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Introduction to Manufacturing Key Product and Process Characteristics

Introduction to Manufacturing Key Product and Process Characteristics. Defense Acquisition Guidebook. “The quality management process shall ...: Establish capable processes Continuously improve processes Monitor and control critical processes and product variation

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Introduction to Manufacturing Key Product and Process Characteristics

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  1. Introduction to Manufacturing Key Product and Process Characteristics

  2. Defense Acquisition Guidebook • “The quality management process shall...: • Establish capable processes • Continuously improve processes • Monitor and control critical processesand product variation • Establish mechanisms for field product performance feedback • Implement an effective root cause analysis and corrective action system. BUT, what are the manufacturing Key Characteristics (of critical process and product features) to focus on to effectively monitor and control products and processes?

  3. Manufacturing Key Product/Process Characteristics(A Risk-Centered Definition) • Features Determined to Be Most Important to User [Product] • Situations With High Probability of Defects Occurring, And/Or Going Undetected if they occur [Process] • Consequences of Failure are Unacceptable • Business loss (loss of business, warranty work) [Product] • Major Environment, Safety, or Health Impacts [Product and/or Process] • High “Re-Do” costs [Process]

  4. “Should Prevent” Efforts: Opportunities for More Waste or Process/Product Variation PROBLEM INVESTIGATION  FAILURE ANALYSIS DISPOSITIONING  CORRECTIVE ACTIONS Such As REWORK REPROCESSING RETEST REINSPECTION REPAIR RETOOLING REPLACEMENT RE-RECORDING RETROFITTING RE-REPORTING REPURCHASING REENGINEERING

  5. Key Characteristics(Another Definition) • A tool to help decide where to focus limited resources. Advanced Quality System for Boeing Suppliers D1-9000 • Note: in the aircraft industry, flight safety and related design features are sometimes called critical characteristics. Key characteristics include these, plus other important parameters.

  6. Key Characteristics(Still another Definition) • Features whose variability has the greatest impact on fit, performance, or service life. • Key characteristics provide a focus for product improvement • Quality is conformance to nominal on all key characteristics • Continuous improvement comes from reducing variation by: • Eliminating special causes • Improving consistency of measurement systems • Control Product by controlling the process • Reducing losses and eliminating waste

  7. KEY Characteristic Identification via Top Down Approach • System Design • Performance • Customer Req’ts • Reliability • Weight • Performance • Cost KEY KEY Subsystem/Component Design Systems Engineering Readability Accuracy KEY Clock KEY Illumination Power Supply Display Assembly Voltage IPT KEY KEY Photo Diode Panel Lamp LCD Manufacturing Current Component Failure Illumination KEY Process Parameters Solder Joints Temperature Time Solder Quality Insertion Depth Hardware Req’ts Voltage Capacitance (C3) Conformal Coating Solder Joints Resistance (R4) KEY KEY KEY KEY KEY Adapted from “Advanced Quality System for Boeing Suppliers” D1-9000

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