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

Myeong Ho Lee; Jae Ho Bae
June 2014
Advances in Natural & Applied Sciences;Jun2014, Vol. 8 Issue 6, p631
Academic Journal
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.


Related Articles

  • Causal tree analysis for quality control of the lead acid battery manufacturing process. Yahmadi, Raja; Brik, Kais; Ammar, Faouzi ben // International Journal of Energy Research;Mar2018, Vol. 42 Issue 4, p1738 

    Summary: The aim of this paper is the quality control of the manufactured lead acid battery by using the causal and fault tree analysis. The causal tree allows the description of the correlations between the battery degradation modes and their causes during the manufacturing process. The causes...

  • What Is a Fault Tree Analysis? Pilot, Simha // Quality Progress;Jan2016, Vol. 49 Issue 1, p43 

    The article focuses on the fault tree analysis (FTA) which was first introduced by Bell Laboratories, to determine specific causes of a system failure in quality control.

  • Statistical Process Control at Motorola's Austin Assembly Plant . Kumar, Sanjoy; Gupta, Yash P. // Interfaces;Mar/Apr93, Vol. 23 Issue 2, p84 

    Many organizations are making massive investments in new manufacturing technologies; at the same time, they are implementing new quality assurance (QA) systems to achieve high quality products. Motorola, a forerunner, has implemented a total quality management (TQM) system at its Austin assembly...

  • Failure Analysis of Automotive Differential Based on the Fault Tree. Pan Yawei; Yu Quanyu; Wang Fei // Advanced Materials Research;2014, Vol. 1049-1050, p871 

    The paper analyzes a variety of reasons differential fault automobile differential and establishes the corresponding fault tree by using Fault Tree Analysis of reliability theory. The failure spectrum of automobile differential is constructed through qualitative analysis of the fault tree....

  • Supercharging Your Pareto Analysis. Stevenson, William J. // Quality Progress;Oct2000, Vol. 33 Issue 10, p51 

    Discusses the appropriate use of the typical frequency based approach of the Pareto Analysis for problem solving and process improvement in quality training. Pareto principle and analysis; Examples of situations where the frequency based approach would be appropriate; Other alternative...

  • The Evolution of ICT: What's Driving Today's Innovations? Albee, Alan J. // SMT: Surface Mount Technology;Sep2013, Vol. 28 Issue 9, p30 

    Many manufacturers employ one or more in-circuit test (ICT) systems in their PCB manufacturing facilities to help them detect manufacturing process and component defects. These bed-of-nails electrical test systems are highly valued for providing the qualities of simple program generation, high...

  • An Accident Prediction and Diagnosis Method Based on Bayesian Network. Shi Lin; Li Zhigang // Applied Mechanics & Materials;2014, Issue 513-517, p1581 

    Against the limitations of some traditional accident prediction and diagnosis methods, a new method based on Bayesian network is proposed on the basis of the Fault Tree Analysis method. Using this method, accident prediction and diagnosis can become easily, quickly and more accurately. The...

  • Reliability Analysis for Wind Turbine. Haiyan Yang; Jiaguang Zhou; Li Dang; Rongde Lin; Rongyi Liu // Sustainable Energy; 

    In this paper, it classifies all faults into general and serious failure in nacelle and hob control system. First, it evaluates the reliability of a system of wind turbine. Then, it assesses the reliability of electric control system by fault tree analysis, the conclusion is the highest failure...

  • Failure Modes Effects and Criticality Analysis and Fault Tree Analysis Case Study of Waste Heat Recovery Plant in a Cement Factory, United Arab Emirates. Shanks, Kirk; Hamad, Abdallah; Ameer, Alaa // Journal of Failure Analysis & Prevention;Feb2020, Vol. 20 Issue 1, p40 

    This article reports a case study of the application of FMECA and FTA methods to inform the design of effective maintenance program for a waste heat recovery power plant in the hot arid climate of the United Arab Emirates. It illustrates the strengths and weaknesses of these approaches through a...


Read the Article


Sorry, but this item is not currently available from your library.

Try another library?
Sign out of this library

Other Topics