subject: Controlling Quality Through Process Control In Metal Fabrication [print this page] Perpetuating product quality is necessary to any organization. Taking a broader stance, perpetuating product quality can be done via controlling the quality of the methods that it takes to make that product. An example of controlling of a process would be to take calculations of something when it is operating at its best so that the calculations can be compared to calculations in the future, to ensure that optimum quality functions are still in place. For instance, strain on the frames of machines can be measured via a strain monitor to rate quality. The machine's frame strain must have been assessed when it was operating optimally and producing quality parts so that measurements from that assessment may be used as a control to measure against when the machine begins operating in a manner that is not optimal. This can help measure the entire production process. Monitoring processes for discrepancies is a revolutionary new way of looking at quality assurance instead of looking for flaws in parts. If a process produces quality parts and is able to be reiterated, this is a model scenario for a manufacturing setting.
Process Valuation Monitoring
The characteristics of process variation monitoring involve monitoring all of the production but not needing to add any additional steps in the process. Also, if a part is discovered to be abnormal, processing is ceased so that there is no squandering of time in manufacturing bad parts and the defective parts do not lead to squandered materials. When process variation monitoring is in effect, maintenance staff do not need to insist that machines are turned off at sporadic times so that they can accomplish their supportive duties or worry about not accomplishing their maintenance often enough, and the machines don't perform. In this environment, the maintenance happens only when it is needed. Maintenance costs will therefore be reduced and efficiency in machine operation and operation as a whole will go up.
Tooling will only be swapped on an as-needed basis in this setting so money will be saved because the tooling will not be replaced too soon or too late. The last characteristic is that all employees in the organization will focus on process rather than the actual pieces being produced so gains will be found in several areas including the quality of the end product.
For process control to be useful in any environment, it must have a goal that is focused and comprehensive. There must also be a system of measurement in place so that it can be found if the goal is within reach or at what point it will have been attained. There should also be a set of procedures with responses that are expected to operate, so that effectiveness can be measured.
Process Control: Case Study
At Maloya, they used process control in their manufacturing environment. They utilized it as part of their scheduled maintenance of machinery which involved regular calibration of the machines. Their laser machines were equipped with test elements and these would be assessed and the results documented to make sure that the machine was delivering precise results within the original equipment manufacturer (OEM) specifications. This afforded Maloya with a proven process capability to guarantee that their methods are operating at their best which then transforms to their quality levels and standards. This process can also be duplicated in areas such as machining and welding, as well as in developing work centers.
By instituting process controls, you will discover it a productive way of maintaining quality management in a metal manufacturing environment. Rather than concentrate on the parts, concentrate on the processes and everything will fall into place if done correctly.
