Assignment #3-3: SQC – Part I – Process Defect Analysis

Production information for a machining process is as follows:

• Product: Roller Shaft
• Material: Alloy Cast Steel
• Process: Turning Machining
• Total Production Quantity = 500 ton
• Defect Quantity = 28 ton
5 Machines Total
Defect Types
M1 M2 M3 M4 M5 Defect
A Wrong Dimension 1 0 0 2 1 4
B Surface Burn 1 1 2 1 1 6
C Axis is not straight 1 1 0 0 0 2
D Porosity 1 1 0 1 0 3
E Bad Surface Finish 2 2 1 3 2 10
F Out-of-Roundness 0 0 0 1 1 2
G Surface Crack 1 0 0 0 0 1
Total Defect 7 5 3 8 5 28
Based on this information; discuss the following:
1) Defect Analysis 2) Defect Presentation
3) Pareto Analysis 4) Defect RCA & Fishbone diagram
5) Improvement Recommendations (QA Checklist & QC Checklist)
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1) Defect Analysis:
Defect = Rework +Rejected
= 28 / 500 = 5.6%
Quality Rate = 94.4%
94.4%
Target:
• Target Defect Ratio = 4.0%

Sigma Level:
Sigma Six Sigma Table
Defect = 56,000 DPPM Performance
Level DPPM Yield %
Sigma Level = 3.09 1 691,462 30.8538 F
Performance = C 2 308,537 69.1463 D
3 66,807 93.3193 C
3 66,807
4 6,210 99.3790 B
X=3.09 56,000 5 233 A
99.9767
4 6,210 6 3.4 99.99966 A+
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 2) Defect Presentation; for example

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2) Defect Presentation; for example

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 3) Pareto Analysis: Pareto Chart & Rule 80/20

5 Steps:
Rule 80/20
1) Sorting

2) Defect
Ratios

3) Cum. %

4) Pareto
Chart

5) Rule
80/20

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4) Defect RCA & Fishbone diagram:

Main Defect Root Causes Solution (Actions)
Bad Surface
E
Finish
Surface
B
Burn
Wrong
A
Dimension
D Porosity
Axis is not
C
straight
Out-of-
F
Roundness
Surface
G
Crack

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 4) Defect RCA & Fishbone diagram:
Main Defect Root Causes Solution (Actions)
• Error in machining parameters, • Check machining parameters,
Bad Surface
E work-piece Parameters or tool work-piece Parameters and tool
Finish
Parameters. Parameters.
Surface • High cutting speed • Check cutting speed
B
Burn • High feed rate • Check feed rate
• Improve labor skills by
Wrong • Poor labor skills advanced training program
A
Dimension • Wrong measurement method • Standardize measurement
method
D Porosity • Defective raw materials • Check raw materials quality
Axis is not
C • Error in clamping method • Check clamping method
straight
Out-of- • Check machine vibration
F • High machine vibration
Roundness • Update maintenance program
Surface • High cutting speed • Check cutting speed
G
Crack • High feed rate • Check feed rate
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4) Defect RCA & Fishbone diagram: (Brainstorming)

(Ishikawa Cause & Effect Diagram)

Environmental Manpower Method

Low Awareness Operation
lighting sheet
Motivation Machining
Unsafe parameters
Working conditions Skills & Machining
conditions training tools Machining
Accuracy of
Types & Defects
inspection High
Vibration specs Effect
tools Analysis
tools Old Dimensions (Y)
Analysis Poor equipment Hardness
errors Maintenance

Measurement Machine Materials

Root Causes (Xi) Y = f (Xi)

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 5) Improvement Recommendations:
Quality Assurance (QA) Checklist; for example
‫اﻹجراءات المطلوبة لضمان جودة العملية‬
• Product: Roller Shaft
• Material: Alloy Cast Steel
• Process: Turning Machining
• Shift: Date:
Phase Item Status Responsibility
Check Raw Material
Before Check … Standard
Process Check … Template
During Check Machining Parameters
Process Check …
After Check …
Process Check Final Product
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5) Improvement Recommendations:
Quality Control (QC) Checklist; for example
‫اﻹجراءات المطلوبة لفحص المنتج النهائي‬
• Product: Roller Shaft 3
2
• Material: Alloy Cast Steel 1
• Process: Turning Machining
• Item No. : 5
• Shift: Date: 4

Inspection Sample Actual

# Target Responsibility
Checkpoint Size Result
1 ɸ 8.4  0.2
2 ɸ
3 ɸ
4 ɸ
5 ɸ
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