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SECTION 27
PROCESS INDUSTRIES
Donald W. Marquardt
QUALITY MANAGEMENT IN THE PROCESSINDUSTRIES
27.2
CHARACTERISTICS OF THE PROCESSINDUSTRIES
27.2
DEALING WITH LARGE MEASUREMENTVARIABILITY
27.3
FUNDAMENTAL CONCEPTS
27.4
Generic Product Categories
27.4
Every Product Is the Result of a Process
27.4
Facets of Quality
27.5
Quality of Product Design
27.5
Quality of Conformance with ProductDesign
27.5
A BALANCED APPROACH TO ACHIEVEEXCELLENCE IN QUALITY
27.5
The Quality Management Success Triad
27.5
Quality Philosophy, Culture, and Policy
27.6
Quality Management System
27.6
Quality Technology System
27.6
QUALITY PROBLEMS IN THE PROCESSINDUSTRIES
27.6
Systems Problems Versus WorkerProblems
27.6
Chronic Quality Problems
27.6
True Rare-Event Quality Problems
27.7
Chronic Quality Problems That Appear toBe Rare Events
27.7
On-Aim Control Contrasted with In-Limits Control
27.8
DESIGNING THE PRODUCTION PROCESS
27.9
Strategic Aspects of Economy of Scale
27.9
Building Flexibility into the ProductionProcess
27.9
THE ROLE OF PRODUCTION SCHEDULINGAND INVENTORY CONTROL
27.10
THE PRODUCTION PROCESSES CRITICALFOR QUALITY MANAGEMENT
27.11
The Sampling Processes
27.12
The Measurement Processes
27.12
The Decision/Control Processes
27.13
The Computing Processes
27.13
CONCEPTS OF STANDARD PROCESS ANDSTANDARD PRODUCT
27.13
Production Process Specifications
27.13
The Standard Process as an InsurancePolicy
27.13
Control of Both Production andMeasurement Processes
27.14
Every Process in a Quality ManagementSystem Must Be Audited
27.14
Conforming Product
27.14
QUALITY EVALUATION BASED ON TRUEPRODUCT VARIABILITY FOR CRITICALPROPERTIES
27.15
IMPORTANCE OF OBJECTIVELYDESCRIBED PRODUCT SPECIFICATIONS
27.16
Product Specifications—Content andFormat
27.16
Definitions of Product Unit Terms
27.17
MEASURING QUALITY OF CONFORMANCEWITH PRODUCT DESIGN
27.20
Quantitative Definition of Conformance
27.20
Goal Conformance as a Fixed Referencefor Product Specifications
27.21
Experience Curves as Measures ofContinual Improvement
27.21
REFERENCE BASES FOR MEASUREMENTCALIBRATION AND PRODUCT CONTROL
27.21
Hierarchy of Reference Bases
27.21
Recognized Standards as ReferenceBases
27.22
Control Samples as Reference Bases
27.22
CONTROL OF THE MEASUREMENTPROCESS
27.22
Test Method Administration
27.22
Availability of Means of Calibration
27.23
Specification of Aim Point
X 
0
27.23
Specification of Other Statistical ProcessControl Parameters
27.23
SPROCM Estimation
27.24
Sampling Frequency and Test Protocol
27.24
SELECTION AND PREPARATION OFCONTROL SAMPLES
27.24
Control Supply Selection
27.24
Control Sample Preparation
27.25
Composite, Multiple, and StaggeredControl Samples
27.25
Control Samples at More Than One Level
27.25
27.1
 
QUALITY MANAGEMENT IN THE PROCESS INDUSTRIES 
In the process industries,as in other sectors of the economy,Quality Management is the umbrellaframework for managing the quality of a product. The philosophy,managing procedures,and technol-ogy should provide an operational system in which Marketing,Research and Development,Production,and Support personnel can work together to meet increasingly stringent customer requirements.The system must deal with all facets of a product’s life span from the product’s conceptionthrough commercialization and subsequent improvements,as shown in Figure 27.1. When a productinitially is developed,the emphasis is on designing quality into the product through optimizingfunctionality and producibility. For established products,the emphases are on maintaining andcontinually improving product conformance to quality requirements.The most significant quality improvements are accomplished in those businesses that broadlyimplement a quality management system. The “system”feature:
G
Provides an implementation process
G
Interconnects the operational techniques
G
Requires and expedites communications in the organization.The system feature is the vehicle that drives quality improvements as a business strategy. The sys-tem approach is particularly important in the process industries.
CHARACTERISTICS OF THE PROCESS INDUSTRIES 
The “process industries”have special needs in the technology for quality management. The processindustries typically have continuous processes,or batch processes with many batches per year of agiven product type.
27.2
SECTION TWENTY-SEVEN
USING CONTROL SUPPLIES
27.26
Control Samples as ComputationalReferences
27.26
Multiple Measurement ProcessConfigurations
27.26
Confirming the Effectiveness of aMeasurement Adjustment or Calibration
27.26
TESTING PRODUCT WHEN MEASURE-MENT PROCESS IS OFF-AIM
27.26
VALIDATING NEW MEASUREMENTMETHODS
27.27
ESTIMATING AND MAINTAININGVARIANCE COMPONENTS FOR THEPRODUCT AND MEASUREMENTS
27.27
Analysis of Variance Using ProductionProcess Data
27.28
Guideline for Obtaining VarianceComponents Data
27.28
Variance Component Estimates fromProduction Process Data
27.29
Estimating VWP, VST, and VLT from theMaintenance Sampling Plan
27.29
Maintenance Sampling for MeasurementComponents of Variance
27.30
Contrast Method of VarianceComponents Estimation
27.30
Estimating and Maintaining VLL and VPP
27.31
PRODUCT CHARACTERIZATION
27.32
USE OF THE VARIANCE COMPONENTSFOR IMPROVEMENT OF THE QUALITYMANAGEMENT SYSTEM
27.33
USE OF THE VARIANCE COMPONENTSFOR ROUTINE SAMPLE DESIGN
27.34
QUALITY MANAGEMENT SYSTEMUPDATES
27.34
Intent, Definition, and Timing of anUpdate
27.34
AUDITS
27.35
Lower-Level and Higher-Level Audits
27.35
Numerical Audits and Procedures Audits
27.35
REFERENCES
27.37
 
Typical products of the process industries are:
G
Solid materials:Pieces,particles,powdersDiscrete or continuous sheetsChopped or continuous filaments
G
Liquid materials:High and low viscosity
G
Gaseous materials:Such products can be sampled in specified volumes or weights at specified production points tomeasure a quality property. The property value may vary throughout a volume or quantity of product,and may change with time. Often the relationship between a measured property and thefunctionality of the end-use product is not fully understood.Frequently,the process industry product is an input material for the customer’s process. The prod-uct must meet this customer’s processing requirements as well as requirements of the end user of theultimate product. Such products are examples of the generic product category called “processedmaterials.”The foregoing features distinguish the process industries from the mechanical industries,wherethe emphasis is on the making of parts or the assembly of parts,that is,products of the generic productcategory called “hardware.”Most existing quality control methodology was developed for hardware products of the mechan-ical industries,so it may not be too surprising to find that emphases and methodologies in this sec-tion are often different from the traditional quality control literature. However,small parts made inlarge quantities often benefit from the statistical methodologies for processed materials.
DEALING WITH LARGE MEASUREMENT VARIABILITY 
A primary difference between the process industries and the mechanical industries is the amountof variability associated with measurement processes. In the mechanical industries,measurementvariability often is,or is perceived to be,small or negligible,usually less than 10 percent of total vari-ability. Many measurements in the mechanical industries are based on properties that have absoluteor near absolute reference standards,such as dimension,weight,or electrical or optical properties.
PROCESS INDUSTRIES
27.3
FIGURE 27.1
The product life span. [
From Marquardt 
(
1991
).]
of 00

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