Sec 27 Process Industries

PROCESS INDUSTRIES
1
QUALITY MANAGEMENT IN THE PROCESS INDUSTRIES
m in which Marketing, Research and Development , Production , and Support personnel can work t
uct conformance to quality requirements .
2
Sec 27 PROCESS INDUSTRIES
CHARACTERISTICS OF THE PROCESS INDUSTRIES
ments
this customer’s processing requirements as well as requirements of the end user o
3
DEALING WITH LARGE MEASUREMENT VARIABILITY
n is, or is perceived to be, small or negligible, usually less than 10 percent of
y must therefore be taken explicitly into account in virtually all quality manage
4
FUNDAMENTAL CONCEPTS
ISO 9000-1:1994) recognizes that the term “product” encompasses four “generic produ
ll work is accomplished by a process, whether in Marketing, Manufacturing, Deliver
provide the intended characteristics and functionality. There is an important li
5
FUNDAMENTAL CONCEPTS
design is said to be “robust.” The attainment of robustness in product design ha
acteristics and the consistency of functionality of all product units produced da
6
A BALANCED APPROACH TO ACHIEVE EXCELLENCE IN QUALITY
ent Success Triad . Quality management requires three coequal and interrelated
sophy and policy

ement systems
ology systems
losophy is the first facet. It affects the operation of financial systems, the cho
7
A BALANCED APPROACH TO ACHIEVE EXCELLENCE IN QUALITY
ria (“report cards”) to monitor and evaluate the performance of the organizational
the driving force behind great changes in the arts, in philosophy, in life style.
8
QUALITY PROBLEMS IN THE PROCESS INDUSTRIES
ment or systems problem is one that the individual production worker did not crea
9
are:
ts should be focused toward personnel in product design, production process desig
10
when such slippage occurs, and the occurrence of such problems can be detected ear
quently counted in a typical routine sample. Such counts are representative of the
blems.
11
the process status is considered to be acceptable. Commonly, the “within acceptabl
nherent process variability.
from its aim point. As soon as the accumulated evidence from the statistical proce
12
DESIGNING THE PRODUCTION PROCESS
by production process design. Unfortunately, achievement of product uniformity und
13
DESIGNING THE PRODUCTION PROCESS
promising strategy is to construct a series of small-volume plants, bringing small

wn full-time dedicated equipment. This eliminates unnecessary variability introduc
There are examples in automobile assembly operations. Modular process design is
14
THE ROLE OF PRODUCTION SCHEDULING AND INVENTORY CONTROL
nore the indirect cost of inadequate product quality.
n run may be nearly over before it is possible to attain and maintain on-aim oper
15
THE ROLE OF PRODUCTION SCHEDULING AND INVENTORY CONTROL
tempting to cope with these problems:
sed to blend final product for the purpose of smoothing out property variations, e
e reworked or recycled to bring it within specifications after further processing.
cycled material can be included with, or blended into, regular shipments of on-aim
terial can be discarded or sold at a reduced price. This has obvious economic pena
16
THE PRODUCTION PROCESSES CRITICAL FOR QUALITY MANAGEMENT
he Figure shows the critical production processes diagrammed , these processes are
17
ned quantitatively. This sampling plan will depend on where the major sources of
conducted in the laboratory, while others are done on the production floor. Some a
18
entry. Automated instrumentation may be used to produce sample measurements. Data
19
CONCEPTS OF STANDARD PROCESS AND STANDARD PRODUCT
t of the producer’s knowledge, encompass all the characteristics of the product th
of the properties and characteristics the producer does measure. Thus, there is ne
20
ocess control variable limits should be determined by conducting a statistically
mental” purposes without prior notification of all potentially affected organizati
21
tandard process and is a fundamental concept of good quality management. The produ
sure integrity of a producer’s financial management system. Likewise, periodic aud
uced from standard materials in conformance with the standard process. It is the u
22
QUALITY EVALUATION BASED ON TRUE PRODUCT VARIABILITY FOR CRITICAL PROPERTIES
e as to cause persistent difficulty in meeting current or near-term anticipated cu
luation of the quality of the product shipped. Variability in critical product cha
o unit. Thus, we are always faced with the necessity of making decisions about a v
23
IMPORTANCE OF OBJECTIVELY DESCRIBED PRODUCT SPECIFICATIONS
quirements into measurable product properties which can be used by the producer t
ation of the (specified or implied) agreement between the customer and a producer
ering designs and drawings.
evels of properties and ranges or limits. Most products have from 10 to 100 such m
24
to which product specifications will apply.
unit package should be a unit of product such that within-package variability is
25
based on experience and judgment. The problem of basing specifications on incompl
r, or fail to take into account the conditions imposed by a new technology.
26
MEASURING QUALITY OF CONFORMANCE WITH PRODUCT DESIGN
suitable period of
need to distinguish:
duct made and conformance of product shipped can be estimated using appropriate c
27
suitable period of
need to distinguish:
duct made and conformance of product shipped can be estimated using appropriate c
nce becomes the fixed reference point against which product quality of conformanc
28
of the product specification range can decrease, with goal conformance held consta
oth approaches have the same ultimate intent.
examples of “experience curves.” Experience curves can be plotted for properties
29
REFERENCE BASES FOR MEASUREMENT CALIBRATION AND PRODUCT CONTROL
he measurement process. Reference bases are used for the purpose of maintaining me
y are the most important properties for many products of the “mechanical industrie
30
REFERENCE BASES FOR MEASUREMENT CALIBRATION AND PRODUCT CONTROL
hese test methods requires more than just a good metrology program, more than just
31
SELECTION AND PREPARATION OF CONTROL SAMPLES
“on-aim” during the period when the control packages were produced.
mits for all properties.
nal test times to ensure that long-term measurement variability is well represent
damage and minimize degradation. If the product is a discrete, particulate, or li

(s) each time, or by virtue of thorough stirring or blending of the control packag
urement should be spaced widely enough to be a representative sample of the whole
32
SELECTION AND PREPARATION OF CONTROL SAMPLES
blended, or composited into a single control sample to give a single test result.
een-control-sample variability to SPROCM, to the maximum degree feasible, and also
edule rather than all at once.
s are produced—a type that runs high in the data range and a type that runs low
33
USING CONTROL SUPPLIES
rrors at any one test time

to reduce the time-to-time variability that inflates the long-term measurement va
y be used in routine testing of the same product property, it is necessary that al
34
TESTING PRODUCT WHEN MEASUREMENT PROCESS IS OFF - AIM
returned promptly to the aim point, the measurement process output should not be r
35
VALIDATING NEW MEASUREMENT METHODS
methods is a principal route to quality improvement. It is not enough to demonstr
measured to provide the needed average responsiveness.

t an adequate signal-to-noise ratio is obtained.
ed to be stable and reliable in actual use.
derstood that the observed numerical correlation coefficient between two measurem
36
STIMATING AND MAINTAINING VARIANCE COMPONENTS FOR THE PRODUCT AND MEASUREMENT
d within groups ANOVA “Analysis Of Variance” is a statistical method for isolatin
37
SE OF THE VARIANCE COMPONENTS FOR IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTE
d are most in need of improvement. The five variance components are invaluable in
e components. It is then clear that the biggest quality management problem is with
lot. In the absence of such quantitative information about the magnitude of key so
38
QUALITY MANAGEMENT SYSTEM UPDATES
ystem elements must be updated on a periodic basis. The activities necessary to ac
39
AUDITS
surance requirements. When audits and their resulting reports are wisely administe
ly of local personnel.
40
AUDITS
ation at the same site; and personnel from staff specialties such as Research and
ce data and of routine product data should be inspected to detect flinching, outl
41

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PROCESS INDUSTRIES

uct conformance to quality requirements .

this customer’s processing requirements as well as requirements of the end user o

n is, or is perceived to be, small or negligible, usually less than 10 percent of

ll work is accomplished by a process, whether in Marketing, Manufacturing, Deliver

provide the intended characteristics and functionality. There is an important li

design is said to be “robust.” The attainment of robustness in product design ha

acteristics and the consistency of functionality of all product units produced da

sophy and policy

ts should be focused toward personnel in product design, production process desig

the process status is considered to be acceptable. Commonly, the “within acceptabl

nherent process variability.

by production process design. Unfortunately, achievement of product uniformity und

promising strategy is to construct a series of small-volume plants, bringing small

nore the indirect cost of inadequate product quality.

tempting to cope with these problems:

e reworked or recycled to bring it within specifications after further processing.

entry. Automated instrumentation may be used to produce sample measurements. Data

t of the producer’s knowledge, encompass all the characteristics of the product th

ocess control variable limits should be determined by conducting a statistically

mental” purposes without prior notification of all potentially affected organizati

sure integrity of a producer’s financial management system. Likewise, periodic aud

e as to cause persistent difficulty in meeting current or near-term anticipated cu

ering designs and drawings.

to which product specifications will apply.

unit package should be a unit of product such that within-package variability is

based on experience and judgment. The problem of basing specifications on incompl

r, or fail to take into account the conditions imposed by a new technology.

oth approaches have the same ultimate intent.

examples of “experience curves.” Experience curves can be plotted for properties

damage and minimize degradation. If the product is a discrete, particulate, or li

urement should be spaced widely enough to be a representative sample of the whole

een-control-sample variability to SPROCM, to the maximum degree feasible, and also

edule rather than all at once.

rrors at any one test time

y be used in routine testing of the same product property, it is necessary that al

methods is a principal route to quality improvement. It is not enough to demonstr

measured to provide the needed average responsiveness.

d within groups ANOVA “Analysis Of Variance” is a statistical method for isolatin

ystem elements must be updated on a periodic basis. The activities necessary to ac

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