Browse Topic: Total quality management

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Systems Engineering Capability Model Appraisal MethodEIA731_2A (Current)3/16/2021
G-47 Systems Engineering
Systems Engineering Capability Model Appraisal MethodEIAIS731_2 (Current)6/16/2016
G-47 Systems Engineering
Industry Implementation of International Standard ISO/IEC 12207:1995 (ISO/IEC 12207) Standard for Information Technology Software Life Cycle ProcessesIEEEEIA12207_0 (Current)6/16/2016
This International Standard establishes a common framework for software life cycle processes, with well-defined terminology, that can be referenced by the software industry. It contains processes, activities, and tasks that are to be applied during the acquisition of a system that contains software, a stand-alone software product, and software service and during the supply, development, operation, and maintenance of software products. Software includes the software portion of firmware. This International Standard also provides a process that can be employed for defining, controlling, and improving software life cycle processes.
Systems Management Council
Managing the Cost of Quality2012-01-18839/10/2012
Quality itself is no longer a differentiator among aerospace manufacturers. High quality is expected and achievable. With enough time and money, any manufacturer can turn around a high-quality product. Around the globe, the focus of manufacturing quality is shifting to a discussion about the cost of quality and how to manage it. The question being asked by manufacturers is no longer how to achieve quality, but how to achieve it within cost and time constraints. The aerospace manufacturer that can achieve quality with the least expense, while producing products the fastest, is the one that will win in today's tough, global market. This paper will describe the “closed-loop” approach to dimensional engineering, utilizing virtual simulations and tolerance analyses, and how such an approach can link cost factors with tolerance adjustments so that users have the data they need to make the most strategic business decisions regarding the balance between quality and cost. With such an approach, users are able to determine how to precisely meet their quality requirements by identifying and focusing on the key points affecting quality while avoiding unnecessarily tight tolerances that can prevent them from achieving cost and time goals.
Jasurda, Don
Carbon Remediation for the Airline Industry via ATF Drop-in Substitution: Strategic and Operational Perspective2012-01-15092/29/2012
The need to address environmental challenges by aviation industry is apparently obvious. As evidenced within the industry, it takes a three pronged strategy - more efficient aircraft, improving operational efficiencies and development of sustainable biofuels. In terms of actual growth of airline business, the two major drivers are domestic air service expansion within BRIC economies and rapid spread of Low Cost Carrier (LLC) models. Focusing not only on environmental challenges, even sustainable business development and growth of LCC depends critically on ATF substitution by alternative fuels. The inherent need for carbon subsidy and airline-airport partnership towards sustainable substitution with bio-alternatives is discussed in first part of the paper. A framework for such an airline airport win-win partnership is delineated. In the second half of the paper, focus shifts to complexity of operationalisation of blended ATF strategy for airlines as well as manufacturer from a sophisticated operational safety and liability perspective. The need for aircraft manufacturer and airline cum airport partnerships for globally acceptable and operational safety for partial drop-in substitution on the lines of biofuel certification standardisation and usability is examined. The authors highlight that carbon neutral strategy by aviation industry is not just critical in terms of environmental dimension but as would be evidenced in the coming decades critical in terms of capitalistic interests as well.
Varadarajan, Venugopal, Pathak, Maitrayee, Gupta, Ashish
Advanced Data Analysis for Resistance Weld MonitoringTBMG-89481/1/2011
Medical device manufacturers are experiencing an ever-increasing emphasis on process accountability. ADAM (Advanced Data Analysis Monitor) is a technology developed for resistance welding that gives manufacturers the information they need to support process development and production monitoring. It also supplies the data necessary to document quality requirements contained in ISO (International Organization for Standardization), good manufacturing practice (GMP), and total quality management (TQM) programs. The instrument monitors not only what happens after the trigger point of a typical weld monitor, but also before the trigger point, giving a 360-degree view of the process.
Optimizing Valve Rotational Speed Using Taguchi Techniques2010-01-10964/12/2010
As fuel economy regulations increase and customer preference shifts to smaller, higher power density engines it is more important to effectively cool certain areas of the cylinder head and valvetrain. In order to maximize valvetrain life and increase engine performance it is critical to maintain a near uniform valve seat temperature to enable proper sealing. As cylinder head bridges narrow, and the temperature increases, the water jacket may not be sufficient. An alternative method to ensuring equal temperature distribution across the valve is to promote low speed valve rotation. This will not only aid, cooling the valve seat, as well as cooling and cleaning the valves' seating surface. This paper describes the development and testing of a valve rotation study, utilizing the Taguchi approach in order to determine the most robust design. A test stand was utilized to examine the valve rotation in which the cam was driven directly using a DC motor. The testing was performed on a type II valvetrain, using a donor cylinder head. The Taguchi based project focused on three noise factors: cylinder head machining variability, oil pressure and engine speed, as well as various control factors including valve guide clearance, valve tip surface finish, keeper geometry, valve seal tension, spring shim amount, spring design, rocker arm tab clearance, rocker arm roller radius and rocker arm pad alignment. The testing was conducted using an L18 orthogonal array and a subsequent L9 to further optimize the system.
Refalo, Kevin, Bowyer, Stephen, Smith, Mahlon, Hijawi, Mohammad
Effects of Material Type, Surface Roughness, Compressibility, Shape, Gender, Age and Sense Modality on Perception of Automotive Interior Materials2010-01-06824/12/2010
This paper presents the results of an experimental study conducted to evaluate the effects of four material characteristics and two driver characteristics on the perception of automotive interior materials. The perceptual characteristics of the materials were measured using two sensing conditions, namely, visual sensing only and combined visual and tactile sensing. The experiments were conducted using the Taguchi's L16 orthogonal array with seven independent variables, namely material type, surface roughness, compressibility, driver's age, driver's gender, and sensing method. Twenty-four subjects participated in the experiments. Each subject was asked to evaluate four treatment combinations and provide ratings using seven 5-point semantic differential scales. In addition, physical measurements were made on surface roughness, coefficient of friction, and compressibility. This paper presents the results and discussion of a) the correlation models developed between the seven factors chosen for the Taguchi experiment and the subjective data and b) the relationship developed between the subjective rating and the measured physical characteristics measurements.
Sarma, Vishnuvardhan, Bhise, Vivek, Mallick, Pankaj
Laser Tracker and Digital Photogrammetry's Merged Process for Large Scale Rapid Scanning2009-01-308811/10/2009
Aircraft factories today must increase their speed of measurement and manufacturing operations, to remain competitive in the ever expanding global Partner/Supplier environment. Reducing the time required, for data collection and analysis, will increase the implementation of metrology solutions in our collectively networked factories. For aircraft, the challenge is to measure very large areas rapidly, receive near real time feedback, with minimal impact to the production schedule. Several different types of metrology equipment can measure large structures. Combining the strength of two different systems, laser tracker and Digital Photogrammetry, has increased the speed and volume of data collection. The speed and accuracy improvement is achieved by integrating the laser tracker's interferometer for precise distance and scaling calculations, and photogrammetry's rapid large area measurement capabilities. This paper illustrates a simple and complete guide, to fully automate Laser Tracker, Laser Radar, and Digital Photogrammetry, networked together, for Large Area Rapid Scanning (LARS). This combined metrology system, can measure 30 square meters (270 square feet), to within .020 of a millimeter, (.008 of an inch), in all three axis (X Y & Z), in 6 minutes. The three inspection points (per square inch point density) is made possible by accelerating Digital Photogrammetry to a rapid scanner level.
Marsh, Bobby J.
Achieving Breakthrough on Manufacturing Floor through Project-Based Organization2009-36-033310/6/2009
Many companies around the world have adopted the lean thinking as their strategy to operate, in a global market where changes happen all the time. One foundation for the success of lean manufacturing appliance is the continuous improvement approach which has been considered even on company statements, or it can be also considered as part of the genetic code of any enterprise. However, if in one side the continuous improvement thinking, set people mind to look for opportunities of improvement all the time, on other hand these improvements are incremental and they do not have significant impact on company performance on both short-term and medium-term and sometimes, the activities performed by the employees are not sustainable due to the lack of structure to manage and follow up these activities. Therefore, based on lean manufacturing concept, this paper has per its main purpose to discuss and make a proposal of an project-based manufacturing including the development of core competencies to reach breakthrough on critical areas of value stream that are strongly related with the company strategy and its performance, so this paper proposes an structure to focus company personnel on critical areas and provide tools to get significant and sustainable improvements with case study to support the proposals.
Júnior, Joel da Conçeião
Development of a model to measure the efficiency of outsourced companies in the process of aircraft spare parts technical publications2008-36-009210/7/2008
This paper presents a proposal of a model to measure the efficiency of outsourced companies in the aeronautical industry applying the methods DEA and AHP. It also proposes an evaluation in the relation between the variables of the process and the value obtained for the effiiency. The criteria of Quality, Time and Cost were considered the outputs of the process, and those criteria were quantified by AHP for DEA matrix.The number of technical documents received by those outsorced companies were considered the input of the process. The other purpose is to separate the companies in groups considered able to receive an investment to improve their process. Este artigo apresenta uma proposta de um modelo para medir a eficiência de empresas terceirizadas na indústria aeronáutica aplicando-se os métodos DEA e AHP. Também propõe uma avaliação na relação entre as variáveis do processo e os valores de eficiência obtidos. Os critérios da Qualidade, do Prazo e do Custo foram considerados os outputs do processo e os mesmos foram quantificados pelo AHP para a matriz DEA. O número de documentos técnicos recebidos pelas empresas terceirizadas foram considerados como os inputs do processo. O outro objetivo será o de separar as empresas em grupos considerados aptos em receber um investimento nos seus processos.
Filho, Angelo José Castro Alves Ferreira, Salomon, Valério Antonio Pamplona, Marins, Fernando Augusto Silva
Laser Tracker Assisted Aircraft Machining and Assembly2008-01-23139/16/2008
The patented (US 7,277,811 B1) Position Bar provides precise measurement, machining and drilling data for large Engineering and Tooling structure. The Position Bar also supports end item verification seamlessly in the same machining control code. Position Bar measurements are fast, accurate, and repeatable. The true centerline of the machine tool's spindle bearings are being measured to within .002 in a 20 foot cubic volume (20×20×20). True “I”, “J”, & “K” machine tool spindle positions are also precisely measured. Any Gantry or Post Mill Tool can be converted to a Coordinate Measurement Machine (CMM) with this laser tracker controlled Position Bar. Determinant Assembly (D.A.) holes, for fuselage and wing structures are drilled and then measured to within .006 in X, Y, & Z, over a 40 foot distance. Average laser tracker measurement time, per hole, is 2 seconds. Precise D.A holes, drilled to within .007 in X.Y. & Z, over a distance of 45 feet, are possible with Position Bar and Laser Tracker corrected drilling. More accurate Determinant Assembly holes, at Final Assembly, help to more accurately align and position the 787 fuselage and wing sections.
Marsh, Bobby J.
Using the Six Sigma Methodology for Process Variation Reduction2007-01-287211/28/2007
This paper is about the use of the Six Sigma Methodology, to solve variation problems in the manufacture area, at one of the Delphi Automotive Systems unit that manufacturer electrical harness. The DMAIC framework was followed, the improvements were done, eliminating the rots causes, and the use of Six Sigma methodology, was showed very efficient in solve problems. The methodology power, is in using a structured frame work, the DMAIC (Define-Measure-Analyze-Improve-Control), completing by quality quality tools (Pareto Chart, Five Why's, Cause and Effect Diagram) and statistical analyses, for example: variance analyses, hypotheses tests and Design of Experiments.
Maciel, Helio, Ferreira, Luciano, Castro, Rodrigo
Product Quality & Software Quality2007-01-274111/28/2007
The industries have been working hard, for decades, to improve quality in their products, using process that assure a quality level which meets customers needs. An important and strategic component, the IT area, collaborates with the companies to meet the goals satisfactorily, which is not considered with the necessary attention. The IT area of an organization should be managed with the same importance dedicated to product manufacturing process. The object of this paper is to convince the industries that the desired quality in products depends on more and more of IT resources and because of it, is strategically important an adequate monitoring of IT quality, based in corporative governance.
Murakami, Lélis Tetsuo
Concept Car: Excellence in preparing people for new car releases2006-01-284711/21/2006
This article presents a training strategy applied to Volkswagen employees, at the Curitiba plant, with the goal of enabling them for the production of the VW 249 (Fox), in the matters of production system related knowledge and some key pointers for team and process performance in the company. The training hereby presented has been named Concept Car and had, as its core, activities performed in a production line simulation. In this simulation there were rows of production of a miniature. The results were compared to a result matrix and the teams sought to improve their performance. Este artigo apresenta a estratégia de treinamento aplicada aos funcionários da Volkswagen, planta de Curitiba, com o objetivo de capacitá-los à produção do VW 249 (Fox), no que tange aos conhecimentos relativos ao sistema de produção e ao gerenciamento de alguns indicadores chave para o desempenho dos times e processos da empresa. O treinamento aqui apresentado foi denominado Concept Car e teve como base atividades em uma simulação de linha de produção. Nesta simulação aconteciam rodadas de fabricação de uma maquete. Os resultados eram medidos e comparados a uma matriz de objetivos e os times procuravam melhor sua performance.
da Silva, Paolo Bicca
As9100 Registration Difficulties and Organizational Benefits: A Supplier Satisfaction Survey2006-01-24388/30/2006
A supplier satisfaction survey was developed and administered to 129 Aircraft suppliers who are AS9100 registered. The primary objective of the survey was to assess organizational benefits, attributed to the AS9100 standard, and registration process difficulties. Survey results from 49 responses indicated that the primary reason for seeking AS9100 registration was customer requirement, followed by improving production and service. Further analysis indicated that the top three difficulties were evaluating effectiveness of employee training, obtaining and analyzing data on customer feedback and satisfaction, and monitoring and measuring processes. The top three reported benefits, improved quality awareness among employees, an increase in employee training, and improved internal communication, respectively, were all non-financial in nature. Overall, the suppliers strongly expressed satisfaction with the AS9100 standard, but claimed that the registration process did not improve their financial position.
Weheba, Gamal, Mahmassani, Ahmad, Malzahn, Don
A SYSTEMS PERSPECTIVE NEEDED FOR ENGINEERING EDUCATION2004-01-17373/8/2004
Today, our manufacturing enterprises exist in a climate of accelerating change. This climate necessitates that engineers understand a systems approach and that they can function as integrators in the process of design and manufacture of products and services. Consequentially, it is incumbent upon our educational systems to see that the education and training of future work forces, as well as the retraining of present workers, include an interdisciplinary approach. Such an approach will produce engineers capable of imparting knowledge integrated from a holistic view and applying a systems approach to practical solutions. The old principles where one understands a single system and attempts to assemble the resulting systems from that perspective are no longer viable. To be the best no longer means building a manufacturing advantage around standard designs and mass production of products. Organizations must be both flexible and agile in order to achieve a level of quality that will enable them to benchmark against the best. Engineers of the 21st Century will face issues in an exploding environment, expanding their vision from the factory floor to interaction with businesses globally. Product sophistication, advanced tools, a global manufacturing environment, and a multitude of social and economic changes will add to the exploding scope of the engineer. All of this means the engineer must be educated to respond to these conditions.
Mizdail, Barbara E.
A Case Study: The Balancing of the Performance Indicators of the Assembly Plant and its Chain of Suppliers in the Automotive Segment2003-01-369111/18/2003
Today we are aware that the traditional system for assessing performance, derived from the also traditional cost accounting, has a limited financial view, leads to the optimization of short term actions and procedures, and hampers the evaluation of new investments and the introduction of new products. Besides that, performance measurements for quality, stock and productivity are lacking (Kaplan, 1983). In the automobile segment, such a situation raises an important issue, and that is the grounds for this present research: Concerning performance, can the suppliers' view on their own technical and commercial performance conflict with the that of the assembly plant? The proposal of this work is to evince the view of the suppliers on the application in the strategic level of the assembly plant's system for measuring performance. The source of information of this research was the unit of the DaimlerChrysler of Brazil, located in São Bernardo do Campo, São Paulo, which is an assembly plant of trucks and cars; and its vendor park.
Martins, Denise Maria
Design for Six Sigma (DFSS) and Reliability2003-01-13743/3/2003
This article is attempting to address the issues of reliability and design for six sigma. Specifically, it starts out with an overview of the DMAIC model, summarizes the DCOV model which is the prevention model of the six sigma approach and then progressively addresses the issues of reliability. The issues addressed here are: 1) concepts and time categories 2) specific issues of DFSS and reliability 3) characteristics of reliability and DFSS 4) approaches of using reliability 5) concerns about six sigma and 7) consequences and closing remarks.
Stamatis, Diomidis (Dean) H.
Three-Dimensional Vision of Competitive Strategy in ‘Optimized Capability’ Organization- Entitlement2002-01-350511/19/2002
The main and common focus of some strategy specialists, aiming at obtaining a competitive advantage and added value for organizations will be the objective of this study. We describe in the study the methods used and the indicators that reflect the trends in the development and the transformations in process, products and services in the organizations. Through the models used and the results reached by the organizations, the study intends to show critical and common aspects that allow reaching a differentiated position in the market.
Stachoviak, Ana Vitória E. O., Martins, Denise Maria
Where Customer Product Validation Programs Add Value in the New Product Development Cycle2002-21-001210/21/2002
To try and bring together customer needs and product quality within the new product development cycle, Hewlett-Packard’s LaserJet Group has created a program known as Delta. LaserJet Delta is an extension of what is commonly known as a Beta Program but the objectives are changed - the LaserJet Delta program is used to assess product quality, usability, and functionality while manufacturing is beginning production. Beta is commonly done within the product development cycle with the primary purpose to determine what customers like and dislike about the product. First reactions to a program like LaserJet Delta should be it is not the right thing to do. Pre-release testing should be comprehensive enough to catch the issues that are likely to be found in customer testing, allowing an organization to minimize costs associated with expensive last-minute fixes and product reworks. The reality is, printers operate in wide variety of unstable and unpredictable environments and it would be impossible to completely test these products in a competitive time frame and at a competitive cost. The program results shed significant light on why LaserJet Delta is such a compelling program. When program objectives and site selection are done correctly, LaserJet Delta identifies and isolates customer issues quickly, allowing the design teams time to implement fixes before significant volumes of product have entered the marketplace. Early resolution of issues gives the customer support organization time to document and train for responsiveness required on any known issues, thus reducing warranty costs. LaserJet Delta also provides a conduit from design team members to real users that otherwise does not exist. This conduit supplies actionable feedback to the design teams so that eventually the in-house test and evaluation is reshaped to be more comprehensive without being a cost burden. The feedback carries more significance because it is coming straight from the customer.
Hurty, Brett
Systems Engineering Capability Model Appraisal MethodEIA731_2 (Historical)8/1/2002
G-47 Systems Engineering
Quality, Manufacturing and Quality Education2002-01-21007/9/2002
In recent years manufacturing and quality are not separate concepts. At first these concepts were thinking different step and process. In this world of tightening competition among manufacturer at a national and international level, the question of quality of important emerges as a serious issue. This concern is shared by all members of manufacturing and consumer. The manufacturing sector today, quality standards (ISO 9000) registration could become a requirement for any institute of standard wanting to do business in the international and/or national market-place. Therefore quality education and assurance are very important factors in higher education and engineering faculty. Quality is dynamic interaction and changeable. In the world of engineering education has been changing rapidly. This study about quality of manufacture, standards and quality system in Turkey and Sakarya on the basis of engineering faculty with some questionnaires about industrial company.
Uzun, Abdullah
Six Sigma: Product Improvement and Culture Change at AutoAlliance2002-01-07663/4/2002
Six Sigma is a comprehensive and flexible methodology for achieving, maintaining, and maximizing business success by sustaining a disciplined use of facts, data, and statistics while managing, improving, and reinventing business processes based on customer requirements and cost targets. Six Sigma is a holistic approach to reducing concerns tied directly to achieving organizational objectives. AutoAlliance uses structured processes based on problem-solving methodologies known as D-M-A-I-C: define - measure - analyze - improve - control. Six Sigma deployment involves hard work, frustration, starts/stops, and disappointments that go along with launching a long-term culture change. AutoAlliance's goal is to have the entire workforce utilizing the methodologies in their everyday work. At that point, the “Six Sigma” change is complete.
Pruitt, W. David, Van Tiem, Darlene M., Doyle, Thomas R.
Romanian Reefer Trade Face to Face with Efficiency and Environment2001-01-377111/12/2001
Marine refrigeration plants must address two major matters: efficiency and environment. This paper approaches efficiency from the ice storage point of view. Because this technology is performs well on shore, we propose to adjust it for on board the ship. On the basis of the excellent results obtained by CEMAGREF laboratories, we made a calculation for an Ice Balls Storage System adapted for a fishing vessel, in order to perform in the Romanian fishing sector. The results was a smaller distribution ductwork. The necessary daily refrigerant requirements are 47% smaller than a conventional system. The environment is one of the big challenges that Romanian reeferis facing. This is why we present ammonia as being a promising refrigerant for the reefer trade. The comparison made in this paper between R22, a traditional refrigerant for the Romanian fleet, and ammonia shows that ammonia is the perfect alternative refrigerant to R22.
Memet, Feiza, Bătrânca, Gheorghe
Quality, QFD and Control Charts: A Managerial Assessment During the Product Development and Production Process2001-01-336510/1/2001
Quality Engineering looks at designing Quality into every product and all the processes. Design is surely the most important phase for Quality both of products and processes. Quality Function Deployment (QFD) and Taguchi Methods were both originated in Japan and is claimed as very important for Quality design. They are usually considered synergical for the development of products and processes. Are they good? Productivity improves as the quality of the process moves upwards. The Japanese learned in 1950 that this can be achieved if the process is in control. Economic manufacturing requires quality control and improvement and, consequently, the use of “Quality tools” such as Statistical Process Control, Control Charts, and DOE. The paper will consider show that an incompetent approach to Quality, and to Quality Methods, can do more harm than good.
Galetto, F.
A Role-Playing Paradigm for Teaching Six Sigma QC2001-01-336310/1/2001
Six Sigma is a popular methodology for implementing industrial quality control. Six Sigma seeks to provide a virtually zero product defect rate. Six Sigma combines elements of traditional statistical analysis methods with novel communication and management structures. Industrial training in the Six Sigma strategy has been hampered by the difficulty of presenting these core concepts in communications and management structures in the context of traditional lecture-workbook training schemes. This paper describes a curriculum based on role-playing exercises that seeks to provide a vivid, interactive learning experience for industrial trainees learning the Six Sigma process.
Kashef, Ali E., Timmerman, Marc A.
The Six Sigma Implementation Process2001-01-11093/5/2001
Six Sigma, if implemented successfully, is a strategic business improvement approach that increases both customer satisfaction and an organization’s financial health through systemic process change. In this paper we will be describing a Smarter Six Sigma SolutionsSM (S4) business strategy, which can lead to significant new opportunities and the reduction of fire fighting. This long-term, process focused strategy facilitates companies in identifying and understanding critical business processes such that they become more proactive, as well as productive.
Breyfogle, Forrest W., Meadows, Becki
High Consistency Glass Mat Reinforced Thermoplastic (GMT): Thin Wall Structural Applications with Surface Requirements2001-01-00983/5/2001
Glass fibre mat reinforced thermoplastics (GMT) are now able to be designed for light weight applications with lower than ever before wall thicknesses and high surface finish. This is made possible as result of new material developments using the Azdel chopped fiber technology. Highly isotropic in-plane material properties are now attainable over very long material flow trajectories in combination with the thinnest wall sections. This breakthrough has been enabled by an economical method to maximise the macroscopic fibre-fibre interaction, without loss of mechanical, flow and other performance properties. Further, the fiber content and part weight distribution capability are of the highest quality available, further ensuring that molders and OEMs may design reliably at the lowest part weight.
Peterson, Charles W., Spencer, Dennis O., Rosin, Jonathan, Haque, Enamul
The Effect of ISO 14253-1 Standard on the Quality and Economy of Manufacturing1999-01-308012/1/1999
A norma ISO 14253-1:1998 estabelece que, para provar a conformidade com a especificação, o fornecedor deve criar um intervalo reduzido de aceitação, deslocando os limites de especificação uma quantidade igual à incerteza de medição (U95). Neste trabalho são estudados os efeitos dos deslocamentos dos limites sobre a qualidade e a economia da fabricação. A função perda quadrática da qualidade é usada para calcular o custo de falha interna e externa em lotes sujeitos a inspeção 100% com instrumentos de medição não ideais. Usando simulação computacional, é mostrado que a perda total da qualidade no lote aumenta com o valor dos deslocamentos dos limites, devido à rejeição de unidades que atendem às especificações. The standard ISO 14253-1:1998 establishes that, to prove the conformance with tolerance specifications, the supplier must create a reduced acceptance interval, displacing the specification limits by an amount equal to the value of measurement uncertainty (U95). In this paper the effect of limit displacements on the quality and economy of manufacturing is analysed. The quadratic quality loss function is used to compute internal and external failure costs in batches subjected to 100% inspection with non-ideal measuring instruments. Using computer simulation, it is shown that the total quality loss in the batch is expected to grow with the value of limit displacements due to the massive rejection of conforming units.
Donatelli, Gustavo Daniel, Schneider, Carlos Alberto
Study on Exterior Idling Sound Quality Evaluation Method for Diesel Engine Trucks1999-01-17395/17/1999
In diesel engine trucks, the sound quality improvement as well as the noise level reduction is demanded because of their annoying exterior noise. The semantic differential method was applied to evaluate the sound quality of trucks. In order to improve the analytical accuracy, subjects who can evaluate the characteristics of sound quality were statistically selected among all the subjects. Comfortability and powerfulness were extracted as the principal components by using the data of the selected subjects. It has been clarified that the comfortability strongly relates to high frequency element ratio, high frequency level, etc. The powerfulness strongly relates to the Zwicker loudness.
Sato, Naoki, Miura, Yasuo
A Hybrid Neuro-Fuzzy Based Fault Diagnostic Technique for Bearings Condition-Based Maintenance9812084/6/1998
Vibration monitoring consists of the analysis of vibration data coming from vital components of the plant to detect features that reflect the operational state of the machinery. The condition-based maintenance of the bearing leads to the identification of potential failures and their causes, and make it possible to perform efficient preventive maintenance. Early fault detection in bearings is important because it can decrease the probability of catastrophic failures, reduce forces outage, maximize utilization of available assets, increase the life of the plant, and reduce maintenance costs. Subsequent to developing vibration condition assessment procedures that can distinguish between good and faulty bearings, it is necessary to choose requirements for diagnostics and condition prediction. There are four primary activities about bearing fault diagnosis and prognosis. These activities include: detection of changes in bearing condition during operation, short term prediction of bearing serviceability, determination of the type and degree of severity of all life threatening defects appearing as a result of bearing quality, installation, and operation, and prediction of defect development and determination of guaranteed time for trouble-free operation. In this paper, we discuss a newly developed technique for bearing fault diagnosis and prognosis. The proposed techniques is based on a hybrid neural network-fuzzy logic methodology which integrates explicit and implicit expert's knowledge in recognition and classification of bearing faults. Furthermore, we discuss the critical issues regarding the bearing data acquisition, signal filtering, signal pre-processing, and signal features enhancement. Some applications of this techniques for detection of bearing faults of manufacturing machinery are demonstrated. The proposed approach has a number of applications in both manufacturing and aviation maintenance.
Shirkhodaie, Amir, Muthuswamy, Senthil K., Saravanan, Siva S.
On Determining the Relationship Between Vehicle Value and Interior Noise9806212/23/1998
A PC based survey tool has been used to measure the value of a luxury vehicle as a function of its interior noise level at 70 mph. Two straight lines were required to fit the change in value (measured in dollars) with noise level depending upon whether noise was greater or less than a baseline level of 66 dB(A). The slopes of the lines differed by a factor of two with the value loss curve asociated with a noise increase from the baseline level being the steeper of the two. A difference in the value relationships between gains and losses in this manner is expected from prospect theory. When the noise level in dB(A) was adjusted to represent a sones-like scale using a conversion based upon a broadband noise spectrum, the measurements followed a single straight line reinforcing the view that the sones scale is more nearly a “pure” psychometric scale than dB(A). The results also suggest that, when persons are asked for their willingness to pay, their response threshold for losses is much more sensitive than their threshold for gains. The findings are discussed in terms of their implications on designing automobiles for competitive markets.
Pozar, M., Cook, H. E.
Implementing ISO 9000 through Value Engineering9806222/23/1998
Common Process Initiative, also known as ISO 9000 is the largest and most ambitious Acquisition Reform Innovation ever taken on by the Federal Government. It is fundamentally, a broad based, universally applicable Value Engineering (VE) Program, yet it is not utilizing any of the VE fundamentals. Years of value experience is being lost. The size of the initiative (in financial impact and universality of application); its direct relevancy to the “Cost Reduction Mission” of VE; and its need for enlightened use of the VE contractual protocol and change facilitation techniques, (i.e. VECP's), makes it vital that it be heard at this conference.
Copperman, William H.
Deriving Targeted Interventions for Ground Damage9725918/5/1997
Ground damage is economically important to airlines, but it also represents a source of well-investigated human errors. This study of maintenance-related ground damage incidents at one airline showed a small number of consistent patterns of both the final ground damage events and the latent failures which contribute to these events. This analysis led directly to specific interventions which can be targeted at specific types of ground damage incidents. Beyond ground damage, the technique can be used to focus human factors interventions on other manifestations of error, such as operational incidents.
Wenner, C. A., Drury, C. G.
Managing Multiple Accreditation Programs in Today's Manufacturing Environment9722506/3/1997
Managing the multiple accreditation and registration programs required by industry today requires considerable resources. An analysis of the similarities and differences between programs such as ISO 9000, QS-9000, ARD9000, NADCAP, ISO Guide 25, and the Fastener Quality Act will allow one system to be developed that will meet the multiple requirements of multiple accreditation plans. Understanding the different audit structures and styles of various programs and accreditation bodies allows you to manage the accreditation process instead of you being managed by the accreditation process.
Meyer, Heather, Wagner, William G., Poriss, Sherry, Solomon, Barton S., Campbell, Robert
Evaluating Mail Survey Techniques for Determining the Value of Vehicle Options9707642/24/1997
In developing new products and improving existing products, engineers make numerous trade-offs between the cost of a new or modified feature and its value to the customer. One method for estimating value is to ask potential customers their willingness to pay (WTP) for the product change. Their stated WTP may, however, depend upon how the question is framed. Mail survey techniques based upon simulated choice experiments were used for estimating value to the customer. The main objective was to explore how the framing of the survey questions affected the WTP response and if one or more of the methods provided simulated responses in reasonable agreement with actual buyer behavior. It was found that the best way to frame the questions was to give respondents multiple choices for price of the alternative versus the baseline product as opposed to having a choice of only one price or having to write in a price representing their WTP.
McConville, G. P., Cook, H. E.
Methods for Analyzing the Value of Automobiles9707622/24/1997
Engineers, marketing specialists, and planners responsible for making the numerous cost/benefit trade-offs that arise in the development of a new product need to understand how the attributes of the product generate value to the customer. A recently proposed methodology for benchmarking product value is tested here using five family automobiles competing in the middle product segment. Reasonable agreement is found between value differences estimated from an analysis of demands and prices and those estimated from attribute differences. This finding supports the use of the methodology in forecasting the demands and profits of future products based upon the improvements expected in their attributes.
Donndelinger, J. A., Cook, H. E.
The Elements of a Process Re-Engineering Program - A Case Study at the Boeing Commercial Airplane Group96551210/1/1996
Boeing is currently fundamentally rethinking and radically simplifying the processes related to airplane configuration definition and production. The presentation will describe reasons for embarking on this effort and a description of the fundamental production control processes Boeing will deploy. Process Engineering will be described using Boeing's program as an example.
Bickeboeller, Martin, Strohschnitter, William G.
Fundamentals of Value Benchmarking9600012/1/1996
Cook, Harry E.
Maintenance Integrated System.93165110/1/1993
Deak, Gabor J., Budahazi, Carlos S., Marcon, Sérgio O. H.
A.C.H. Support of aircraft conception; A step in the direction of simultaneous engineering.93160310/1/1993
It was developed a computerized system which generates information, for each aircraft system, concerning predicted components from a design conception phase. This work allows the transference of information among several areas inside the company, contributing to a simultaneous engineering approach which in turn facilitates the material administration along the aircraft conception process. The work philosophy and obtained results are the main themes herein described.
da Cunha Campelo, Antônio
Improving Manual Manufacturing with a Computer Based Laser Projection System93287810/1/1993
The application of computers to manufacturing has been largely in the area of total automation. (CNC, robotics, etc.). This paper describes a computer based laser projection system which is currently in use in several specialized aerospace applications. The system delivers accurate dimensional information directly onto large (meters), complex work surfaces for manual manufacturing tasks. Most manual manufacturing processes can be dramatically improved by delivering electronic dimensional information (CAD data) accompanied by electronically based multi media work instructions directly to the person performing the work. The results of applying this system will be lower costs, higher quality and improved time to market for products which are manually prototyped or manufactured.
Blake, Scott
Rapid Prototyping of Composite Aircraft Structures9312195/1/1993
The faculty, staff and students of the Raspet Flight Research Laboratory (RFRL) have developed a rapid prototyping capability in a series of research aircraft and unmanned aircraft development projects. There has been a steady change in the technologies used to accomplish these tasks at the RFRL. The most recent development has been the utilization of computer graphics and a 5-axis gantry robot router to accelerate the design, moldmaking and parts trimming tasks. The composite structure fabrication processes at the RFRL have evolved from wet-lay-up to autoclave cure. Currently, the feasibility of the stitched composite material preform and resin transfer molding process is being explored. The organizational structure of the RFRL rapid prototyping group has been found to be most important in accomplishing a vehicle development that is technically sound, safe, and reasonable in cost. A close, free interaction among all participants is encouraged since it is essential for correct decisions to be made in the limited time available. Experience shows it is essential for the project leader to be well versed in most aspects of aircraft design, fabrication, and testing. The structural configuration and layout must be established within the framework of concurrent engineering through detailed analysis and design optimization with the fabrication process and test plans as major considerations. Another requirement is to have a very rapid purchasing authority use overnight delivery if necessary to ensure that the materials and supplies are readily available to support the project. The RFRL faculty adopted a plan to invest in advanced computing, automation, and composite processing equipment to enhance the rapid prototyping expertise that has been developed over the years. The recent RFRL experience with the National Aerospace Plane 50 ft. long mock-up student project and a 200 lb. unmanned vehicle airframe development project has shown that the combination of analysis and AUTOCAD 12 (an engineering drawing software), a powerful PC computer, the 5-axis gantry robot router, and the “one-shot” mold process technique can significantly improve the quality and reduce the cost associated with the construction. The use of a stitched composite material preform and the resin transfer mold process holds the promise to produce composite structures with reduced cost, improved crashworthiness, and improved quality. The incorporation of optimization techniques and concurrent engineering in the design holds the promise to produce certificated custom configuration aircraft at current mass production costs levels.
Bennett, George, Rais-Rohani, Masoud, Hall, Kenneth, Holifield, Walt, Sullivan, Rani, Brown, Scott
AIRCRAFT GAS TURBINE ENGINE MONITORING SYSTEM GUIDEARP1587A (Historical)4/1/1993
This SAE Aerospace Recommended Practice (ARP) is a system guide for Engine Monitoring System (EMS) definition and implementation. This keystone document addresses EMS benefits, capabilities, and requirements. It includes EMS in-flight and ground applications consisting of people, equipment, and software. It recommends EMS requirements that are a balance of selected benefits and available capabilities. This ARP purposely addresses a wide range of EMS architecture. The intent is to provide an extensive list of possible EMS design options. NOTE: a Section 3 describes an EMS. b Sections 4 and 5 outline benefits and capabilities that should be considered for study purposes to define EMS baselines for how much engine monitoring is required. c Section 6 provides implementation requirements that should be considered for an EMS after study baseline levels of EMS complexity are selected.
E-32 Aerospace Propulsion Systems Health Management
On the Use of the Principles of Total Quality Management in University Engineering Education9304723/1/1993
This paper describes some considerations for the use of the principles of total quality management (TQM) at universities. A broad discussion on the use of TQM in industry is included. Basic definitions, philosophy of TQM, generic product requirements, and leadership responsibilities are described. The goals are to improve the quality, customer satisfaction, delivery, quantity, responsiveness, cost, etc. of all the university's products (goods and services). The major challenges are for senior leadership to understand TQM and its implications, to redefine organizational goals to include TQM, to obtain faculty support, and to refine organization systems and practices including tenure criteria to facilitate implementation of TQM.
Nordeen, Donald L.
Use of a Repeatable Car to Improve Intra-Lab Variability of Emissions Tests9300773/1/1993
A Repeatable Car (REPCA) program has been developed at the Environmental Protection Agency's National Vehicle and Fuel Emissions Laboratory (NVFEL) as part of an ongoing effort to improve the precision of fuel economy and emissions measurements. This concept of using a repeatable car as an integrated system diagnostic tool is not a new idea in the emissions testing field; however, our statistical analyses and organizational approach may be different from what other laboratories are using. Furthermore, given the NVEFL's role in automotive emissions testing, we felt it appropriate to provide related industries a detailed account of our standard laboratory practices, both for informational and comparative purposes. In order to separate vehicle and measurement variability in a relatively simple manner, a process was developed to track REPCA data based on Statistical Process Control principles using the calculation of individual site offset values from two week moving averages. Eleven individual parameters are monitored for each test site, and the moving averages of these eleven parameters are based on the previous two week's REPCA data. Therefore, a minimum of 44 REPCA control charts are generated and analyzed each week. In conjunction with this, routine equipment diagnostics are also recorded, thus producing an additional 34 control charts. Based on the maintenance history of a specific site and a review of the weekly control charts, recommendations regarding corrective action or preventive maintenance are formulated. Since implementing this program in August of 1990, we have seen a 65% reduction in our site to site testing variability as measured by a comparative inter-laboratory round-robin test program conducted in 1991.
Lindner, Jim, Schrodt, Tom
Value Creation Through Investment and Continuous Improvement9216789/14/1992
Near the end of the 1970's evidence showed that the competitive advantage of alloy steel and tapered roller bearings manufactured in the United States was being challenged by the European and Japanese steel and bearing companies. The response to this challenge by a company that participates in both the steel and bearing markets is presented. The challenge was met with technology applied through investment in plant and equipment and continuous improvement of processes to make steel and bearings. Results of these efforts including new products and comparisons to worldwide benchmarking of steel cleanness are discussed.
Widner, Ronald L.
That-s A Great Technical Solution! Why Isn't Anyone Using It! (Getting the Organization to Internalize Technological Innovation)9221019/1/1992
Many creative and brilliant technical experts have developed innovative technologies only to have them misunderstood, under-valued, and under-utilized by their companies. This paper answers the question: How do we effectively transfer and deploy new technologies and technical approaches across a diverse corporation? A typical scenario finds an R&D team or advanced technology team working on the definition and rollout of new technology or technical strategies. The team has a clear vision of what the corporation needs to do. But how do you get a diverse organization to understand, value, and implement changes to establish practices and activities? Based on over 25 years of experience in technology deployment and transfer, a Technology Implementation Model has been applied and perfected. The Model has four main elements. Key elements of the approach to be presented include: Process Definition and Implementation Planning Training and Change Interventions Implementation Support Evaluation and Continuous Improvement.
Bond, Thomas H., Sweeney, Robert V.
Plant Growth Modeling at the JSC Variable Pressure Growth Chamber: An Application of Experimental Design9213567/1/1992
This paper describes the approach and results of an effort to characterize plant growth under various environmental conditions at the Johnson Space Center variable pressure growth chamber. Using a field of applied mathematics and statistics known as design of experiments (DOE), we developed a test plan for varying environmental parameters during a lettuce growth experiment. The test plan was developed using a Box-Behnken approach to DOE. As a result of the experimental runs, we have developed empirical models of both the transpiration process and carbon dioxide assimilation for Waldman's Green lettuce over specified ranges of environmental parameters including carbon dioxide concentration, light intensity, dew-point temperature, and air velocity. This model also predicts transpiration and carbon dioxide assimilation for different ages of the plant canopy.
Miller, Adam M., Edeen, Marybeth, Sirko, Robert J.
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