today's tough world market environment, need better more demanding, ne

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statistical process control. competitive manufacturing
today's tough world market environment, need better more demanding, need more competitive necessity survive. company cannot rest success past performance expect continue remain successful. There many well known examples companies both large small that were once leaders their field skeletons themselves just plain dead buried. does more competitive? answer simple. Exceed your customers' needs expectations.provide, manner required customer, quality product cost, time, every time. most manufacturing organizations significant cost factor attributed cost purchased materials they range from cost entire product. Because significance purchased material total cost, quality purchased material important essential competitiveness manufacturing organization. This paper will discuss effects quality direct indirect causes that contribute real cost purchased material. measure quality material will described quality factor, Cpk. higher value Cpk, better quality product. measure repeatability material performance. higher number, better consistency performance less variation performance. Therefore, once designed material should consistent enough that variations transparent final product.
2.25 SP=2.25
manufacturing, variation evil! value purchased part low, varies from production lotto-lot, then projected process manufacturing part control, performance will inconsistent, rejects expected, true cost purchased part will significantly higher than price shown purchase order. With abundance cost computers hand held scientific calculators, ability calculate easily attainable. quality factor that based statistical calculation mean value, standard deviation, sigma. difference value between mean value closest spec limit divided sigma. (spec limit mean value) sigma
Cpk=
0.75
Cpk=
SP=4.5
Mini-Circuits
INTERNET http://www.minicircuits.com P.O. 350166, Brooklyn, York 11235-0003 (718) 934-4500 (718) 332-4661
Distribution Centers NORTH AMERICA 800-654-7949 417-335-5935 417-335-5945 EUROPE 44-1252-832600 44-1252-837010
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Mini-Circuits (Sigma Performance) times Cpk. must measure variation control measure tell when gets better worse. need know what works what doesn't work. much manufacturing process varies measured Sigma figures shown, average (AVG) tells where process centered. spread width measured sigma. figures show product distributed. height graph measures often values occur. spread measures values from AVG. product well controlled, there will little variation, more values units will occur nearer target, sigma will small. Manufactured products either good depending whether they what customer wants them Specification limits were measure success, where product within spec good spec bad. enough today's market place just meet spec! figures shown, spec limit (SL) compared product distribution. Product built outside, right spec limit, very bad; even product built just left spec limit good. Small (skinny) Sigma means product will from spec limit close value (very good product, what today's customers demand). compare different processes measuring variation distance from average spec limit. only measure distance terms sigma, shown figures. real distance same both figures (C-B), meaning both processes centered values equal. But, terms product quality, figure bottom superior (4.5>2.25) because variation between units much less given skinnier value sigma. convenience, normalize dividing distance (C-B) sigma (considered relative ideal), capability index, Cpk, figure merit. skinnier higher Cpk, less variation, unit-to-unit.
Mini-Circuits/TECHNICAL SECTION
"goodness" purchased parts, Cpk, will affect actual real cost purchased material. This real cost vary will depend original design specifications describing purchased material. real cost depends both direct indirect costs. These are: Costs additive cost purchased parts: Direct Direct costs poor quality parts: Warranty Scrap repair Inspection/test Indirect costs poor quality parts: Indirect Lost sales-customers switching competition Field trips, retrofits, settlements Downtime, line shut downs, delinquencies, rescheduling Inventory build-up, obsolete material, MRB, material expediting, material shrinkage Engineering changes redesign, documentation changes, material selection separation Indirect Indirect costs, demands manufacturing company's resour esources: system company's resources: Space Manpower, receiving, production control, manufacturing,sales, finance, engineering, accounting, maintenance, house cleaning Utilities (lighting, heating, conditioning, telephone) Capital equipment (testing, incoming inspection production, data processing) Finances, cost maintain higher inventory material Data processing data entry Description costs manufacturer poor quality parts received. When poor quality parts received, manufacturer must maintain incoming inspection department check parts conformance specifications. parts were received with Sigma Performance =1.5, then demands incoming inspection would evaporate. However, this case real world today. Therefore, cost inspection department visually spread amortized percentage total cost material received. However, when poor quality parts received, there direct additional costs that incurred manufacturing organization. These costs include additional testing inspection that additional manpower capital equipment required. addition, there added costs associated with documents DMR, etc.; meetings; purchasing costs such expediting, search alternatives, rescheduling issuing p.o. change orders; engineering costs evaluation test. addition incoming inspection costs, delays incoming material production floor will generate additional manufacturing costs. These include rescheduling smaller production runs (less parts available); inefficiency resources, such manpower machines, increased space requirements WIP; increased material shrinkage increased manufacturing throughput time. results these manufacturing delays costs will cause shipment delays increased manufacturing costs that passed customers. Both factors contributing less competitive position! pursue Mini-Circuits' goal exceed customer's expectations, Mini-Circuits striving achieve 1.5. mixer modulator conversion loss specified statistical terms. vigorously pursuing statistical process control statistical specifications products enable customers receive highest quality value, lowest cost.the competitive manufacturing.
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