Quality Engineering in Manufacturing Technology

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1. INTRODUCTION 9

2. MACHINING TECHNOLOGIES USED IN THE MACHINING INDUSTRY, INCLUD­ING THE AUTOMOTIVE AND AVIATION INDUSTRY 20

2.1. Classification of basic manufacturing technologies 20

2.2. Characteristics of basic manufacturing technologies 22

2.2.1. Metal cutting technology 22

2.2.2. Abrasive machining 30

2.2.3. Erosive machining 34

2.2.3.1. Electro-chemical machining 35

2.2.3.2. Electro-erosive machining 36

2.2.4. Casting 37

2.2.5. Polymer processing 41

2.2.6. Metal forming 42

2.2.7. Bonding 44

2.2.8. Assembly 47

2.3. Technological process design rules 52

2.4. Example of technological process design 56

3. GEOMETRICAL PRECISION OF MACHINE PARTS 65

3.1. Tolerances and fittings 65

3.1.1. Basic concepts 65

3.1.2. Selection of tolerance field location 67

3.1.3. Basic formulas 67

3.1.4. Calculation examples 68

3.2. Shape tolerance 70

3.3. Orientation tolerance 70

3.4. Location tolerance 71

3.5. Run-out tolerance 72

3.6. Roughness of machined surfaces 73

3.6.1. Basic concepts 73

3.6.2. Surface roughness measurement methods 75

4. QUALITY ENGINEERING IN MANUFACTURING TECHNOLOGIES – INTRODUC­TION 79

5. PRODUCT AND PROCESS QUALITY ASSURANCE AND IMPROVEMENT SYSTEMS 83

5.1. Economic aspects of quality 83

5.2. Quality management rules 89

5.3. Quality assurance system certification 93

5.4. Total quality management (TQM) 101

6. STATISTICALTECHNOLOGICAL PROCESS CONTROL (SPC) 103

6.1. Function and place of SPC in quality engineering 103

6.2. Process stability analysis with control charts 104

6.2.1. Control charts structure basics and types 104

6.2.2. Classic control charts for continuous data 109

6.2.3. Control charts for unconventional technological processes 113

6.2.3.1. Control charts with variable samples size 113

6.2.3.2. Control charts with variable sampling intervals 113

6.2.3.3. Control charts with variable control limits 123

6.3. Process capability analysis using quality capability indices 125

6.4. Examples of process quality analysis for basic manufacturing technologies 131

6.4.1. Metal cutting technology 131

6.4.2. Metal forming 137

6.4.2.1. Sheet folding process control with a vision system [103, 104, 109] 137

6.4.2.2. Quality analysis in the cutting process [105] 138

6.4.3. Casting [67, 106, 107, 108] 139

6.4.4. Polymer processing 142

6.4.5. Welding 144

7. STATISTICALACCEPTANCE INSPECTION 157

7.1. Introduction 157

7.2. Batch creation and sampling criteria 158

7.3. Alternative assessment inspection 159

7.3.1. One-stage alternative sampling plan 159

7.3.2. Two-stage alternative sampling plan 160

7.3.3. Multi-stage alternative sampling plan 162

7.3.4. Sequential alternative sampling plan 162

7.4. Test plan specifications 163

7.4.1. Operating-characteristic function (OC curve) 163

7.4.2. Reception inspection with the alternative method 164

7.4.3. Recipient inspection with the numeric method 167

7.5. Example of use of the Statistical Reception Inspection procedure [63] 169

7.5.1. Batch diagnosis with the alternative method 170

7.5.2. Batch diagnosis in statistical reception inspection (SRI) using a method with numerical assessment 172

8. MEASUREMENT SYSTEM ANALYSIS (MSA) 175

8.1. Measurement systems and data collection 176

8.1.1. Measurement uncertainty 178

8.1.2. Measurement accuracy 180

8.1.3. Measurement error 181

8.2. Methodology of stability and measurement system capability analysis 182

9. METHODS AND TECHNIQUES USED IN QUALITY ENGINEERING 188

9.1. FMEA method 189

9.2. QFD method 197

9.3. Ishikawa diagram 202

9.4. Pareto-Lorenz diagram 204

9.5. 5S method 207

9.6. Six Sigma methodology 211

10. INFORMATION AND IT SYSTEM IN QUALITY ENGINEERING 214

11. HUMAN FACTOR IN QUALITY ENGINEERING 218

REFERENCES 221

 

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