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Process Control Power Point

Date post: 09-Jun-2015
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Page 1: Process Control Power Point

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Process Control

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History - Silk Pliny, 70 B.C. wrote about silk. Artifacts date silk making back 6,000 – 7,000 years. Smuggling silk worms or knowledge of the process was punishable by death. Chinese kept the art of silk-making secret for thousands of years to avoid

international competition.

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Silk Worms – A Process Silk worms are very fragile and

require the right amount of light and water.

The little buggers have a supply chain for food. Mulberry Tree leaves.

Waste byproduct is the boiled caterpillar. Villagers eat them.

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Process Control

Sumerians brewed beer by following instructions written on clay tablets.

Several varieties of beer from that time.

5,000 – 3,000 B.C. Ancient recipes have

been reformulated by doing chemical analysis of vase residue.

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History – Olive Oil 1st Century B.C. The Amphora

was one of the first known seals of product quality.

A fortune in olive oil was presented to the winner of the athletic games during the celebration of Panathenea. A sample of the prize olive oil was presented in a "Panathenaic Amphorae". .

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Early Smelting Parameters 3rd century B.C. Sri

Lanka – Steel for Swords.

Three tree species were used for charcoal. Marang Path Beriya Damba

Iron ore Only three mineral deposit

sites were used 3 cm size hewn ore pieces Iron oxide content of 79% -

87%

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History – Damascus Steel

By the 3rd century A.D. the military had picked up on quality.

Damascus steel swords are among the strongest, flexible yet strong.

They could cut other swords in half without any damage.

A delightful combination of killing effectiveness and art.

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History – Samarai Sword 700 A.D. Making swords became

an art form wrapped in mystery, science, and with quality functional and aesthetic attributes. Early civilization arms race.

Process control was extremely personal.

Samarai swords made Damascus steel swords look like clumsy and cumbersome.

About 30 winners of the Japanese Sword-making contest each year.

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History - Glass

4th century Roman Glass.

How was such an intricate and fragile object created?

How would we control the process?

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Common Attributes of Silk, Beer, Olive Oil, and Steel? They are aesthetic. They require a form of technology. They are not created by serendipity. They have value. Some production processes were secret. They define a country and a culture. They cannot be made without a process. A posteriori and actual evidence suggests

process control.

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Beginning of Modern Process Control

In the 13th century Guild craftsmen put a mark on the product they made.

It began as a way to track someone down.Voice of the customer.

Due to incentives, it became a mark of craftsmanship and quality.

In contemporary times some machinists still stamp their initials into the product they make.

Pride in workmanship.

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Tools for Process Control

A plan Evaluation criteria

Dimensional Visual Tactile

Parameters - tolerances Evaluation instructions? Word of mouth? Checking frequency?

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AIAG Control Plan

Sample

http://www.aiag.org/ CONTROL PLANFM-75-12 - Downloaded 9-23-09

  Prototype Prelaunch   Production Key Contact/Phone    Date(Orig)   Date (Rev.)  

Control Plan Number                      

Part Number/Latest Change Level     Core Team       Customer Eng. Approval/Date

 

Part Name/Description       Organization/Plant Approval/Date   Customer Quality Approval/Date (if Req'd)

Organization/Plant   Organization Code

Other Approval/Date (If Req'd)   Other Approval/Date (If Req'd)

 

 

    Characteristics   Methods        

Part/ Process Number

Process Name/ Operation

Description

Machine, Device, Jig, Tools, for

Mfg.

No.

Product Process Special Char. Class

Product/Process Specification/

Tolerance

Evaluation/ Measurement

Technique

SizeFreq

.

Control Method

Reaction Plan

                         

                         

 

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Control Plan Elements

Header Information Product/part Contact(s) Print revision Organization Team members

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Control Plan Elements

Plan Information Product/part number Process number (linked to flow diagram) Machine(s) used Product or process characteristics being

monitored. Special characteristics.

Either from the drawing.Or based on tacit knowledge.

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Control Plan Elements, cont. Product or process tolerance. Measurement technique

The device or tool used to measure the product or process.

Sample size. Frequency of picking samples.

This is based on probability and risk. Control method.

In what form in the process control data going to be maintained?

Out of control protocol.

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Why Process Control?

•Some isometric views can be seen from two different perspectives – looking up from underneath of looking down from above.• The customer may have had the same issue and a complaint was forwarded with no corroborating data.

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Why Process Control?

Crane:

This made the last dimension short by about 1/8”. This caused the part to not function properly. The error was not caught by the press operator, not caught by the machinist, (the out of spec flange was drilled), not caught by the welder, (the out of spec flange had a pin welded into it), and was likely not inspected.

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Why Process Control?

The base plate was not square.

A control plan would have had a check for this.

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Process Control

The base plate, foot, is not perpendicular to the post.

This is a critical functional characteristic.

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Questions

Does it make sense to improve our process control?

Why? Why not?

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Group Assignment PowerPoint Presentation

Pick an object or a commodity that has its roots going back thousands of years.

Describe its quality characteristics Aesthetic Functional

Conjecture and create a process control plan that may have existed prior to modern times.

Summarize the implications for modern society.


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