Application of Quality Control Techniques -LARGE
beanlad
Assignment_2_2017-18.pdf
1
2 of 3 Assignment brief number (e.g.1 of 1, 1 of 2 etc.) ASSIGNMENT FRONT SHEET
Student Name MAG Group EGP0025
Unit Number Unit 30 Unit Title Quality Assurance and Management Start Date w/c: 16/10/17 Deadline w/c: 20/11/17
Qualification Pearson BTEC Higher National Certificate/Diploma in Manufacturing Engineering Assessor Name G. Preston
Assignment Title Application of Quality Control Techniques
The purpose of this assignment is to (learning outcomes or aims): This assignment will give you the opportunity to demonstrate your understanding of the common elements associated with quality control techniques. It will allow you to explore QC principles and techniques and allow you to apply them so as to assist with problem solving and quality management within a manufacturing engineering organisation.
Vocationally Relevant Scenario: Nexus Motor Company is an automotive company which manufactures and assembles a number of luxury vehicles in a number of market segments. Nexus has recently merged with Xeon and is working towards the successful implantation of its quality assurance system. There are however a few teething problems relating to the production function, namely around quality control techniques and their application. It is your job as the lead operative within the production ‘Kaizen Team’ to provide information and guidance so as to overcome barriers and assist with consistency and continuity in terms of quality within the production function.
Tasks Targeted Criteria (listed in full, as detailed in specification) Deadline
Task 1a: As the lead operative within the production kaizen team you have been asked to create a report on the techniques highlighted which can be shared with all production operatives. Task 1b: Provide a table showing books, catalogues, journals and websites that have been used to research the above tasks. Task 1c: You have been tasked to investigate the production line and determine the workstation which is most cause for concern
AC3.1‐ Report on the applications of quality control techniques M2‐ Select/design and apply appropriate methods/techniques
AC3.1‐ Report on the applications of quality control techniques M3‐ present and communicate appropriate findings
w/c: 20/11/1
a) In the first instance you should use the data from table 1.1 in case study 1 to apply an appropriate quality control technique in order to determine which workstation is most cause for concern. Comment on your findings and select with justification a set of sample data from table 1.2 in case study 1 that needs to be interrogated.
b) You should then access the fastening diameter sample data in case study 2 which is most relevant to your findings and use appropriate SPC tools to generate a control chart that shows:
Mean value of the components in question
Control limits up to 3 standard deviations from the mean (+ and ‐)
Finally you should use the data that you have derived in to calculate the ‘standard scores’ (z‐scores) for the components. You should plot these score on the chart between the relevant deviation values; from this you should justify the use of the technique in order to conclude you findings.
It should be noted that the ideal variation (specification) for the component sizes should be within +1σ and ‐1σ. c) As the lead Kaizen operative you should comment on your findings and data. What conclusions can be drawn from your investigation? What are the next steps in assuring quality within the process?
M1 – Identify and apply strategies to find appropriates solutions D1‐ Use critical reflection to evaluate own work and justify valid conclusions M3‐ present and communicate appropriate findings D3‐ Demonstrate convergent/lateral/creative thinking M3‐ present and communicate appropriate findings
Task 2: Using the details and data in case study 2 determine the process capability for the door assembly line.
You should comment on your findings and propose decisions for the process moving forward.
AC3.2 – Apply quality control techniques to determine process capability
w/c: 20/11/17
Task 3a: Use appropriate software packages to collect, present and analyse the data in relation to the failures discussed in case study 3.
You should identify the process causing and the shift most responsible for headliner process failures; it is recommended that the use of
AC3.3‐ Use software packages for data collection and analysis.
w/c: 20/11/17
sequential application of quality improvement tools is applied using software.
Task 3b: Once you identify the process failure you should establish the cause, again you should use a quality improvement tool to do this. You should comment on your findings and make a decision/recommendation of the way(s) forward so as to eliminate the process failure. Again any analysis/findings should be presented using associated software.
D2‐Take responsibility for managing and organising activities
In addition to the above PASS criteria, this assignment gives you the opportunity to submit evidence in order to achieve the following MERIT and DISTINCTION grades
Grade Descriptor Indicative characteristic/s Contextualisation
M1 – Identify and apply strategies to find appropriate solutions.
Effective judgements have been made.
Task 1c: Requires you to apply quality control techniques in order to identify problems. From this you are required to select and use a data set relevant to your findings so as to effectively solve the problem.
M2 – Select/design and apply appropriate methods/techniques
A range of sources of information has been used. Task 1b: Produce a table showing the books, catalogues, journals and websites that have been used to research the task.
M3 – Present and communicate appropriate finding
A range of methods of presentation have been used and technical language has been accurately used.
Task 1c (a‐c): This task requires you to present your findings using calculations, charts and table. In addition written communication/findings must include the use of technical language.
D1 ‐ Use critical reflection to evaluate own work and justify valid conclusions
Conclusions have been arrived at through synthesis of ideas and have been justified
Task 1c (b): You should justify the technique used to project your data and comment on its effectiveness in order to make conclusions from your findings.
D2 – Take responsibility for managing and organising activities
Activities have been managed The unforeseen has been accommodated
Task 3b: You should make decisions on the way forward as a result of your findings in task 3a. You should use a suitable technique to plan and accommodate for the unseen.
D3‐ Demonstrate convergent/lateral/creative thinking
Ideas have been demonstrated and decisions taken
Problems have been solved
Task 1c (c): You are to make decisions and generate ideas from your investigation. You can the highlight what the next steps are in assuring quality within the process so as to assist with solving the problem.
This brief has been verified as being fit for purpose:
Student Declaration:
Assignment Author
G. Preston Signature Date 31/08/2017 On submission: I certify that the work submitted for this assignment is my own and research sources are fully acknowledged. Student Signature:
Internal Verifier
M. Rosenthal Signature Date 31/08/2017
This brief covers: Supporting Information (what you need to do)
Task 1: Report on the applications of quality control techniques
AC3.1‐ Report on the applications of quality control techniques M3 – Present and communicate appropriate finding (A range of methods of presentation have been used and technical language has been accurately used) M2 – Select/design and apply appropriate methods/techniques (A range of sources of information has been used.)
AC3.1‐ Report on the applications of quality control techniques M1 – Identify and apply strategies to find appropriate solutions (Effective judgements have been made) M3 – Present and communicate appropriate finding (A range of methods of presentation have been used and technical language has been accurately used) D1 ‐ Use critical reflection to evaluate own work and justify valid conclusions (Conclusions have been arrived at through synthesis of ideas and have been justified)
Task1a: The work for this task should be presented as a written report. You should report on how the techniques are used and applied within a manufacturing/production environment. The aim is for you to demonstrate the application of the following quality control techniques:
J.I.T Kanban MRP SPC Acceptance sampling
Task 1b: For this part of this task you should produce a table showing the books, catalogues, journals and websites that have been used to research the task. You should discuss which of these you did use and which you decided not to take information from? Why did you make the decision not to use these sources?
Task1c (a&b): For these tasks you will be expected to use the information and data in case study 1, table 1.2.
Points to consider: Make sure you select an appropriate SPC tool and remember to make judgement from the recommended specified values/variations.
In the first instance you should demonstrate the effective use of calculation from the data. You will be expected to derive the mean and standard deviation values using the relevant calculations/methods. You should present all calculations in report form (excel or word is sufficient).
For the next stage a control chart should be drawn using graph paper (as minimum), again computer programs can be used but I will expect additional information (in the form of instructions) on how you used the program to generate your graph. The control chart should be used to show the 3 standard deviations from the mean for the data provided.
Your next task will be to use the ‘z‐score’ formula to calculate/convert the first 10 component values so that they can be inserted into the standard distribution chart as standard scores, again you should present all calculations in a report form (excel or word is sufficient).
When presenting this data on the chart you will be required to highlight: a)the standard deviation value b)the initial component value c)the component number
M3 – Present and communicate appropriate finding (A range of methods of presentation have been used and technical language has been accurately used) D3‐ Demonstrate convergent/lateral/creative thinking (Ideas have been demonstrated and decisions taken) (Problems have been solved) Deadline: w/c: 20/11/17
This will provide a clearer view of the data which will allow you to refer and comments more effectively when writing your report for part 1c (c).
Task1c (c): The aim here is for you to consider what decisions should be taken as a result of the ideas and conclusions you generate. You may want to draw on prior learning and previous experiences in relation to quality assurance and relevant TQM techniques.
This task requires you to use case study 1. Below is the question for ease of reference: Task 1a: As the lead operative within the production kaizen team you have been asked to create a report on the techniques highlighted which can be shared with all production operatives. Task 1b: Provide a table showing books, catalogues, journals and websites that have been used to research the above tasks. Task 1c: You have been tasked to investigate the production line and determine the workstation which is most cause for concern a) In the first instance you should use the data from table 1.1 in case study 1 to apply an appropriate quality control technique in order to determine which workstation is most cause for concern. Comment on your findings and select with justification a set of sample data from case study 2 that needs to be interrogated.
b) You should then access the fastening diameter sample data in case study 2 which is most relevant to your findings and use appropriate SPC tools to generate a control chart that shows:
Mean value of the components in question
Control limits up to 3 standard deviations from the mean (+ and ‐)
Finally you should use the data that you have derived in to calculate the ‘standard scores’ (z‐scores) for the components. You should plot these score on the chart between the relevant deviation values; from this you should justify the use of the technique in order to conclude you findings.
It should be noted that the ideal variation (specification) for the component sizes should be within +1σ and ‐ 1σ. c) As the lead Kaizen operative you should comment on your findings and data. What conclusions can be drawn from your investigation? What are the next steps in assuring quality within the process?
Task 2: Apply quality control techniques to determine process capability AC3.2 – Apply quality control techniques to determine process capability Deadline: w/c: 20/11/17
This task will enable you to show the relationship between specification limits and control chart limits. You should consider using the process capability index and check process variability if required. The following formula may assist.
This task requires you to use case study 2. Below is the question for ease of reference: Task 2: Using the details and data in case study 2 determine the process capability for the door assembly line.
You should comment on your findings and propose decisions for the process moving forward. Task 3: Use software packages for data collection and analysis. AC3.3‐ Use software packages for data collection and analysis. D2 – Take responsibility for managing and organising activities (Activities have been managed) (The unforeseen has been accommodated) Deadline: w/c: 20/11/17
Task 3a: For this task you should apply quality techniques that allow you to collect, analyse and present the failure data so as to assist with solving the overall problem. You should use software packages to generate tables and charts. In the first instance you should consider using a checklist or tally cart to correlate the failure date, from this you will be expected to carry out a Pareto analysis in order to identify the major process failures. It is then recommended that you produce a histogram/bar chart that proportions the failure across the three shifts.
Task 3b: You will be expected to carry out a cause and effect analysis relating to the process failure. From this you will be expected to link this to your previous findings (proportion of defects per shift) and recommend the way forward so as to eliminate the process failure. You should use software packages to generate the cause and effect diagram.
This task requires you to use case study 3. Below is the question for ease of reference: Task 3a: Use appropriate software packages to collect, present and analyse the data in relation to the failures discussed in case study 3. You should identify the process causing and the shift most responsible for headliner process failures; it is recommended that the use of sequential application of quality improvement tools is applied using software.
Task 3b: Once you identify the process failure you should establish the cause, again you should use a quality improvement tool to do this. You should comment on your findings and make a decision/recommendation of the way(s) forward so as to eliminate the process failure. Again any analysis/findings should be presented using associated software.
8
Case Study 1
Now that Xeon has fully merged with Nexus, Nexus has to ensure quality control techniques are being applied. There is still some hesitation between production workers in understanding how the ‘quality control’ techniques can be applied and why they are necessary for assuring quality within the production system.
In addition to this one of the production lines which is responsible for door assembly has recently been hit with a number of stoppages as a result of poor quality in relation to fastenings and fixtures. The door assembly line consists of 5 workstations. The following data has been captured over a 10 hour period.
Table 1.1 Stoppage Data
Workstation Stoppages over a 10 hour period
3 3 5 3 4 3 2 5 1 2 3 2 5 2 3
9
Case Study 1
Table 1.2: Fastening diameters for workstations 1‐5. (Samples taken at rate of 1 per hour over a 10 hour period).
Workstation 1: Fastening and Sizes Workstation 2: Fastening and Sizes Workstation 3: Fastening and Sizes
Fastening No Size Fastening No Size Fastening No Size 1 33 1 65 1 20 2 33 2 39 2 34 3 40 3 42 3 66 4 40 4 37 4 65 5 38 5 39 5 34 6 55 6 55 6 19 7 41 7 41 7 20 8 42 8 66 8 55 9 39 9 65 9 60 10 38 10 38 10 65
Workstation 4: Fastening and Sizes Workstation 5: Fastening and Sizes
Fastening No Size Fastening No Size 1 26 1 39 2 33 2 38 3 65 3 35 4 28 4 31 5 34 5 27 6 55 6 20 7 25 7 15 8 44 8 15 9 50 9 18 10 36 10 35
10
Case Study 2
After analysing the fastenings and fixtures issue the engineering management at Nexus decided to do a time and motion study of the door assembly line.
It was found that the average time for a door to be completely assembled was 26.2 minutes with a standard deviation time of 1.35 minutes. The nominal value for the production line is 25 minutes with an upper specification limit of 30 minutes and a lower specification limit of 20 minutes. The management initially wants to have four sigma performance on the assembly line.
Case Study 3
In another area of production in which the headliners are fitted to the roof interior of the car there have been a number of process failures at the point of fit.
There are three shifts that work on the roof fit. Table 3.1 shows the data for headliner failures and proportion of failures per shift.
Table 3.1 Headliner Failures
Process failure Number of Fails Proportion of fails per shift (%)
Shift A Shift B Shift C
A. Tears in fabric 12 33 33 33
B. Discoloured Fabric 9 20 50 30
C. Broken Fibre Board 60 30 50 20
D. Ragged Edges 8 20 20 60
