Dear Respected Research Gate Members,
Nowadays, every company is interested to reduce/eliminate the defects in the product. Now, everyone knows the impact of defective products on the profitability of the company. So, there are many practices to minimize the manufacturing defects. Please, share your expert suggestions on the following question.
Which manufacturing/management practices are more useful in reducing/eliminating defects?
Thanks & Regards
There are several Quality Management tools developed over the years that have significantly reduced defects & failures. There is plenty of research & publications available on this. Demming, 6 sigma, the Toyota way - Lots of literature. Mostly from Japanese experience.
Total quality management is a useful tool for defective product reduction. However, when it is combined with other tools such as lean manufacturing it will give a robust result.
Dear Md Ali,
Cellular manafucturing is often used to help reduce/eliminate defects in the manufacturing process. I have attached an article for you to review.
SPC too :-) You can also combmine tools from diffrent methods -adequate to your process
Latent defects, those that eventually cause failure in the hands of the user, are the most costly for any company. It is not only warranty and material costs, but loss of brand market share costs more and difficult to quantify.
Most latent defects are due to loss of process control, mistakes in the many tiers of suppliers, errors in manufacturing, or an overlooked weakness in the design. It is possible to cost effectively detect and discover many of those errors and weaknesses through accelerated stress testing.
Finding the strength of the design through empirical methods of stress testing to operational (and sometimes destruct) limits, and then using the known empirical strength with tests to precipitate and detect manufacturing caused failures (i.e. HALT and HASS) has proven to be very useful by many companies.
Kirk Gray it is interesting. I will check this option because I don't heard of such a solution. Thank you :-)
Dear Muhammad ;
good human factors engineering of control systems, appropriate processes and work environment can eliminating defects .
regards
We can identify defective items and defect free items using the Statistical Quality Control (SQC) Techniques. Therefore control charts are the best one to use. Further, we can look at the continous improvement tools such as KAIZEN, LEAN, Six Sigma and QFD etc.
With Best Wishes,
Prof. Venkat
There will always be problems, the key is to find them as close to the their point of occurrence as possible and as soon as as they happen. This requires having sustainable process stability through good standard work practices coupled with effective team leader and team member roles and systematic problem solving (P/S). In this way it is possible to separate normal from abnormal work and therefore to more quickly identify and eliminate abnormal conditions leading to defects and waste (problems). Good standardization and P/S will keep problems form coming back and allow the group doing the work to see problems when they occur and thus learn how to eliminate and anticipate them on their own, the basis for continuous improvement.
I have opportunity to participate in the implementation of two methods in industrial processes: 6S and Total Productive Maintenance (TPM).
To apply directly in the proccess TPM is awesome, but needs a good 6s culture before.
This a too general question, like "which is the best girl to marry?" or "which is the best car to buy?" all and none
Please: first define the process (definition of customer request, design, production, delivery, etc.)
for each process you can find many different sub-classification (e.g for manufacturing the results can depend from: setup, man, process, information and so on)
Each process must be managed at the best to get consistent results using correct instruments, we have a big tool box: FMEA for design and SPC for production and so on.
This is the MAP of the "identification of nano particles" topic.
file topic_report.docx = 20 topics from 109 articles which have words
ti=((manufact* OR detail* OR product* OR manag*) AND defect* AND (eliminat* OR reduc* OR minim* OR less* OR dimin*))
in their titles,. Each topic is represented through 20 words and 20 thrases with which it is discussed in these articles. Really this terms are the names of methods, objects, properties, laws and so on for topic in question. In addition each topic has quotes from two articles in which it is most manifested.
Why is it difficult to read the topic_report.docx file? Imagine that we are students and we are going to study an unknown course, for example, atomic physics. As a guide, a list of the chapters of the course is proposed in the form of key phrases of the chapter. A curious student will look at the Internet unfamiliar concepts, and also try to generalize the list of terms attached to the chapter, into a whole, so that before the lectures begin he will know what the questions arising in this training course. To another student, the reading of the list of topics in the form of terms will be accessible and useful only when all lectures will be finished, as confirmation for himself of his views on the subject.
Feel free to ask the analysis of more specific topic.
We will be grateful for the feedback.
Dear Md Ali,
There are a lot of tools in the Total Quality Management, which was summarized by the Japanese experiences. One of the basic tool is the "process analysis", step by step, as Professor E. Deming recommended, because when you have the process working well, the products will be with the less number of defects as possible. Remember there is a central part of TQM which is called "Process Management", because you can direct a company controlling all the processes, the core and the secondary or auxiliary ones.
I agree with others comments saying there are a lot of tools you can choose: KAIZEN, 5 S, 3 G, 5 Whys, Statistical Quality Control (SQC) Techniques whose application is previous to Six Sigma System.
One important thing to underline: there is a path towards the Total Quality all over the company, and always it begins with the application of simple tools.
I´ll appreciate your feedback.
Regards.
Toyota production system is the most advanced manufacturing system. Tps is a framework of concepts and methods to enhance corporate vitality through continual gains in quality while increasing productivity.
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