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Manufacturing Quality
Quality tools, measurement systems, SPC, FMEA, PPAP, traceability and zero-defect methods for small factories.
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Chapters
- 01The seven basic quality tools: what each one shows and how to use them togetherMost quality problems can be diagnosed with simple tools and data you already have. How check sheets, Pareto charts, histograms, fishbones, scatter diagrams and control charts work together.
- 02Statistical process control on the shop floor: control charts, real signals and when to leave a process aloneControl charts separate the normal noise of a process from real change. How to choose a chart, set limits, read the signals and stop well-meant adjustments that make variation worse.
- 03Measurement system analysis: making sure your gauges can tell good parts from badEvery accept, reject and adjust decision trusts a measurement. How to check bias, repeatability and reproducibility, run a gauge R&R study, judge the result and fix a weak system.
- 04Process FMEA and control plans: turning what could go wrong into controls that work on the floorA process FMEA is useful only if it changes the process. How to analyse failure chains, rate and prioritise risk, prefer prevention to detection, and build a control plan people follow.
- 05PPAP for small suppliers: what a customer needs before approving your partsA first PPAP request can look like a mountain of forms. What the production part approval process tries to prove, how its parts fit together and how a small supplier gets approval calmly.
- 06Product traceability in manufacturing: lots, serial numbers and records that make recalls manageableTraceability links finished products to their materials, processes and customers. How to choose the level of detail, record and label it, test it and use it when something goes wrong.
- 07Responding to a customer quality complaint: containment, root cause and corrective action with 8DA complaint is a test of the whole quality system. How to contain suspect product, describe the problem precisely, find why it happened and why it escaped, and prove the fix works.
- 08Zero-defect manufacturing in a small factory: prevention, mistake-proofing and the real cost of reworkWhat zero defects really means, why prevention beats inspection, and how a small manufacturer can use mistake-proofing, training, maintenance and cost-of-quality data to cut rework.
These topic-based reading collections are organised alphabetically; chapters may be read in any order.
Apply This in Practice
Use these BIZOMAT tools to try the method from this reading with your own numbers.
Explained in this book
Gauge Repeatability and Bias Check (Type 1 Study: Cg, Cgk, Bias t-Test)
Runs the bias and repeatability check this chapter describes, from repeated readings of a master: Cg, Cgk, a bias t-test and resolution against the tolerance.
Used in Measurement system analysis: making sure your gauges can tell good parts from bad
Applies this method
c-Chart Check (Defects per Unit, Poisson Control Limits, Counts Out of Control)
Builds the c chart this chapter recommends for counts of defects per unit, such as blemishes per panel, with Poisson limits and the count that signals.
Applies this method
Individuals Control Chart Check (Moving Range, Control Limits, Points Out of Control)
Builds the individuals chart this chapter describes from your readings: moving ranges, control limits and any point outside them.
Applies this method
p-Chart Check (Fraction Defective, Control Limits, Samples Out of Control)
Builds a p chart for pass or fail inspection, as this chapter recommends, from equal-size samples; varying sizes need limits per sample.
Applies this method
X-bar and R Control Chart Limits
Calculates centre lines and control limits for X-bar and range charts.
Related Tools and Examples
Useful alongside
CUSUM Control Chart Check (Tabular Upper and Lower Sums, Decision Interval, First Signal)
Runs a tabular CUSUM, an alternative to this chapter’s run rules for catching a small, sustained shift in the process mean early.
Useful alongside
EWMA Control Chart Check (Weighted Moving Average, Control Limits, Small Shifts)
Charts an exponentially weighted moving average, which shows the small sustained shifts and drifts this chapter’s run rules look for sooner than a Shewhart chart.
Useful alongside
Linear Calibration Check (Straight-Line Fit, Calibrated Value, Calibration Interval)
Fits a calibration line against reference standards and tests offset and gain, the calibration side this chapter separates from MSA.
Related to Measurement system analysis: making sure your gauges can tell good parts from bad
Useful alongside
Process Capability Check (σ from R̄, Cp, Cpk, Rejects, Limits)
Checks process capability (Cp, Cpk and expected rejects) once a control chart shows the process is stable.