TITLE

Proposed Model to Improve Level of Field Quality Control in Roll-type Film Manufacturing Using Notation of Fault Tree Analysis

AUTHOR(S)
Myeong Ho Lee; Jae Ho Bae
PUB. DATE
June 2014
SOURCE
Advances in Natural & Applied Sciences;Jun2014, Vol. 8 Issue 6, p631
SOURCE TYPE
Academic Journal
DOC. TYPE
Article
ABSTRACT
Intense competition among companies makes defect prevention more important than inspection in quality control. Therefore, the focus of management is on approaches to process control, such as statistical process control and engineering process control. This paper presents a method for solving field-level quality problems using the notation of fault tree analysis (FTA), which is one of the deductive methods used in safety or reliability engineering. The method presented can be used to solve problems in the production field quickly. We set engineering characteristics determined from the house- of-quality phase of quality function deployment to level 0 and frequently occurring defect types to level 1. Operation groups, which are designed to be accessed easily by field operators, are set to level 2. Key process operations, which are deduced from the process planning phase of quality function deployment, are set to level 3 and are connected to the results of process mapping between key process input/output variables and production requirements. The level-3 key process operations are divided into three types: constant conditions (type C), conditions that could deteriorate (type N), and controllable conditions (type X). Checklists are used to verify that type-C conditions, which have binary statuses, such as on/off or run/stop, are in the desired states before beginning new work orders. Progress-based maintenance is used to prevent type-N conditions from reaching deteriorated status, and a control chart is used to maintain the desired status of type-X conditions. If abnormal patterns of level 0 are detected, field operators use the proposed defects tree to determine the process control attributes that need to be corrected from level 0 to level 3. Correcting the condition will immediately improve the quality level. The model proposed in this paper is also implemented in a roll-based film manufacturing process to verify its applicability to real problems. This model will be helpful in improving the level of field quality control management of complicated process control attributes in the manufacturing field.
ACCESSION #
97105798

 

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