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Process Two Manufacturing Solutions

Process Two Manufacturing Solutions. Using process engineering. John Hayter. Industry background Tool fitter and mechanical engineer/design. 38 years experience in the manufacturing industry in Australia, South America, Africa, Asia Pacific, Europe and North America.

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Process Two Manufacturing Solutions

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  1. Process TwoManufacturing Solutions Using process engineering

  2. John Hayter Industry background Tool fitter and mechanical engineer/design. • 38 years experience in the manufacturing industry in Australia, South America, Africa, Asia Pacific, Europe and North America. • Process engineer / Manager • Supplier quality Assurance engineer • Product development engineer • Production Engineer • Project manager.

  3. Greg Vincent Industry background Fitter and turner, tool maker, and production technician. • 35 years of experience in the manufacturing industry in Australia, South Africa, Asia Pacific, Japan and Thailand. • Tool maker/maintenance fitter • Engine plant and machining • Production supervision • Apprentice master (training) • Production management • Manufacturing manager for Asia Pacific • Manufacturing engineering manager for Asia Pacific and South Africa.

  4. Objectives of session This course is designed to increase awareness and develop practical skills for process engineering and will include: • Process controls and auditing documents • Testing and inspection • Process improvements.

  5. Part one: Process controls Auditing documents Flow charts Issue control Process control plan SOP Testing and inspection Destructive/non-destructive Patrol inspections Machine set up data Part two: Process improvements Takt time vs cycle time Process mapping Plant layout PFMEA. Topics to be covered

  6. Process controls 6

  7. Objectives Process control is a method for controlling the output of a specific process. Documents used in the manufacturing process: • Process control flow chart • Process control plan (PCP) • Standard operating procedures (SOP) • Machine set up data • Non Destructive / Destructive testing • Inspection records.

  8. Auditing documents Documentation is used for following the history of a production process and assists with: • Traceability • Conforms to quality assurance (QA) standards • Provides evidence through recording data • Protects staff.

  9. Auditing documents The following documents are used for the life of the project: • Process control flow chart • Process control plan • Patrol inspection records • Standard operating procedures (SOP) • Test records • 5S records.

  10. What is a flow chart? • A flowchart is a visual diagram of a process. • They are used for presentations to help people easily understand the content or to find flaws in the process.

  11. Process control flow chart A legend helps you identify the different parts of the production process. It identifies the shapes used in the flow chart and describes what each shape represents.

  12. Process control flow chart Each step in the flow chart is represented in the diagram. Process steps include: • Raw materials • Process operations • Robotic operations • Number of parts to be produced • Packaging • Transport.

  13. Process control flow chart Important information found on the process control flow chart includes: • Customer name • Item/part description • Your company item/part number • Customer part number • Estimated annual volume (EAV) • Engineering responsibility and name • Date • List of all assemblies made by the same robot/process.

  14. Flow chart issue control • This assists with: • Tracking the history of the production process • Identifies who has authority to make the change • Date of change. .

  15. Process control plan Definition A process control plan PCP is the detailed planning of manufacturing processes, required to convert raw materials into finished product before commencing an operation.

  16. Process control plan Important information in the PCP header: • Part name • Part number • Customer name • Customer product number • Type of process • Number of operations involved in production • Number of pages in document • Next operation instructions.

  17. Process control plan • A labelled photograph of the part is included in the PCP • Each number represents an item number in the production sequence.

  18. Process control plan Production sequence instructions are divided into: • Special notes • Item numbers • Characteristics/features of each item number • Tolerance required.

  19. Process control plan Production sequence instructions are divided into: • Assure/monitor • Method (ie. Visual check or measure specific gauge) • Assured by whom? • Frequency of quality checks (ie. 1/shift – last off). • Comments • Packaging • Quantity • Prepared by • Responsible engineer / product designer.

  20. Process control plan This sample PCP demonstrates: • the production instructions given to machine operators in a PCP document.

  21. Process control plan In this example the operator is required to compare the first and last piece manufactured in a shift, to the FOA.

  22. Process control plan • The number of quality inspections are determined by: • quality characteristics of the product • the severity associated with not detecting a deviation from the approved design.

  23. Process control plan Instructions for testing and set-up are provided in: • Destructive spot weld peel test • Standard operating procedures (SOP) • Machine set-up data

  24. Product testing Product testing and inspection is performed many times throughout the production process. This includes: • Visual inspection • Measured/gauged inspection • Non Destructive testing • Destructive testing • Capability Analysis.

  25. Product testing Recording test information allows you to refer to the history of manufacturing for a product. • Record keeping documents for testing include: • Spot weld peel test (destructive) record • Non- destructive test records • Patrol inspection record sheet. • Lineal Dimensional tests • Strength tests • Shrinkage Tests • Visual Tests.

  26. Destructive spot weld peel test • Frequency of testing (daily/monthly etc) • Labelled image of part • Table to fill in test data • Action required • Document prepared by • Date. Test information for spot welding a part includes: • Type of test • Part number • Part name • Operation number • Machine/cell number • Calibration details • Weld specification

  27. Destructive spot weld peel test The SOP for a destructive spot weld peel test specifies the: • procedures to follow • the tools to be used • results for a passed part • results for a failed part • the action to be followed for a passed part • the action to be followed for a failed part.

  28. Destructive spot weld peel test In this example, three parts per shift have the weld nugget tested/measured and results recorded in the table. • D (mm) = diameter of fused nugget. • d (mm) = diameter of fused nugget at right angle to D. • The minimum average diameter of the weld nugget needs to be 3.0mm.

  29. Destructive spot weld peel test Using weld number 03 as the example: (3.0mm + 2.5mm)5.5mm 2 = 2 = 2.75mm average To calculate the average results of the weld nugget diameter:(D + d) 2 = the average

  30. Destructive spot weld peel test • A failed part will have failed spot welds and can be scrapped or reworked as appropriate. • If the manufactured part fails testing, refer back to the Patrol inspection record which will show historical performance. After testing • A passed part will have distorted metal from the testing, carefully hammered back to its original position.

  31. Standard operating procedures • The SOP document will include: • SOP number • Part Description • Purpose • Special notes • Instructions • Result expected • Action to be taken for a passed part • Action to be taken for a failed part • Revision and update details. Every operation has a specific Standard operating procedure (SOP) that must be followed which include diagrams and written instructions.

  32. Standard operating procedures Standard operating procedures are developed to implement best practice manufacturing systems, that support: • safe work environments • quality products • traceability. SOP’s are located near the operator for easy reference.

  33. Patrol inspection record The Patrol Inspection Record (PIR) sheet is to record the data and measurements of specified part, over time. • Used to identify that a part is manufactured within specified limits. • The frequency of data recording is referenced from the related PCP. • Used for auditing purposes.

  34. Patrol inspection record The header of the Patrol inspection record requires specific part and machine information from the Process control plan (PCP). • Part number and name • Setter name • Machine number • Operation number and total number of operations in process • Page number and number of pages in document.

  35. Patrol inspection record Concession A ‘once off’ only change to a process or part which requires approval by the customer.

  36. Patrol inspection record Breakpoint When a design change is required in either process or product a breakpoint is made, it identifies when the new part or process starts on the production line. • assists with traceability of new products • prevents incorrect shipment to the client.

  37. Patrol inspection record Specific information for gauges, tools and visual checks are included in the note section of the patrol inspection record. For example: • Operator to use gauge number • Item numbers for gauges • Operator to visually check item number.

  38. Patrol inspection record This includes: • Date and time of inspection • Gauged measurement of part • Comment for visual checks ie. Ok • Pass or reject • Setter initial • Operation number. The machine operator enters measurements or comments into the table of the Patrol inspection record (PIR).

  39. Patrol inspection record Checks and inspections There are two types of data required: • Attributed dataie. A visual inspection • Variable dataie. A required tolerance.

  40. Patrol inspection record • Each number at the top of the table refers to an item number in the Process control plan (PCP). • If there are more than 10 items in the process sequence, add more pages to fully document the process. The data entered into the table first relates to the First of approval (FOA) data.

  41. Patrol inspection record The Process control plan (PCP) specifies the frequency of inspections. Often the operator is required to inspect the ‘first off’ part at the beginning of the shift and the ‘last off’ part produced at the end of the shift for QA purposes.

  42. Patrol inspection record If the measurements are within the specified tolerance for a part it will be passed. Variations in measurements can occur as result of: • tooling wearing out • materials.

  43. Patrol inspection record When a part fails inspection the PIR identifies: • Which part of the operation sequence is failing to meet the customers specifications. • Time of day part failed. • Product batch that needs to be quarantined and audited. • Operator and operation number.

  44. Machine set-up data Machine set-up data are pre-programmed instructions and specifications for a machine to manufacture a specific part. Machine set-up data links to: • Part number • Machine number • Tool part numbers.

  45. Machine set-up data The operator must follow the parameters given in the Machine set-up data. • They are designed and engineered to meet required manufacturing targets. • It is critical that the machine data set-up information is correctly entered. • If the manufactured part fails testing, it is recommended that the machine set-up data is checked and re-entered if incorrect. • Only the relevant team leader/manager or nominee may alter the machine or any machine setting.

  46. Machine set-up data Important information in the Machine set-up data includes: • Part number • Machine number • Part description • Labelled diagrams of machine set-up • Settings for each element of manufacturing • Important notes.

  47. Machine set-up data This example is part of the machine set-up data for spot welding a specific part. The part number also refers to a program number, used to instruct the machine to manufacture a specific part. There are different/unique instructions for each part manufactured.

  48. Summary Documentation provides: • A history of the manufacturing process • Identifies break points in production • Identifies concessions in production • Traceability for auditing information • Conforms to QA standards • Provides evidence through recording data • Protects staff • Improves manufacturing performance.

  49. Process TAKT vs CYCLE

  50. Objectives • Satisfy the customer schedules • Maintain company reputation • Improve productivity • Apply lean initiatives • Reduce manufacturing costs • Improve house keeping • Meet OHS requirements • Reduce WIP • Better utilisation of machinery • Improved QA

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