manufacturing science

Small reaserch on



IMPORATNCE OF QUALITY IN DIFFERENT MANUFACTURING PROCESS




















prepared by
Mr. Gautam saurav






Acknoledgement


I would like to express my greatest gratitude to the people who have helped & supported me throughout my project. I am grateful to my teacher Mr. SUMIT SHARMA for her continuous support for the project, from initial advice & contacts in the early stages of conceptual inception & through ongoing advice & encouragement to this day.


A special thank of mine goes to my colleague who helped me in completing the project & she exchanged her interesting ideas, thoughts & made this project easy and accurate.



I wish to thank my parents for their undivided support and interest who inspired me and encouraged me to go my own way, without whom I would be unable to complete my project. At last but not the least I want to thank my friends who appreciated me for my work and motivated me and finally to God who made all the things possible...





thank you all....................
by
Gautam Saurav












Contents
1. Impotance of quality assurance in manufacturing
1.2.Tips for seven step quality manufacturing process improvement
3.Ensure qulaity in maufacturing process
4. Computer aided quality assurance
5.Machining
6.Turning
7.Welding































Importance of Quality Assurrance in Manufacturing
Giving Quality is the process of using systems and methodologies that ensure that the manufactured products meet the required quality standards consistently. The aim of QA is to produce goods right at the first time, without any rework. Organizations, usually, have a separate department to assure the quality of their products. For this they may also use the services of the consultants.
QA is crucial for the manufacturing industry. With so much competition and such few margins, no manufacturing industry can afford to spend time and money on rework. Every activity in the industry costs money and so does rework, but customers do not pay for rework. Customers pay for the value addition by the company and if they see more valuable additions by some other company being offered at same or lower costs, they move to that company. Hence to assure good quality to customers, quality assurrance plays a significant role.
Benefits of Quality Assurrance.
Some of the benefits the organization derives from this role are:
o Improve Quality
QA professionals are involved in all critical activities of the organizations like design, manufacturing, material procurement, packaging, logistics etc. Since all the processes are being tracked and monitored properly, there are fewer chances of bad quality or non-compliance of products with respect to the requirements. These requirements could be standard requirements, customer requirements, or even legal requirements.
o Low Cost
It reduces the overall costs to the organization. When the product is right the first time, there are no rework costs, no wastage of material, no wastage of manpower, and no disruptions in the production process. There are fewer claims for warranties and guaranties. In short, the cost of poor quality goes down. All this reduces the operating costs of the organizations and hence results in increased operating profits.
o Reputation
Since the organizations are able to manufacture good quality products that are made according to the requirements of the customers, the market reputation of those organizations improves. This helps the organizations to retain the existing customers and get more business from them. At the same time this also helps them in attracting new customers. These in turn increase the revenue and profit of the organizations.
o Reduce Execution Time
The systems implemented to improve quality reduce the cycle time i.e. time taken for the execution of the orders. If the quality of products is bad then there will be more customer complaints and more production downtime. This results in huge loss of time and resources. Hence, if QA systems are implemented properly in the organization, the order execution time automatically gets reduced.
o Compliance To Standards
It ensures that the organizations meet all the standards and guidelines required for different quality management systems like ISO and other quality certifications awarded to it.
In short, to meet customer requirements effectively and consistently, it is very important for every manufacturing industry to have a QA department. This will ensure that the efforts and processes are moving in right direction so that the end product not only meets but exceeds the customers expectations.














Tips for seven step quality manufacturing process improvement
Improving quality manufacturing processes can result in decreased waste, better quality products, and an overall improvement in customer satisfaction.
The following are tips for seven step quality manufacturing process improvement. Before you start, however, you will want to develop a committee that is in charge of overseeing the steps and making sure they come to fruition. It's best to involve the whole company if possible, but in the beginning a committee can help to ensure the steps are completed and taken from beginning to end.
Step one:
The first step is to define the actual process. This is important as it provides a foundation for improving your processes. During this first step, you should name the process and its purpose, as well as its starting and ending points, inputs and outputs, and your overall requirements. It would also be a good idea to identify the customers and suppliers who will be affected by this process.
Step two:
The next step involves identifying areas of improvement that are needed. This process is usually done by selecting a random sampling of a particular product that is being manufactured. This product is then tested for a variety of things that will have an impact on the end user and consumer. This can include durability, materials, toxicity, and so forth. There are a number of ways to go about this in manufacturing. Some of the more common areas of improvement in manufacturing include disintegration of parts, loose fasteners, and so forth and should be a main focus.
Step three:
Identify potential solutions for the problems. Once the problems have been identified, it is important to then find solutions for them. Brainstorm with the committee, or consult specialists or higher ups in the manufacturing plants that can help you to arrive at the best possible solution. Additionally, you will want to get feedback from those who work on or with the process on a daily basis.
Step four
: After you have identified problem areas and then brainstormed for improvements, step four involves developing a more detailed solution for each problem area. In detailing how to solve the problem, include a budget, determine what personnel are necessary for making the improvements, conduct a projected cost analysis, and a time frame for completing the overall improvements. You will also need to determine how the rest of the manufacturing plant will be affected by this and whether it will slow production at any level.
Step five:
Put your plan into action. After a detailed plan has been made, it is time to implement it to improve your processes. Now is the time to involve everyone, from the highest levels of management in the manufacturing company
down to the workers who utilize the process.
Step six:
Evaluate. Once you have put your plan into action and have achieved the results from it, you will need to evaluate your improvement process as a whole. Ask yourselves if the process had its desired effect. Was the process successful? Did it fix the problem? Did it eliminate waste? Did you implement the improvements on time and within budget? All of these factors should be taken into consideration.
Step seven:
Continue to repeat steps two and six as often as necessary to achieve improvement within the manufacturing plant. The overall goal is to decrease the need for a committee, and instead have all members of the plant continually working to improve.









Ensure Quality in your Manufacturing Processes
Every aspect of the manufacturing process must be controlled and monitored. In order to ensure the integrity of the enterprise and to maintain quality assurance, the implementation of standards such as ISO 9000 must be pursued. This means installing efficiently designed processes throughout the operation from product development, to supply chain and shipping. By adopting a strong, process-centric culture, your company can smoothly transition from chaotic and ad hoc management systems to a smooth running operation that will increase profits.

By using our products, your company gains the accountability and consistency that will give you a cutting edge over your competition. Our tools ensure that all processes are properly understood, allowing you to increase the safety as well as the efficiency of your operations.

ISO Quality Control – Our process methodology and support for business rules and risk/control management allows effective process design that has all the appropriate checks and balances.
Utilize resources or business power will expose unused resources and allow you to take better advantage of them along the length of the process.
Manage Work Flow – Integrate your people, processes, and technology by taking advantage of our workflow engine to deliver work to where it is needed, and keep all employees up to date with the most important priorities.

Ensure transparancy – Know where resources are being used and maintain efficient work habits by planning well in advance.
Model Business Rule – Our approach to Business Process Mnagement allows your company to easily implement business rules that can be reused and easily updated along the length of your processes.

Create portable Process manuals – Our products have the ability to generate a complete output of your processes and all of the related information that is ready for print. This makes for an excellent collaborative tool, and allows your agents to share information more widely.
Implement Standard Methodologies – Avoid the need for continual trial and error in improving your agency’s operational efficiency; get a head start by taking advantage of industry standards.
Encourage Collaboration – By uniting goals and creating a common framework for your agents, they will be able to cooperate at a previously unattained level.









Computer-aided quality assurance
Computer-aided quality assurance (CAQ) is the engineering application of computers and computer controlled machines for the definition and inspection of the quality of products.
This includes:
Measuring equipment management
Goods inward inspection
Vendor rating
Attribute Chart
Statistical Process Control(SPC)
Documentation
Additional themes:
Advanced Product Quality Planning (APQP)
Failure Mode and Effect Analysis (FMEA)
Dimensional tolerance stack-up analysis using product and manufacturing information (PMI) on CAD models
Computer aided inspection with coordinate measuring machine(CMM)
Comparison of data obtained by mean of 3D scanning technologies of physical parts against CAD models





















Machining
Conventional machining, one of the most important material removal methods, is a collection of material-working processes in which power-driven machine tools, such as lathes, milling machine and drill presses are used with a sharp cutting tool to mechanically cut the material to achieve the desired geometry. Machining is a part of the manufacture of almost all metal products, and it is common for other materials, such as wood and plastic, to be machined. A person who specializes in machining is called a machinist. A room, building, or company where machining is done is called a machine shop. Much of modern day machining is controlled by computers using Computer numerical control(CNC) machining. Machining can be a business, a hobby, or both.









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Turning
Turning is the process whereby a single point cutting tool is parallel to the surface. It can be done manually, in a traditional form of lathe, which frequently requires continuous supervision by the operator, or by using a computer controlled and automated lathe which does not. This type of machine tool is referred to as having computer Numeric Control, better known as CNC. and is commonly used with many other types of machine tools besides the lathe.
When turning, a piece of material (wood, metal, plastic, or stone) is rotated and a cutting tool is traversed along 2 axes of motion to produce precise diameters and depths. Turning can be either on the outside of the cylinder or on the inside (also known as boring) to produce tubular components to various geometries. Although now quite rare, early lathes could even be used to produce complex geometric figures, even the platonic solids; although until the advent of CNC it had become unusual to use one for this purpose for the last three quarters of the twentieth century. It is said that the lathe is the only machine tool that can reproduce itself.











Welding
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a nonconsumable tungustun electrode to produce the weld. The weld area is protected from atmospheric contamination by a shelding gas (usually an inert gas such as argon), and a filler metal is normally used, though some welds, known as autogenous welds, do not require it. A constant-current, welding power supply produces energy which is conducted across the arc through a column of highly ionized gas and metal vapors known as a plasma.
GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminium, magnesiumand copper alloys. The process grants the operator greater control over the weld than competing procedures such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and difficult to master, and further the more, it is significantly slower than most other welding techniques. A related process, plasma welding, uses a slightly different welding torch to create a more focused welding arc and as a result is often automated.