Panda / Jurko / Pandová Monitoring and Evaluation of Production Processes

An Analysis of the Automotive Industry
1. Auflage 2016
ISBN: 978-3-319-29442-1
Verlag: Springer International Publishing
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 128 Seiten, eBook

This book presents topics on monitoring and evaluation of production processes in the automotive industry. Regulation of production processes is also described in details. The text deals with the implementation and evaluation of these processes during the mass production of components useful in the automotive industry. It evaluates the effects and results achieved after implementation in practice. The book takes into account the different methodologies of the world's automakers and applicable standards, such as standard EN ISO 9001 and the requirements of VDA and ISO/TS 16949. The content is used to those working with the development, production and quality control of new products in the demanding automotive industry. The information provided may also be useful to engineers and technical staff in organizations working with series production and production of spare parts for the automotive and other demanding industries. The content presented was written based on discussions with various companies and organizations, such as Magna Steyr (Graz, Austria), Ford (Cologne, Germany; Prague, CZ), GM Powertrain (Gyor, Hungary), VW (Škoda), ZF (Passau, Friedrichshafen, Germany), Bosch-Rexroth AG (Fellbach, Germany), John Deere (Mannheim, Germany; USA), Claas (Paderborn, Germany), Allison Transmission (USA), Landini (Reggio Emilia, Milan, Italy), Timken Polska (Sosnowiec, Poland), SNR France (Annecy, France), Sweden SKF Group (Lutsk, Ukraine), ZVL Ltd. (Hattingen, Germany), ZVL SpA (Milano, Italy), FAG Schaeffler Group (Debrecen, Hungary), VPZ (Vologda, Russia), ZKL OJSC  (Brno, CZ), ZVL Auto Company Ltd. (Prešov, Slovakia), ZVL (Žilina, Slovakia), MAN (Munich, Germany), FTE Automotive (Kerpen, Germany), Rösler (Untermerzbach, Germany; Vienna, Austria), Spaleck (Bocholt, Germany) and Caterpillar (USA). This comprehensive study was supported by grant VEGA 1/0409/13.

Zielgruppe

Professional/practitioner

Autoren/Hrsg.

Panda, Anton

Jurko, Jozef

Pandová, Iveta

Inhaltsverzeichnis

1;Contents;6
2;About the Authors;10
3;About the Book;14
4;Symbols and Abbreviations;16
5;1 Introduction;20
6;2 Statement of the Goals of This Work;22
7;3 Analysis of the Current State of the Regulation of Manufacturing Processes;24
7.1;3.1 State of the Problem in Slovakia and Abroad;27
7.1.1;3.1.1 State of the Problem in Slovakia;27
7.1.2;3.1.2 State of the Problem Abroad;28
7.2;3.2 Development Trends;28
8;4 Specification of Problems Solutions;30
8.1;4.1 Regulation of Location the Production Process;33
8.2;4.2 Regulation of Variability (Dispersion) of the Production Process;34
8.3;4.3 Combined Regulation of Location and Variability of the Production Process;35
8.3.1;4.3.1 Control Chart of the Middle Values and Ranges xpriem–R;35
8.3.1.1;4.3.1.1 Calculation of Control Limits for xpriem–R Under STN 01 0265 Before Adjustment;37
8.3.1.2;4.3.1.2 Calculation of the Control Limits for xpriem–R Under STN 01 0265 After Adjustment;41
8.3.1.3;4.3.1.3 Calculation of the Control Limits for xpriem–R Under STN ISO 8258;43
8.3.2;4.3.2 Control Chart of Medians and Ranges xmed–R;43
8.3.3;4.3.3 Control Chart of the Middle Values and Standard Deviations xpriem–S;44
8.3.4;4.3.4 Control Chart of Medians and Standard Deviations xmed–S;44
8.3.5;4.3.5 Control Chart of the Largest and Smallest Selected Value Max–Min;44
8.3.6;4.3.6 Control Chart of the Individual Values xi;45
9;5 Deployment of Regulation of the Production Processes in the Serial Production of a Specific Production Company;47
9.1;5.1 Choice of Regulated Parameters for the Production Process of Tapered Roller Bearing;47
9.2;5.2 Verification of the Statistical Stability of the Process;51
9.3;5.3 Verification of the Technical Stability of the Process;52
9.4;5.4 Selection of the Suitable Method of Regulation of the Production Processes;54
9.5;5.5 Determination of the Prescription of Regulation;55
9.5.1;5.5.1 Object of Detecting the Values of Regulated Variable;56
9.5.2;5.5.2 Time Interval Between Individual Selections;56
9.5.3;5.5.3 Determination of the Regulated Variable (Dimension);57
9.5.4;5.5.4 Method of Sample Collection, Range Selection n, Method of Detecting the Values of Regulated Variable;57
9.5.5;5.5.5 Method of Calculation of the Selected Characteristics;58
9.5.6;5.5.6 Form of the Control Chart;59
9.5.7;5.5.7 Method and Procedure of Recording the Values of Selection Characteristics and Other Data in the Control Chart; the Person Responsible for Conduct and Implementation of SPC;59
9.5.7.1;5.5.7.1 Procedure of the Machine Operator;62
9.5.7.2;5.5.7.2 Procedure of Machine Adjuster;63
9.5.7.3;5.5.7.3 Procedure of the Controller;63
9.5.7.4;5.5.7.4 The Method of Determining xmed;63
9.5.8;5.5.8 Evaluation Process According to the Principles of Regulation;63
9.5.9;5.5.9 Assessment of the Production Process;67
9.5.9.1;5.5.9.1 Analysis of the Diagram Range R;67
9.5.9.2;5.5.9.2 Analysis of the Diagram Range xmed;67
9.5.9.2.1;5.5.9.2.1 Points Outside the Control Limits;68
9.5.9.2.2;5.5.9.2.2 Group Special Points Successively;68
9.5.9.2.3;5.5.9.2.3 Points Which Indicate a Trend;68
9.5.9.2.4;5.5.9.2.4 Groups of Points Very Close to the Mean Value or to the Control Limits;69
9.5.9.3;5.5.9.3 Assessment of the Course of the Production Process—Conclusions;69
10;6 Evaluation of the Capability of the Production Processes;70
10.1;6.1 Determination of the Coefficient of Process Capability cP;71
10.2;6.2 Determination of the Coefficient of Usage of the Process Capability cpk;72
10.3;6.3 Relation Between cp and cpk;73
10.4;6.4 Organizing the Evaluation of Coefficients of the Production Capability of Processes cp and cpk;73
10.5;6.5 Calculation of the Rate of Occurrence of the Reject;75
10.6;6.6 Diagram of Accuracy;80
10.7;6.7 Diagnosis—Assessment of the Course of Production Processes;80
10.7.1;6.7.1 Grinding the Hole of the Inner Ring, the Machine for Bore Cone Bearing Grinding;81
10.7.2;6.7.2 Turning the Height of Outer Rings on the Turning Department Machine for Height of the Cup Bearing Turning;81
10.7.3;6.7.3 Turning the Raceways of Outer Rings, Machine for Raceway Cup Bearing Turning;81
10.7.4;6.7.4 Turning the Raceways of Inner Rings, Machine for Raceway Cone Bearing;82
10.7.5;6.7.5 Turning the Raceways of Inner Rings, Machine for Raceway Cone Bearing Turning;82
10.7.6;6.7.6 Turning the Height of Leaned Fronts the Inner Rings, Machine for Height Cone Bearing Turning;83
10.7.7;6.7.7 Grinding the Raceways of Outer Rings, Machine for Raceway Cup Bearing Grinding;83
10.7.8;6.7.8 Grinding the Raceways of Inner Rings, Machine for Raceway Cone Bearing Grinding;84
10.7.9;6.7.9 Grinding the Leaned Fronts of Inner Rings, Machine for Cone Bearing Grinding;84
10.7.10;6.7.10 Pressing the Length of Tapered Roller, Machine for Pressing of Rollers;85
10.7.11;6.7.11 Grinding the Diameter of Tapered Roller-1. Transition, Machine for Grinding of Rollers Diameter;85
10.7.12;6.7.12 Grinding the Length (Spherical Head) of Tapered Roller, Machine for Grinding of Rollers Length;86
10.7.13;6.7.13 Grinding the Diameter of Tapered Roller-2. Transition of the Machine for Grinding of Diameters of Rollers;86
10.8;6.8 Diagnosis—Summary of the Results of Representative Production Processes Based on the Coefficients of Capability cp, cpk;86
10.8.1;6.8.1 Achievable Status Capability of the Production Processes;88
10.8.2;6.8.2 Achieved—Real Status of the Capability of Production Processes;88
10.9;6.9 Diagnosis—Summary of the Results of Production Processes Based on the Coefficients of Capability cp, cpk Throughout the Production Company;88
10.9.1;6.9.1 Achievable Status of the Capability of Production Processes;89
10.9.2;6.9.2 Achieved—Real Status of the Capability of Production Processes;89
11;7 Evaluation the Capability of Machine;90
11.1;7.1 Flow Chart for the Establishment of the Capability of Machine;90
11.2;7.2 Planning for the Determination of the Capability of a Machine;90
11.3;7.3 Determining the Capability of a Machine;92
11.3.1;7.3.1 Establishing the Minimum Number of Selections;92
11.3.2;7.3.2 Method the Marking Protocols;92
11.3.3;7.3.3 Procedure for Calculating the Coefficients of Capability cm, cmk;94
12;8 Evaluation of the Capability of Gauges;97
12.1;8.1 Flow Chart for Determining the Capability of Gauges;97
12.2;8.2 Rating the Capability of Gauges;97
12.3;8.3 Evaluation of Organization of the Capability of Gauges;104
12.4;8.4 Method of Labelling the Protocols;105
13;9 Capability According to the German Association of the Automobile Industry (VDA 6.1);106
14;10 Method for the Remuneration of Employees, Working in the Controlling System of a Manufacturing Process;107
14.1;10.1 Necessary Conditions for the Introduction of Remuneration;107
14.2;10.2 Method of Remuneration;108
15;11 Automation of the Control of Production Processes;112
16;12 Results and Benefits of the Implementation of Regulation and Further Procedures and Methodologies; Benefits for Science and for Practice;115
17;13 Conclusion;122
18;References;124