exam2

LCA (Life Cycle Assessment)

A systematic tool for evaluating the environmental burdens associated with a product, process, or activity from 'cradle to grave.'

Quality planning costs

Costs of developing and implementing the quality management program.

Training costs

Costs of developing and implementing quality training programs for employees and management.

Inspection and testing costs

Costs of testing and inspecting materials, parts, and products at various stages of production.

Operator costs

Costs of time spent by operators gathering data, making adjustments, and stopping work to assess quality.

External failure costs

Costs incurred after poor-quality products are delivered to customers.

Customer complaint costs

Costs of investigating and resolving customer complaints.

Product liability costs

Costs from legal issues due to defective products causing harm.

quality management costs

achieving good quality

1. prevention costs

2. appraisal costs

cost of poor quality

3. internal failure costs

quality assurance(prevention costs)

- quality planning costs

- product design costs

- process costs

- training costs

- information costs

product yield formula

yield=(total input)(%good units)+(total input) (1-%good units)(%reworked)

Y = (I)(%G) + (I)(1-%G)(%R)

three categories where you can have failures

1. infant mortality: early in the life

2. expected decay: wear you expect to happen with intended use

3. random failure modes

natural variability

-random common causes

- randomness in the process

- expected and cant be controlled or prevented

machine

computer related or physical, electrical

sustainable manufacturing: whole systems thinking in design

- holistic approach

- interconnectedness

- feedback loops

- adaptability

- stakeholder involvement

ISO 14001

The international standard for Environmental Management Systems (EMS) focused on the Plan-Do-Check-Act cycle.

Engineered Materials

Substances that have been designed or processed to have specific properties (e.g., carbon fiber, specialized alloys).

appropriate layout resutls

- improved product quality

- short lead times/faster customer response

- improved communication

- decresased costs

- improved safety and security

- maximized capacity

fixed position layout

work on it where it is

Prevention costs

Costs of trying to prevent poor-quality products from reaching customers (doing it right the first time).

Product-design costs

Costs of designing products with quality characteristics.

Process costs

Costs of ensuring the production process conforms to quality specifications.

Information costs

Costs of acquiring and maintaining data related to quality and analyzing performance.

Appraisal costs

Costs of measuring, testing, and analyzing materials, parts, and products to ensure quality standards are met.

Test equipment costs

Costs of maintaining equipment used in testing the quality characteristics of products.

Internal failure costs

Costs incurred when poor-quality products are discovered before delivery to customers.

Scrap costs

Costs of poor-quality products that must be discarded, including labor, material, and indirect costs.

Rework costs

Costs of fixing defective products to meet quality specifications.

Process failure costs

Costs of determining why the production process is producing poor-quality products.

Process downtime costs

Costs of shutting down production to fix problems.

Price-discounting costs

Costs of selling poor-quality products at reduced prices ("seconds").

Product return costs

Costs of handling and replacing returned defective products.

Warranty claims costs

Costs of honoring product warranties.

Lost sales costs

Costs from losing future sales due to dissatisfied customers.

quality

product that conforms to specifications

external quality failure

happens in hands of customer

internal quality failure

happens in the factory

cost of quality

difference between price of nonconformance and conformance

quality of conformance

- from manufacturers perspective

- making sure a product is manufactured to pre defined standards and specifications

quality assurance/prevention

building in quality through product design and effective systems management

quality control/appraisal

checking after parts, components products are actually made

external quality costs

- customer complaint costs: cost of investigating and responding to customer complaints due to poor product

- product return costs: costs of handling and replacing poor quality proudcts returned by customer

quality control(appraisal costs)

- inspection and testing

- test equipment costs

- operator costs

costs of internal failure

- scrap costs

- rework costs

- process failure costs

- process downtime costs

- price downgrding costs

product reliability

chances that a product will perform its functions over its expected product life under conditions of normal use

- quality dimension of functional design

reliability rating

is a probability

- rating of 0.95 means there is a 95% likelihood this product will work over expected period of time for that product ex. 5 years

failure rate

opposite of reliability rating

reliability

involves every part of the product

- times all reliabilities of the product to find total

MTBF

mean time between failures

- focused on wear out and normal life failures

Statistical Process control

- internal and emphasized early detection and prevention of problems

- focus is on machinery and quality, precision of unit operations

variability

exists and we CANT get rid of it

non random causes

- special causes or assignable causes

- variability due to a problem that can be identified

man

operator related issues

materials

documents, drawings,standards, specifications

methods

techniques, approaches, procedures

measurements

data, units, metrics

Seven basic tools of quality: flowchart (process map)

-common type of process map that usually represents the stepsof a process. system, or workflow in sequential order

Seven basic tools of quality: cause and effect diagram

- helps find possible causes for an issue by sorting them into categories

- fishbone diagram: causes or input and outputs

Seven basic tools of quality: check sheet

structured prepared form for collecting data

Seven basic tools of quality: bar charts and histograms

Bar charts and histograms are graphical tools used in manufacturing to display and analyze data distributions, helping to identify trends and variations in production quality and efficiency.

Seven basic tools of quality: pareto chart (pareto analysis)

- combines bar chart and line chart

- shows cumulative frequency

Seven basic tools of quality: control chart

- study how a process changes over time

- has upper and lower line and control line

Seven basic tools of quality: scatter diagrams

Scatter diagrams in manufacturing are graphical representations used to identify relationships between two variables, helping to analyze quality and tool performance by visualizing data trends and correlations.

sustaiable manufacturing

manufacturing that minimized economic impact while maintaining economic viability and social responsibility

IPAT equation

analyses impact on the environment through population affluence and technology

lifecycle assessment

- method for evaluating the environmental impacts of a product, process, or system across its entire lifecycle

sustainable materials

- balancing economic and environmental factors is crucial when selecting sustainable materials for products

- not just about materials

- consider:

- form and functionn

-manufacturing process

-energy use

-disassembly and recycling

-regulatory standards

-end of life impacts

sustainable manufacturing: within manufacturing system

spectrum of effort you can make towards sustainable manufacturing

- housekeeping

- process optimization

- raw material subsitution

- new technologies

- new product design

Primary Sector

The segment of the economy involved in the extraction and collection of natural resources (e.g., mining, forestry).

Feedstocks

Raw materials that are supplied to a machine or industrial process for conversion into a product.

Secondary Sector

The economic sector that transforms raw materials from the primary sector into finished goods.

Total Materials Cycle

The global system of material flow: extraction, synthesis, processing, design, use, and disposal/recycling.

poor layout results

- aditional material handling costs

- damage to products

- wasted space

- poor communication

- limited capacity

product layout

assembly line

process layout

move to wehre needs to be worked on in departments

cellular layouts

each cell can do whole operations

specialised

flexible manufacturing systems

flexilbility in manufacturing means the ability to deal with slightly or greatly mixed parts

machine flexibility

ability of a system to use multiple machines to perform same operation on a part and to handle large scale changes

routing flexiblity

ability of a system to use multiple alternative routs to produce a set of parts

three main systems of flexible manufacturing

1. work machines

2. mateiral handling and buffering systems

3. central control computer that plans production and controls material movement and machine flows

its expensive alot of maintenance to do correclty

planning process

1. decide which components, parts you will make in house or outsource

2. determine which broad process strategy you'll use(selection)

3. evaluate cost handoffs associated with demand volume (breakeven analysis)

4. create full specifications and technical documentation of the product and the process itself

planning analysis

1. the systematic examination of all aspect of a process to imporve its operation

2. economic tools such as productivit

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