Monitoring and Evaluation of Production Processes (eBook)

Contents 6
About the Authors 10
About the Book 14
Symbols and Abbreviations 16
1 Introduction 20
2 Statement of the Goals of This Work 22
3 Analysis of the Current State of the Regulation of Manufacturing Processes 24
3.1 State of the Problem in Slovakia and Abroad 27
3.1.1 State of the Problem in Slovakia 27
3.1.2 State of the Problem Abroad 28
3.2 Development Trends 28
4 Specification of Problems Solutions 30
4.1 Regulation of Location the Production Process 33
4.2 Regulation of Variability (Dispersion) of the Production Process 34
4.3 Combined Regulation of Location and Variability of the Production Process 35
4.3.1 Control Chart of the Middle Values and Ranges xpriem–R 35
4.3.1.1 Calculation of Control Limits for xpriem–R Under STN 01 0265 Before Adjustment 37
4.3.1.2 Calculation of the Control Limits for xpriem–R Under STN 01 0265 After Adjustment 41
4.3.1.3 Calculation of the Control Limits for xpriem–R Under STN ISO 8258 43
4.3.2 Control Chart of Medians and Ranges xmed–R 43
4.3.3 Control Chart of the Middle Values and Standard Deviations xpriem–S 44
4.3.4 Control Chart of Medians and Standard Deviations xmed–S 44
4.3.5 Control Chart of the Largest and Smallest Selected Value Max–Min 44
4.3.6 Control Chart of the Individual Values xi 45
5 Deployment of Regulation of the Production Processes in the Serial Production of a Specific Production Company 47
5.1 Choice of Regulated Parameters for the Production Process of Tapered Roller Bearing 47
5.2 Verification of the Statistical Stability of the Process 51
5.3 Verification of the Technical Stability of the Process 52
5.4 Selection of the Suitable Method of Regulation of the Production Processes 54
5.5 Determination of the Prescription of Regulation 55
5.5.1 Object of Detecting the Values of Regulated Variable 56
5.5.2 Time Interval Between Individual Selections 56
5.5.3 Determination of the Regulated Variable (Dimension) 57
5.5.4 Method of Sample Collection, Range Selection n, Method of Detecting the Values of Regulated Variable 57
5.5.5 Method of Calculation of the Selected Characteristics 58
5.5.6 Form of the Control Chart 59
5.5.7 Method and Procedure of Recording the Values of Selection Characteristics and Other Data in the Control Chart the Person Responsible for Conduct and Implementation of SPC
5.5.7.1 Procedure of the Machine Operator 62
5.5.7.2 Procedure of Machine Adjuster 63
5.5.7.3 Procedure of the Controller 63
5.5.7.4 The Method of Determining xmed 63
5.5.8 Evaluation Process According to the Principles of Regulation 63
5.5.9 Assessment of the Production Process 67
5.5.9.1 Analysis of the Diagram Range R 67
5.5.9.2 Analysis of the Diagram Range xmed 67
5.5.9.2.1 Points Outside the Control Limits 68
5.5.9.2.2 Group Special Points Successively 68
5.5.9.2.3 Points Which Indicate a Trend 68
5.5.9.2.4 Groups of Points Very Close to the Mean Value or to the Control Limits 69
5.5.9.3 Assessment of the Course of the Production Process—Conclusions 69
6 Evaluation of the Capability of the Production Processes 70
6.1 Determination of the Coefficient of Process Capability cP 71
6.2 Determination of the Coefficient of Usage of the Process Capability cpk 72
6.3 Relation Between cp and cpk 73
6.4 Organizing the Evaluation of Coefficients of the Production Capability of Processes cp and cpk 73
6.5 Calculation of the Rate of Occurrence of the Reject 75
6.6 Diagram of Accuracy 80
6.7 Diagnosis—Assessment of the Course of Production Processes 80
6.7.1 Grinding the Hole of the Inner Ring, the Machine for Bore Cone Bearing Grinding 81
6.7.2 Turning the Height of Outer Rings on the Turning Department Machine for Height of the Cup Bearing Turning 81
6.7.3 Turning the Raceways of Outer Rings, Machine for Raceway Cup Bearing Turning 81
6.7.4 Turning the Raceways of Inner Rings, Machine for Raceway Cone Bearing 82
6.7.5 Turning the Raceways of Inner Rings, Machine for Raceway Cone Bearing Turning 82
6.7.6 Turning the Height of Leaned Fronts the Inner Rings, Machine for Height Cone Bearing Turning 83
6.7.7 Grinding the Raceways of Outer Rings, Machine for Raceway Cup Bearing Grinding 83
6.7.8 Grinding the Raceways of Inner Rings, Machine for Raceway Cone Bearing Grinding 84
6.7.9 Grinding the Leaned Fronts of Inner Rings, Machine for Cone Bearing Grinding 84
6.7.10 Pressing the Length of Tapered Roller, Machine for Pressing of Rollers 85
6.7.11 Grinding the Diameter of Tapered Roller-1. Transition, Machine for Grinding of Rollers Diameter 85
6.7.12 Grinding the Length (Spherical Head) of Tapered Roller, Machine for Grinding of Rollers Length 86
6.7.13 Grinding the Diameter of Tapered Roller-2. Transition of the Machine for Grinding of Diameters of Rollers 86
6.8 Diagnosis—Summary of the Results of Representative Production Processes Based on the Coefficients of Capability cp, cpk 86
6.8.1 Achievable Status Capability of the Production Processes 88
6.8.2 Achieved—Real Status of the Capability of Production Processes 88
6.9 Diagnosis—Summary of the Results of Production Processes Based on the Coefficients of Capability cp, cpk Throughout the Production Company 88
6.9.1 Achievable Status of the Capability of Production Processes 89
6.9.2 Achieved—Real Status of the Capability of Production Processes 89
7 Evaluation the Capability of Machine 90
7.1 Flow Chart for the Establishment of the Capability of Machine 90
7.2 Planning for the Determination of the Capability of a Machine 90
7.3 Determining the Capability of a Machine 92
7.3.1 Establishing the Minimum Number of Selections 92
7.3.2 Method the Marking Protocols 92
7.3.3 Procedure for Calculating the Coefficients of Capability cm, cmk 94
8 Evaluation of the Capability of Gauges 97
8.1 Flow Chart for Determining the Capability of Gauges 97
8.2 Rating the Capability of Gauges 97
8.3 Evaluation of Organization of the Capability of Gauges 104
8.4 Method of Labelling the Protocols 105
9 Capability According to the German Association of the Automobile Industry (VDA 6.1) 106
10 Method for the Remuneration of Employees, Working in the Controlling System of a Manufacturing Process 107
10.1 Necessary Conditions for the Introduction of Remuneration 107
10.2 Method of Remuneration 108
11 Automation of the Control of Production Processes 112
12 Results and Benefits of the Implementation of Regulation and Further Procedures and Methodologies Benefits for Science and for Practice
13 Conclusion 122
References 124