Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 12

Search results for: assignable cause

12 Statistical Quality Control on Assignable Causes of Variation on Cement Production in Ashaka Cement PLC Gombe State

Authors: Hamisu Idi

Abstract:

The present study focuses on studying the impact of influencer recommendation in the quality of cement production. Exploratory research was done on monthly basis, where data were obtained from secondary source i.e. the record kept by an automated recompilation machine. The machine keeps all the records of the mills downtime which the process manager checks for validation and refer the fault (if any) to the department responsible for maintenance or measurement taking so as to prevent future occurrence. The findings indicated that the product of the Ashaka Cement Plc. were considered as qualitative, since all the production processes were found to be in control (preset specifications) with the exception of the natural cause of variation which is normal in the production process as it will not affect the outcome of the product. It is reduced to the bearest minimum since it cannot be totally eliminated. It is also hopeful that the findings of this study would be of great assistance to the management of Ashaka cement factory and the process manager in particular at various levels in the monitoring and implementation of statistical process control. This study is therefore of great contribution to the knowledge in this regard and it is hopeful that it would open more research in that direction.

Keywords: cement, quality, variation, assignable cause, common cause

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11 Jointly Optimal Statistical Process Control and Maintenance Policy for Deteriorating Processes

Authors: Lucas Paganin, Viliam Makis

Abstract:

With the advent of globalization, the market competition has become a major issue for most companies. One of the main strategies to overcome this situation is the quality improvement of the product at a lower cost to meet customers’ expectations. In order to achieve the desired quality of products, it is important to control the process to meet the specifications, and to implement the optimal maintenance policy for the machines and the production lines. Thus, the overall objective is to reduce process variation and the production and maintenance costs. In this paper, an integrated model involving Statistical Process Control (SPC) and maintenance is developed to achieve this goal. Therefore, the main focus of this paper is to develop the jointly optimal maintenance and statistical process control policy minimizing the total long run expected average cost per unit time. In our model, the production process can go out of control due to either the deterioration of equipment or other assignable causes. The equipment is also subject to failures in any of the operating states due to deterioration and aging. Hence, the process mean is controlled by an Xbar control chart using equidistant sampling epochs. We assume that the machine inspection epochs are the times when the control chart signals an out-of-control condition, considering both true and false alarms. At these times, the production process will be stopped, and an investigation will be conducted not only to determine whether it is a true or false alarm, but also to identify the causes of the true alarm, whether it was caused by the change in the machine setting, by other assignable causes, or by both. If the system is out of control, the proper actions will be taken to bring it back to the in-control state. At these epochs, a maintenance action can be taken, which can be no action, or preventive replacement of the unit. When the equipment is in the failure state, a corrective maintenance action is performed, which can be minimal repair or replacement of the machine and the process is brought to the in-control state. SMDP framework is used to formulate and solve the joint control problem. Numerical example is developed to demonstrate the effectiveness of the control policy.

Keywords: maintenance, semi-Markov decision process, statistical process control, Xbar control chart

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10 Generation of Quasi-Measurement Data for On-Line Process Data Analysis

Authors: Hyun-Woo Cho

Abstract:

For ensuring the safety of a manufacturing process one should quickly identify an assignable cause of a fault in an on-line basis. To this end, many statistical techniques including linear and nonlinear methods have been frequently utilized. However, such methods possessed a major problem of small sample size, which is mostly attributed to the characteristics of empirical models used for reference models. This work presents a new method to overcome the insufficiency of measurement data in the monitoring and diagnosis tasks. Some quasi-measurement data are generated from existing data based on the two indices of similarity and importance. The performance of the method is demonstrated using a real data set. The results turn out that the presented methods are able to handle the insufficiency problem successfully. In addition, it is shown to be quite efficient in terms of computational speed and memory usage, and thus on-line implementation of the method is straightforward for monitoring and diagnosis purposes.

Keywords: data analysis, diagnosis, monitoring, process data, quality control

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9 The Variable Sampling Interval Xbar Chart versus the Double Sampling Xbar Chart

Authors: Michael B. C. Khoo, J. L. Khoo, W. C. Yeong, W. L. Teoh

Abstract:

The Shewhart Xbar control chart is a useful process monitoring tool in manufacturing industries to detect the presence of assignable causes. However, it is insensitive in detecting small process shifts. To circumvent this problem, adaptive control charts are suggested. An adaptive chart enables at least one of the chart’s parameters to be adjusted to increase the chart’s sensitivity. Two common adaptive charts that exist in the literature are the double sampling (DS) Xbar and variable sampling interval (VSI) Xbar charts. This paper compares the performances of the DS and VSI Xbar charts, based on the average time to signal (ATS) criterion. The ATS profiles of the DS Xbar and VSI Xbar charts are obtained using the Mathematica and Statistical Analysis System (SAS) programs, respectively. The results show that the VSI Xbar chart is generally superior to the DS Xbar chart.

Keywords: adaptive charts, average time to signal, double sampling, charts, variable sampling interval

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8 Timely Detection and Identification of Abnormalities for Process Monitoring

Authors: Hyun-Woo Cho

Abstract:

The detection and identification of multivariate manufacturing processes are quite important in order to maintain good product quality. Unusual behaviors or events encountered during its operation can have a serious impact on the process and product quality. Thus they should be detected and identified as soon as possible. This paper focused on the efficient representation of process measurement data in detecting and identifying abnormalities. This qualitative method is effective in representing fault patterns of process data. In addition, it is quite sensitive to measurement noise so that reliable outcomes can be obtained. To evaluate its performance a simulation process was utilized, and the effect of adopting linear and nonlinear methods in the detection and identification was tested with different simulation data. It has shown that the use of a nonlinear technique produced more satisfactory and more robust results for the simulation data sets. This monitoring framework can help operating personnel to detect the occurrence of process abnormalities and identify their assignable causes in an on-line or real-time basis.

Keywords: detection, monitoring, identification, measurement data, multivariate techniques

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7 On the Bootstrap P-Value Method in Identifying out of Control Signals in Multivariate Control Chart

Authors: O. Ikpotokin

Abstract:

In any production process, every product is aimed to attain a certain standard, but the presence of assignable cause of variability affects our process, thereby leading to low quality of product. The ability to identify and remove this type of variability reduces its overall effect, thereby improving the quality of the product. In case of a univariate control chart signal, it is easy to detect the problem and give a solution since it is related to a single quality characteristic. However, the problems involved in the use of multivariate control chart are the violation of multivariate normal assumption and the difficulty in identifying the quality characteristic(s) that resulted in the out of control signals. The purpose of this paper is to examine the use of non-parametric control chart (the bootstrap approach) for obtaining control limit to overcome the problem of multivariate distributional assumption and the p-value method for detecting out of control signals. Results from a performance study show that the proposed bootstrap method enables the setting of control limit that can enhance the detection of out of control signals when compared, while the p-value method also enhanced in identifying out of control variables.

Keywords: bootstrap control limit, p-value method, out-of-control signals, p-value, quality characteristics

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6 Analyzing On-Line Process Data for Industrial Production Quality Control

Authors: Hyun-Woo Cho

Abstract:

The monitoring of industrial production quality has to be implemented to alarm early warning for unusual operating conditions. Furthermore, identification of their assignable causes is necessary for a quality control purpose. For such tasks many multivariate statistical techniques have been applied and shown to be quite effective tools. This work presents a process data-based monitoring scheme for production processes. For more reliable results some additional steps of noise filtering and preprocessing are considered. It may lead to enhanced performance by eliminating unwanted variation of the data. The performance evaluation is executed using data sets from test processes. The proposed method is shown to provide reliable quality control results, and thus is more effective in quality monitoring in the example. For practical implementation of the method, an on-line data system must be available to gather historical and on-line data. Recently large amounts of data are collected on-line in most processes and implementation of the current scheme is feasible and does not give additional burdens to users.

Keywords: detection, filtering, monitoring, process data

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5 Optimal Bayesian Chart for Controlling Expected Number of Defects in Production Processes

Authors: V. Makis, L. Jafari

Abstract:

In this paper, we develop an optimal Bayesian chart to control the expected number of defects per inspection unit in production processes with long production runs. We formulate this control problem in the optimal stopping framework. The objective is to determine the optimal stopping rule minimizing the long-run expected average cost per unit time considering partial information obtained from the process sampling at regular epochs. We prove the optimality of the control limit policy, i.e., the process is stopped and the search for assignable causes is initiated when the posterior probability that the process is out of control exceeds a control limit. An algorithm in the semi-Markov decision process framework is developed to calculate the optimal control limit and the corresponding average cost. Numerical examples are presented to illustrate the developed optimal control chart and to compare it with the traditional u-chart.

Keywords: Bayesian u-chart, economic design, optimal stopping, semi-Markov decision process, statistical process control

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4 Morphology, Chromosome Numbers and Molecular Evidences of Three New Species of Begonia Section Baryandra (Begoniaceae) from Panay Island, Philippines

Authors: Rosario Rivera Rubite, Ching-I Peng, Che-Wei Lin, Mark Hughes, Yoshiko Kono, Kuo-Fang Chung

Abstract:

The flora of Panay Island is under-collected compared with the other islands of the Philippines. In a joint expedition to the island, botanists from Taiwan and the Philippines found three unknown Begonia and compared them with potentially allied species. The three species are clearly assignable to Begonia section Baryandra which is largely endemic to the Philippines. Studies of literature, herbarium specimens, and living plants support the recognition of the three new species: Begonia culasiensis, Begonia merrilliana, and Begonia sykakiengii. Somatic chromosomes at metaphase were determined to be 2n=30 for B. culasiensis and 2n=28 for both B. merrilliana and B. sykakiengii, which are congruent with those of most species in sect. Baryandra. Molecular phylogenetic evidence is consistent with B. culasiensis being a relict from the late Miocene, and with B. merrilliana and B. sykakiengii being younger species of Pleistocene origin. The continuing discovery of endemic Philippine species means the remaining fragments of both primary and secondary native vegetation in the archipelago are of increasing value in terms of natural capital. A secure future for the species could be realized through ex-situ conservation collections and raising awareness with community groups.

Keywords: conservation, endemic , herbarium , limestone, phylogenetics, taxonomy

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3 Controlling the Process of a Chicken Dressing Plant through Statistical Process Control

Authors: Jasper Kevin C. Dionisio, Denise Mae M. Unsay

Abstract:

In a manufacturing firm, controlling the process ensures that optimum efficiency, productivity, and quality in an organization are achieved. An operation with no standardized procedure yields a poor productivity, inefficiency, and an out of control process. This study focuses on controlling the small intestine processing of a chicken dressing plant through the use of Statistical Process Control (SPC). Since the operation does not employ a standard procedure and does not have an established standard time, the process through the assessment of the observed time of the overall operation of small intestine processing, through the use of X-Bar R Control Chart, is found to be out of control. In the solution of this problem, the researchers conduct a motion and time study aiming to establish a standard procedure for the operation. The normal operator was picked through the use of Westinghouse Rating System. Instead of utilizing the traditional motion and time study, the researchers used the X-Bar R Control Chart in determining the process average of the process that is used for establishing the standard time. The observed time of the normal operator was noted and plotted to the X-Bar R Control Chart. Out of control points that are due to assignable cause were removed and the process average, or the average time the normal operator conducted the process, which was already in control and free form any outliers, was obtained. The process average was then used in determining the standard time of small intestine processing. As a recommendation, the researchers suggest the implementation of the standard time established which is with consonance to the standard procedure which was adopted from the normal operator. With that recommendation, the whole operation will induce a 45.54 % increase in their productivity.

Keywords: motion and time study, process controlling, statistical process control, X-Bar R Control chart

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2 Adaptive Process Monitoring for Time-Varying Situations Using Statistical Learning Algorithms

Authors: Seulki Lee, Seoung Bum Kim

Abstract:

Statistical process control (SPC) is a practical and effective method for quality control. The most important and widely used technique in SPC is a control chart. The main goal of a control chart is to detect any assignable changes that affect the quality output. Most conventional control charts, such as Hotelling’s T2 charts, are commonly based on the assumption that the quality characteristics follow a multivariate normal distribution. However, in modern complicated manufacturing systems, appropriate control chart techniques that can efficiently handle the nonnormal processes are required. To overcome the shortcomings of conventional control charts for nonnormal processes, several methods have been proposed to combine statistical learning algorithms and multivariate control charts. Statistical learning-based control charts, such as support vector data description (SVDD)-based charts, k-nearest neighbors-based charts, have proven their improved performance in nonnormal situations compared to that of the T2 chart. Beside the nonnormal property, time-varying operations are also quite common in real manufacturing fields because of various factors such as product and set-point changes, seasonal variations, catalyst degradation, and sensor drifting. However, traditional control charts cannot accommodate future condition changes of the process because they are formulated based on the data information recorded in the early stage of the process. In the present paper, we propose a SVDD algorithm-based control chart, which is capable of adaptively monitoring time-varying and nonnormal processes. We reformulated the SVDD algorithm into a time-adaptive SVDD algorithm by adding a weighting factor that reflects time-varying situations. Moreover, we defined the updating region for the efficient model-updating structure of the control chart. The proposed control chart simultaneously allows efficient model updates and timely detection of out-of-control signals. The effectiveness and applicability of the proposed chart were demonstrated through experiments with the simulated data and the real data from the metal frame process in mobile device manufacturing.

Keywords: multivariate control chart, nonparametric method, support vector data description, time-varying process

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1 Comparison of Spiral Circular Coil and Helical Coil Structures for Wireless Power Transfer System

Authors: Zhang Kehan, Du Luona

Abstract:

Wireless power transfer (WPT) systems have been widely investigated for advantages of convenience and safety compared to traditional plug-in charging systems. The research contents include impedance matching, circuit topology, transfer distance et al. for improving the efficiency of WPT system, which is a decisive factor in the practical application. What is more, coil structures such as spiral circular coil and helical coil with variable distance between two turns also have indispensable effects on the efficiency of WPT systems. This paper compares the efficiency of WPT systems utilizing spiral or helical coil with variable distance between two turns, and experimental results show that efficiency of spiral circular coil with an optimum distance between two turns is the highest. According to efficiency formula of resonant WPT system with series-series topology, we introduce M²/R₋₁ to measure the efficiency of spiral circular coil and helical coil WPT system. If the distance between two turns s is too close, proximity effect theory shows that the induced current in the conductor, caused by a variable flux created by the current flows in the skin of vicinity conductor, is the opposite direction of source current and has assignable impart on coil resistance. Thus in two coil structures, s affects coil resistance. At the same time, when the distance between primary and secondary coils is not variable, s can also make the influence on M to some degrees. The aforementioned study proves that s plays an indispensable role in changing M²/R₋₁ and then can be adjusted to find the optimum value with which WPT system achieves the highest efficiency. In actual application situations of WPT systems especially in underwater vehicles, miniaturization is one vital issue in designing WPT system structures. Limited by system size, the largest external radius of spiral circular coil is 100 mm, and the largest height of helical coil is 40 mm. In other words, the turn of coil N changes with s. In spiral circular and helical structures, the distance between each two turns in secondary coil is set as a constant value 1 mm to guarantee that the R2 is not variable. Based on the analysis above, we set up spiral circular coil and helical coil model using COMSOL to analyze the value of M²/R₋₁ when the distance between each two turns in primary coil sp varies from 0 mm to 10 mm. In the two structure models, the distance between primary and secondary coils is 50 mm and wire diameter is chosen as 1.5 mm. The turn of coil in secondary coil are 27 in helical coil model and 20 in spiral circular coil model. The best value of s in helical coil structure and spiral circular coil structure are 1 mm and 2 mm respectively, in which the value of M²/R₋₁ is the largest. It is obviously to select spiral circular coil as the first choice to design the WPT system for that the value of M²/R₋₁ in spiral circular coil is larger than that in helical coil under the same condition.

Keywords: distance between two turns, helical coil, spiral circular coil, wireless power transfer

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