues. The paper focuses on the 3DEXPERIENCE platform, a series of modules that span data management, design, simulation and visualization that are bundled together into specific automotive solutions for:   Surface styling (BIW) Advancing performance and minimizing weight Design for manufacture Powertrain innovation Your download of this white paper is sponsored by Dassault Systèmes

05-02-2016 17:03  |  Zero Defect Manufacturing
In the days of World War II aircraft design and production, minor defects were tolerated in order to speed production lines and put planes into service faster. The defects could be addressed during routine repair and maintenance. But as the space age dawned, complex, multi-stage rockets did not return to the hangar for repairs. The rockets that would carry satellites—and later, human beings—into orbit offered only one chance to get it right. One defect would be one too many. It was at the Martin Company’s Orlando plant that a far-reaching and influential program would be born: Zero Defects, the granddaddy of nearly every quality control program in the world. One of the plant’s first jobs was the production of the first Pershing missile for the United States Army. Philip Crosby was...

05-02-2016 16:45  |  Zero Defect Manufacturing
Abstract Manufacturing companies are continuously facing the challenge of operating their manufacturing processes and systems in order to deliver the required production rates of high quality products, while minimizing the use of resources. Production quality is proposed in this paper as a new paradigm aiming at going beyond traditional six-sigma approaches. This new paradigm is extremely relevant in technology intensive and emerging strategic manufacturing sectors, such as aeronautics, automotive, energy, medical technology, micro-manufacturing, electronics and mechatronics. Traditional six-sigma techniques show strong limitations in highly changeable production contexts, characterized by small batch productions, customized, or even one-of-a-kind products, and in-line product inspections...

05-02-2016 16:41  |  Zero Defect Manufacturing
IMG - Zero Defect Manufacturing: A Product and Plant Oriented Lifecycle Approach Volume 12, 2013, Pages 246–251 Eighth CIRP Conference on Intelligent Computation in Manufacturing Engineering Edited By Roberto Teti Abstract The EU project IFaCOM has the objectives to achieve near zero defect level of manufacturing for all kinds of manufacturing. The IFaCOM focus on feedback loops for the zero defect manufacturing approaches is within the shop floor and the manufacturing related activities. Both real-time and knowledge based loops are covered. Zero defect manufacturing also has an extended life cycle oriented process focus. In addition a combination or integrated view to the product and factory life cycle models is important. This paper will focus on a part and plant lifecycle approach to achieve the best possible practice to zero defect manufacturing. Descripti...

25-01-2016 05:10  |  Zero Defect Manufacturing
Journal of Quality in Maintenance Engineering, Volume 22, Issue 1, March 2016. Purpose The purposes of this article are to describe the overall equipment cost loss (OECL) methodology and an implementation of this methodology, to compare the outcomes of OECL with those of overall equipment effectiveness (OEE), and finally to identify the benefits offered by this new methodology. Design/methodology/approach The proposed methodology, OECL, combines six large loss models and a financial model in the performance evaluation of equipment. The six large losses are converted into monetary units. OECL is a new way of evaluating equipment performance that differs from the original OEE methodology and overcomes some of the limitations of OEE. This new methodology can be used to rank problematic machin...