Development of Quality System for Engine Assembly

7/28/2019 Development of Quality System for Engine Assembly

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Title - DEVELOPMENT OF QUALITY SYSTEM FOR

ENGINE ASSEMBLY

What is QUALITY?

The various definition of Quality are as follows:-

1. Quality itself has been defined fundamentally relationally. Quality is

ongoing process of building and sustaining relationships by assessing,anticipating and fulfilling stated and implemented.

2. Quality is customers perception of value of Suppliers work output

3. Quality is Fitness for use (Juran)

4. Quality means conformance to requirement (Crosby)

5. Quality is the system of means to economically produce goods &

service which satisfy customer requirements (Japanese Industrial

Standard Comittee)

6. Quality refers to the amount of upriced attributes contained in each

unit of priced attribute (Leffler)

7. Quality is degree of excellence (Webster)

8. Quality is the totality of features and characteristics of product or

service that bears on its ability to satisfy given needs. (American

Society For Quality)

9. Quality, an inherent or distinguishing characteristics a degree of

excellence (American Heritage Dictionary )


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The most commonly used defination is Quality means

conformance to requirement Today in the competitive world Quality

means Customer Satisfaction.

What is Quality Control?

Quality Control(QC) is a system of routine technical activities, tomeasure and control the quality of the inventory as it is being developed.

The QC system is designed to:

(i) Provide routine and consistent checks to ensure data integrity,

correctness, and completeness;

(ii) Identify and address errors and omissions;

(iii) Document and archive inventory material and record all QC

activities.

QC activities include general methods such as accuracy checks on data

acquisition and calculations and the use of approved standardised

procedures for emission calculations, measurements, estimating

uncertainties, archiving information and reporting. Higher tier QC

activities include technical reviews of source categories, activity and

emission factor data, and methods.

What is Quality Assurance?

Quality assurance demands a degree of detail in order to be fully

implemented at every step. For example, Planning could include

investigation into the quality of the raw materials used in manufacturing,

the actual assembly, or the inspection processes used. The Checkingstepcould include customer feedback, surveys, or other marketing vehicles to


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determine if customer needs are being exceeded and why they are or are

not. Actingcould mean a total revision in the manufacturing process inorder to correct a technical or cosmetic flaw.

Quality Assurance(QA) activities include a planned system of reviewprocedures conducted by personnel not directly involved in the inventory

compilation/development process. Reviews, preferably by independent

third parties, should be performed upon a finalised inventory following

the implementation of QC procedures. Reviews verify that data quality

objectives were met, ensure that the inventory represents the best possible

estimates of emissions and sinks given the current state of scientific

knowledge and data available, and support the effectiveness of the QC

programme.

Quality assurance verifies that any customer offering, regardless if it is

new or evolved, is produced and offered with the best possible materials,

in the most comprehensive way, with the highest standards. The goal to

exceed customer expectations in a measurable and accountable process is

provided by quality assurance.

What is Quality System ?

Quality Management System can be defined as a set of policies

processes and procedures required for Planning and execution

(production/development/service) in the core business area of an

organization

Quality Management System Enables the organisation to identify,

measure, control and improve the various core business process that

will ultimately lead to improved business performance


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Steps in Development of Quality System for Engine Assembly

Petrol Engine :-

Process Flow Diagram.

Process Failure Mode and Effect Analysis.

Development of Control Plans.

Development of Audit Sheets(Check Sheets).

Study of Customer Complaint.

Analysis of customer complaint

Explanation on Each Step of Quality System:-

1. Process Flow Diagram


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2. Process FMEA:-

Failure Mode Effect Analysis

History:-

The FMEA process was originally developed by the US military in 1949

to classify failures "according to their impact on mission success and

personnel/equipment safety". FMEA has since been used on the 1960s

Apollo space missions. In the 1980s it was used by Ford to reduce risks

after one model of car, the Pinto, suffered a fault in several vehiclescausing the fuel tank to rupture and it to subsequently burst into flames

after crashes.

What is FMEA?

Failure Mode and Effects Analysis (FMEA) is a tool that examines

potential product or process failures, evaluates risk priorities, and helps

determine remedial actions to avoid identified problems.

FMEA is a procedure for analysis of potential failure mode within a

system for classification by severity or determination of failures effect

upon the system. It is widely used in manufacturing industries in various

phases of product life cycle.

An FMEA is a form of Brainstorming that generally follows a Cause and

Effect Analysis or Process mapping and it is usually followed by a Pareto

Analysis. It is a granular analysis of a process, a system or a product

design for the purpose of identifying possible deficiencies. It is generally

conducted by a cross functional group with all the participants having a

stake or knowledge about the process, system or product being assessed.


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When to use it?

Failure mode and effect analysis is primarily a quality-planning tool. It is

useful in developing features and goals for both products and processes,

in identifying critical product/process factors and designing

countermeasures to potential problems, in establishing controls to prevent

process errors, and in prioritizing process subunits to ensure reliability.

Types of FMEA:-

1. Process Analysis of Manufacturing and Assembly process2. Design Analysis of Product prior to production

3. Concept Analysis of Systems or Subsystems in the early design

Concept Stages

4. Equipment Analysis of Machinery and Equipment Design before

Purchase

Salient Features of FMEA

First Time Right

Identifies inadequacies in the development of the product

Test and trial may be limited to a few products

Regulatory Reasons

Continues Improvement

Preventive (not Corrective) Approach

Team Building

Required by Procedures


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FMEA Benefits

The FMEA analysis procedure is a tool that has been adapted in many

different ways for many different purposes. It can contribute to improved

designs, products and processes, resulting in:

Reducing the likelihood of customer complaints

Reducing the likelihood of campaign changes

Reducing maintenance and warranty cost

Reducing the possibility of safety failure

Reducing the possibility of extended life or reliability failure Reducing the likelihood of Product Liability claim

3. Development of Control Plan:-

The intent of a process control plan is to control the product

characteristics and the associated process variables to ensure capability

(around the identified target or nominal) and stability of the product over

time.

The Process Control Plan assures that the good improvements established

by your project will not deteriorate once the improved process is returned

to the process owners. Control plan is means of setting out practices,

resources, and sequences of activities relevant to the quality control of a

particular product, service, contract, or project.

The process Failure Modes and Effects Analysis (FMEA) is a document

to identify the risks associated with something potentially going wrong

(creating a defect - out of specification) in the production of the product.

The FMEA identifies what controls are placed in the production process

to catch any defects at various stages on the processing.


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Development of System for Engine Assembly

The system for Engine assembly is developed as follows:-

.We have studied the total process for petrol Engine. After that

we studied different component their product and process

characteristics, same component for different Petrol Engine. Torque

for various component was taken, type of nuts, bolts, studs. The whole

data was collected then started Process Flow Diagram. After process

flow diagram was finished, we started FMEA. After FMEA ,we

started Control Plans. After that we Started Control Plans, Check

Sheets were completed.

Process flow Diagram


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FMEA:-

.A process FMEA should begin with a Flow chart/ Process Flow

Diagram of the general process. The Process FMEA Chart is explained as

follow:-

1. Process Function

Enter the simple description of the process or

operation being analyzed. Indicate the purpose of process or operation of

which is analyzed. The process where numerous operation are present ,

the operation must be list as separate operation.

2. Potential Failure Mode

Potential Failure Mode is defined as the

manner in which the process could potentially fail to meet the process

requirements and design intent. It can be the cause associated with failure

of previous operation. In preparing FMEA the assumption is made that

incoming parts/materials are correct. The various failure modes are

Bent, Binding, Burred, Handling Damaged, Cracked, Deformed, Dirty,

Improper Set up.

3. Potential Effect of Failure:-

Potential Effects of Failure are defined as

the effects of failure mode on the function perceived by customer. The

effect of failure must be described what customer experience and itshould be clearly mentioned the function could affect safety or

noncompliance to regulations. The effect should be properly stated in

specific system. The various types of potential effect of failure are

Noise, Erratic operation, Poor Appearance, Unstable, Intermittent

operation, Rough, Inoperative, Unpleasant odor.


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4. Severity:-

Severity is an assessment of the seriousness of effect of

potential failure mode to the next component, subsystem, system or

customer if it occurs. Severity applies to the effect only. A reduction in

Severity Ranking Index can be effected only through a design change.

Severity should be estimated on a 1-10 scale.

Evaluation Criteria:-

EFFECT RANKING

Hazardous without warning 10

Hazardous with warning 9

Very High 8

High 7

Moderate 6

Low 5Very low 4

Minor 3

Very minor 2

None 1

5. Potential Mechanism of Failure:-

Potential Cause of Failure is

defined as how the failure could occur, described in terms of

something that can be corrected or can be controlled. The causes

should be described so that remedial efforts can be aimed at those

cause which are pertint. Failure causes may include Improper torque,

Improper weld, Improper Heat treat, Part Missing.

6. Occurrence :-


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Occurrence is how frequently Failure cause/

mechanism is projected to occur. The occurrence ranking has a

meaning rather than a value.

Probability of Failure Possible Failure Rates Ranking

Very High 1 in 2 10

1 in 3 9

High 1 in 8 8

1 in 20 7

Moderate 1 in 80 61 in 400 5

1 in 2000 4

Low 1 in 15000 3

Very Low 1 in 150000 2

Remote 1 in 1500000 1

7. Current Process controls:-

Current process control are descriptions of

the controls that either prevent to the extent possible the failure mode

from occurring. The evaluation may occur at the subject operation. There

are three types of process controls to consider

1. Prevent the cause or failure mode from occurring or reduce their rate

of occurrence.

2. Detect the cause and lead to corrective actions

3. Detect the failure mode.

8. Detection:-

Detection is an assessment of the probability that the

proposed type failure mode is detected. Do not assume that Detection


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ranking is low because occurrence ranking is low. Random quality checks

are unlikely to detect the existence of an defect and should not influence

the detection ranking.

Evaluation Criteria:-

Detection Ranking

Almost Impossible 10

Very Remote 9

Remote 8

Very Low 7

Low 6

Moderate 5

Moderately High 4

High 3

Very High 2

Almost Certain 1


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10.Risk Priority Number (RPN):-

.The Risk Priority Number is the

product of Severity, Occurrence and Detection Ranking.

RPN = S*O*D.

.The Range of value of RPN is 1-1000. Incase where the RPN is

high then special attention is to be given.

11.Recommended Action:-

When the Failure modes have been rank

ordered by RPN, corrective action should be first directed at the highest

ranked concerns and critical items. The intent of any recommended action

is to reduced Severity, Occurrence and Detection Ranking.

12.Action taken:-

After an action has been implemented, enter a brief

description of action.

13. Resulting RPN:-

After corrective action has been taken, then

Severity ,Occurrence and Detection again should be recorded. The RPN

has to be calculated again.


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4. Audit Sheets:- The following is the Check Sheet which can

checks/assess the process and product characteristics.

Check Sheet

Area :- Engine Assembly

Sub Assembly-Block Sub Assembly

Station:-MB Cap Tightening

SR.NO Description Specification Actual Remark

1 Tightening TorqueTightening Torque should be 5.55% Kgm

2

Malleting of MB Caps before

Tightening Malleting

3 Socket ConditionNo Wear and Tear of Socket andNo crack

4 Calibration of Nut Runner It is to be Calibrated after 15 Days


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Critical To Quality

CTQs (Critical to Quality) are the key measurable characteristics of

a product or process whose performance standards or specification

limits must be met in order to satisfy the customer. They align

improvement or design efforts with customer requirements.

It is Specific, measurable characteristics of a product or process

that are identified by customers as necessary for their satisfaction

CTQs represent the product or service characteristics that are

defined by the customer (internal or external). They may include

the upper and lower specification limits or any other factors related

to the product or service. A CTQ usually must be interpreted from

a qualitative customer statement to an actionable, quantitative

business specification.

.There are 8 CTQ(Critical To Quality ) Stations in Engine

Assembly which are as follows:-

1. MB Cap Tightening.

2. Conrod Tightening.

3. Cylinder Head Valve Leakage Testing.

4. Cylinder Head Tightening.

5. Idler Bolt Tightening.6. Belt Tensioning.

7. Rocker Arm Setting.

8. Oil And Water Leakage Testing.


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Seven Quality Control Tools for Problem Solving:-

Kaoru Ishikawa developed seven basic visual tools of quality so

that the average person could analyze and interpret data.

These tools have been used worldwide by companies, managers of

all levels and employees.

The Seven QC tools for Problem Solving are as follows:-

1. Pareto diagrams

2. Cause & Effect diagram Ishikawa diagram Fishbone diagramCheck sheet

3. Stratification

4. Check sheets

5. Histogram & frequency distributions

6. Scatter diagrams (concept of correlations)

7. Graph & control charts

1. Pareto charts

Definition: A bar graph used to arrange information in such a way that

priorities for process improvement can be established. A Pareto chart is a

special type of bar chart where the values being plotted are arranged in

descending order.

Purposes:

1. To display the relative importance of data.

2. To direct efforts to the biggest improvement opportunity by

highlighting the vital few

in contrast to the useful many.


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Pareto diagrams are named after Vilfredo Pareto, an Italian sociologist

and economist, who invented this method of information presentation

toward the end of the 19th century.This method was made popular by

Joseph Juran. The basic underlying rule behind Pareto's law is that in

almost every case, 80% of the total problems incurred are caused by 20%

of the problem cause types; such as people, machines, parts, processes,

and other factors related to the production of the product. The Pareto

diagram is a graphical overview of the process problems, in ranking order

of the most frequent, down to the least frequent, in descending order fromleft to right. Thus, the Pareto diagram illustrates the frequency of fault

types. Using a Pareto, you can decide which fault is the most serious or

most frequent offender.

28

16

12 12

64 3

0

5

10

15

20

25

30

Loose

Threads

Incorrect

hemming

Stitching

flaws

Trim

Errors

Button

problems

Color

mismatch

Material

flaws


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2. Ishikawa Diagram:-

Definition: A graphic tool used to explore and display opinion about

sources of variation in a process. (Also called a Cause-and-Effect or

Fishbone Diagram.)

Purpose: To arrive at a few key sources that contribute most significantly

to the problem being examined. These sources are then targeted for

improvement. The diagram also illustrates the relationships among the

wide variety of possible contributors to the effect.

The basic concept in the Cause-and-Effect diagram is that the name of a

basic problem of interest is entered at the right of the diagram at the end

of the main "bone". The main possible causes of the problem (the

effect) are drawn as bones off of the main backbone. The "Four-M"

categories are typically used as a starting point: "Materials", "Machines",

"Manpower", and "Methods". Different names can be chosen to suit the

problem at hand, or these general categories can be revised. The key is to

have three to six main categories that encompass all possible influences.

Brainstorming is typically done to add possible causes to the main

"bones" and more specific causes to the "bones" on the main "bones".

This subdivision into ever increasing specificity continues as long as the

problem areas can be further subdivided. The practical maximum depth

of this tree is usually about four or five levels. When the fishbone is

complete, one has a rather complete picture of all the possibilities about

what could be the root cause for the designated problem


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3. Stratification:-

A technique used to analyze/divide a universe of data into homogeneous

groups (strata) often data collected about a problem or event represents

multiple sources that need to treated separately.

It involves looking at process data, splitting it into distinct layers (almost

like rock is stratified) and doing analysis to possibly see a different

process.

Dividing the data up into different strata is called stratification

Neither improvement nor control is possible withoutstratification

Must for achieving control & for detecting problems

Used for studying improvement measures

Data stratification

Different conditions

Causes

Locations

Lots

e.g. stratify by type of defect, raw material, day, shift, time, group,

person, machine, process, operating method, weather, measuring

instrument, jig, tool, etc

5. Check Sheet

Description

A check sheet is a structured, prepared form for collecting and analyzing

data. This is a generic tool that can be adapted for a wide variety of

purposes.


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When to Use a Check Sheet

When data can be observed and collected repeatedly by the same

person or at the same location. When collecting data on the frequency or patterns of events,

problems, defects, defect location, defect causes, etc.

When collecting data from a production process.

Check tick / tally

Reliable data collection tool

Simple format just ticks & no calculations


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Development of Quality System for Engine Assembly

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