Total manufacturing assurance : controlling product quality, reliability, and safety

Description

Cover Half Title Title Page Copyright Page Table of Contents Foreword Preface Authors SECTION I: Introduction to TMA Chapter 1 The World of Manufacturing 1.1 Industrial Revolution 1.2 Innovation in Management and Manufacturing 1.3 Industry 4.0 References Chapter 2 Total Manufacturing Assurance 2.1 Strategic Manufacturing Management 2.2 Manufacturing System Control 2.3 System Improvement Monitoring 2.4 Summary SECTION II: Strategic Manufacturing Management Chapter 3 Strategic Operations 3.1 Strategic Planning 3.2 Strategic Planning Path 3.3 Product Assurance Strategy 3.3.1 Reliability, Safety, and Quality Requirements 3.4 Summary Questions References Chapter 4 Innovation and Technology Transfer 4.1 Technology Development 4.1.1 Technology S-Curve & Technology Life Cycle 4.2 Strategic Implications on Technology Commercialization 4.3 Global Technology Transfer 4.4 Summary Questions References Chapter 5 Engineering Economic Analysis 5.1 Economic Analysis 5.1.1 Time Value of Money 5.1.2 Selection of Alternatives 5.1.2.1 Initial Cost 5.1.2.2 Interest Rate 5.1.2.3 Annual Cost or Benefit 5.1.2.4 Economic Life 5.1.2.5 Salvage Value 5.1.2.6 After-Tax Cash Flow 5.2 Proforma Development 5.3 Investment Decision Matrix 5.3.1 Time to Market 5.3.2 Initial Investment 5.3.3 Excess Present Value Index 5.3.4 Benefit-Cost Ratio 5.3.5 Investment Payback 5.3.6 Internal Rate of Return 5.3.7 Ownership 5.3.8 Asset Value 5.3.9 Purchase Investment Analysis 5.4 Summary Questions References Chapter 6 Management Control 6.1 Integrated Management Control 6.1.1 Manufacturing Enterprise Focus 6.2 Decision-Making Using Qualitative and Quantitative Tools 6.2.1 Project Management Networking 6.2.2 Optimization Modeling 6.2.3 Linear Programming 6.3 Tactical Operations 6.3.1 Design for Manufacturing 6.3.1.1 DFM Guidelines 6.3.2 Computer-Integrated Manufacturing 6.3.2.1 Computer-Aided Design 6.3.2.2 Computer-Aided Manufacturing 6.3.2.3 Computer-Aided Process Planning 6.3.2.4 Flexible Manufacturing Cells and Systems 6.3.3 Material Requirements Planning 6.3.3.1 Master Production Schedule 6.3.3.2 Bill of Materials 6.3.3.3 Inventory Record File 6.3.4 Just-In-Time Manufacturing 6.3.4.1 Inventory Exposure 6.3.4.2 Pull-Based Production 6.3.4.3 JIT Implementation 6.3.4.4 Pull-Based Startup 6.3.5 Technology Leveraging 6.3.5.1 Mechatronics 6.3.5.2 Artificial Intelligence 6.3.5.3 Machine Learning 6.3.5.4 Automated Machining/Processes 6.3.5.5 Additive Manufacturing 6.3.5.6 Advanced Robotics 6.3.5.7 Autonomous Technologies 6.3.5.8 Man/Machine Interface 6.3.5.9 Internet of Things 6.3.5.10 Big Data and Analytics 6.3.5.11 Virtual/Augmented Reality 6.3.5.12 Supply Chain Visibility 6.3.5.13 Block-Chaining 6.3.5.14 Cyber-Security 6.4 Expert Systems 6.4.1 Expert System Definition 6.4.2 Expert Systems versus Artificial Intelligence 6.4.3 Expert System Structure 6.4.4 Expert System Development 6.4.4.1 Expert System Domain 6.4.4.2 Domain Expert 6.4.4.3 Knowledge Engineer 6.4.4.4 Expert System Shell 6.4.4.5 The Development Process 6.4.5 Expert System Topical Application Areas 6.5 Summary Questions References Chapter 7 Organizational Leadership 7.1 Motivation 7.1.1 Leadership Style 7.1.1.1 Organizational Psychology 7.1.1.2 Strategic Motivation Model 7.2 Teaming 7.2.1 Basic Assumption Theory 7.2.2 Team Effectiveness 7.2.2.1 Personality 7.2.2.2 Team Composition 7.2.2.3 Reactions to Group Situations Test 7.3 Strategic Human Resource Planning 7.3.1 Performance Appraisal 7.3.2 Organizational Development/Training 7.3.2.1 Stages of Development 7.3.2.2 Technical Development Program 7.3.3 Succession Planning 7.4 Summary Questions References SECTION III: Manufacturing System control Chapter 8 System Definition 8.1 System Definition Activities 8.2 Process Planning 8.2.1 Process Planning for Specific Industries 8.3 Plant Layout and Flow 8.3.1 Plant Layout Analysis 8.3.1.1 The From-To Chart 8.3.1.2 The REL Chart 8.3.1.3 Space-Relationship Diagram and Block Plan 8.3.2 Plant Layout Synthesis 8.4 Material Handling 8.4.1 Material Handling Equations 8.4.2 Automated Guided Vehicles 8.5 Automation 8.5.1 Automation Elements 8.6 Flexible Manufacturing Systems 8.7 Simulation 8.7.1 Simulation Example 8.8 Summary Questions References Chapter 9 Product Manufacturing Degradation Control 9.1 Reliability Engineering and Control 9.1.1 Reliability Fundamentals 9.1.1.1 General Approach to Reliability Improvement 9.1.2 Design for Reliability 9.1.2.1 Part Selection and Control 9.1.2.2 Part Derating 9.1.2.3 Design Simplification 9.1.2.4 Redundancy 9.1.3 Reliability Prediction 9.1.4 Growing Product Reliability Prior to Manufacture 9.1.4.1 Test Data Collection and Analysis 9.1.5 Manufacturing System Modeling 9.1.5.1 Defect Removal Planning 9.1.5.2 PRMDA Technique 9.2 Safety Engineering and Control 9.2.1 Safety Assessment 9.2.1.1 Fault Tree Analysis 9.2.1.2 Failure Mode, Effects, and Criticality Analysis 9.2.2 Safety and the Worker 9.2.2.1 Human Factors 9.2.2.2 Safety Program Planning 9.3 Quality Engineering and Control 9.3.1 Design of Experiment 9.3.1.1 Variable Identification 9.3.1.2 Analysis of Variance 9.3.2 Statistical Process Control 9.3.2.1 The Normal Distribution 9.3.3 Process Capability Analysis 9.3.3.1 Process Monitoring 9.3.3.2 Control Charts for Variables 9.3.3.3 Control Charts for Attributes 9.3.4 Acceptance Sampling 9.3.5 Six-Sigma Fundamentals 9.3.6 Cost of Quality 9.3.6.1 Good Costs of Quality 9.3.6.2 Bad Costs of Quality 9.3.7 Total Quality Management 9.4 Lean Manufacturing Fundamentals 9.4.1 Minimize Waste 9.4.2 Perfect First-Time Quality 9.4.3 Flexible Production Lines 9.4.4 Continuous Improvement 9.5 Manufacturing System Effectiveness 9.5.1 Components of Se 9.5.1.1 Quality Capability 9.5.1.2 Operational Efficiency 9.5.1.3 Achieved Availability 9.5.2 Performance Benchmark 9.5.2.1 Quality Capability Data 9.5.2.2 Operational Efficiency Data 9.5.2.3 Operational Availability Data 9.5.3 Business Decision-Making 9.6 Summary Questions References Chapter 10 System Maintenance 10.1 Reliability, Maintainability, and Availability 10.2 Maintenance Program Planning 10.2.1 Corrective and Preventive Maintenance 10.2.2 Maintenance Planning Process 10.2.2.1 Maintenance-Induced Problems 10.2.2.2 Maintenance Documentation 10.3 Maintenance Strategy 10.3.1 Reliability-Centered Maintenance 10.3.1.1 The RCM Process 10.4 Maintainability Analysis 10.4.1 Maintainability Improvement 10.4.1.1 Automated Fault Isolation 10.4.2 Maintainability Levels and Prediction 10.5 Summary Questions References SECTION IV: System improvement Monitoring Chapter 11 Big Data System Planning 11.1 Data System Organization 11.2 Data System Structure 11.3 Data System Operation 11.3.1 Data Collection 11.3.2 Data Processing 11.3.3 Data Reporting 11.4 Data System Implementation 11.5 Summary Questions References Chapter 12 Data Recording and Feedback 12.1 Organizational Data Communications 12.1.1 Types of Databases 12.1.1.1 Automatic Identification Technology 12.1.1.2 Bar Coding 12.1.1.3 Optical Character Recognition 12.1.1.4 Voice Entry 12.1.1.5 Radio Frequency 12.1.1.6 Vision 12.1.1.7 Magnetic Stripe 12.1.2 Programmable Logic Controller 12.2 Failure Recording, Analysis and Corrective Action 12.2.1 Elements of the FRACA System 12.2.1.1 Responsibility 12.2.1.2 Activity Architecture 12.2.1.3 Reporting 12.3 Summary Questions References Chapter 13 Performance Analytics 13.1 Key Performance Indicators 13.1.1 Production Analytics 13.1.2 Financial Analytics 13.1.3 Customer Service Analytics 13.2 Summary Questions References Appendix: Reactions to Group Situations Test (RGST) Index