تعداد نشریات | 161 |
تعداد شمارهها | 6,468 |
تعداد مقالات | 69,902 |
تعداد مشاهده مقاله | 122,420,694 |
تعداد دریافت فایل اصل مقاله | 95,665,170 |
Process Capability Studies in an Automated Flexible Assembly Process: A Case Study in an Automotive Industry | ||
Interdisciplinary Journal of Management Studies (Formerly known as Iranian Journal of Management Studies) | ||
دوره 14، شماره 1، فروردین 2021، صفحه 1-37 اصل مقاله (1.02 M) | ||
نوع مقاله: Research Paper | ||
شناسه دیجیتال (DOI): 10.22059/ijms.2020.222198.672415 | ||
نویسندگان | ||
Bakhtiar Ostadi* 1؛ Mohammadreza Taghizadeh Yazdi2؛ Abdolkarim Mohammadi Balani3 | ||
1Faculty of Industrial and Systems Engineering, Tarbiat Modares University, Tehran, Iran | ||
2Department of Industrial Management, Faculty of Management, University of Tehran, Iran | ||
3Department of Industrial Management, Faculty of Management and Economics, Tarbiat Modares University, Tehran, Iran | ||
چکیده | ||
Statistical Process Control (SPC) methods can significantly increase organizational efficiency if appropriately used. The primary goal of process capability studies is to obtain critical information about processes to render them even more effective. This paper proposes a comprehensive framework for proper implementation of SPC studies, including the design of the sampling procedure and intervals as well as process capability indices. Some of the most essential process capability indices in the literature were reviewed to develop a methodology to utilize process capability indices within the SPC framework. The current study presents an efficiency-oriented criterion designed for measuring SPC implementation productivity. The framework is applied to the windshield installation process of an Iranian automobile assembly line. The process was sampled in various sessions. Results verify that the implemented SPC framework could successfully improve the process and that the proposed framework could significantly address bottleneck in the process and enhance the quality level of the process from satisfactory to excellent according to the reference values of process capability indices. Managerial insights are also drawn from results. | ||
کلیدواژهها | ||
Statistical Process Control؛ Process capability indices؛ Automobile assembly facility؛ Windshield installation process. | ||
عنوان مقاله [English] | ||
مطالعات قابلیت فرآیند در فرآیندهای مونتاژ اتوماتیک انعطافپذیر (مطالعه موردی: در یک شرکت خودروسازی) | ||
نویسندگان [English] | ||
بختیار استادی1؛ محمدرضا تقی زاده یزدی2؛ عبدالکریم محمدی بالانی3 | ||
1دانشکده مهندسی صنایع و سیستم ها، دانشگاه تربیت مدرس، تهران، ایران | ||
2گروه مدیریت صنعتی، دانشکده مدیریت، دانشگاه تهران، تهران، ایران | ||
3گروه مدیریت صنعتی، دانشکده مدیریت و اقتصاد، دانشگاه تربیت مدرس، تهران، ایران | ||
چکیده [English] | ||
سازمانهایی که روشهای کنترل آماری فرآیندها را به نحو موفقیتآمیزی اجرا کنند از بازده قابل توجهی برخودار خواهند بود. هدف یک برنامه بهبود کیفیت بر اساس SPC، بهبود مستمر بطور هفتگی، فصلی و سالی است. SPC برنامهای نیست که فقط سازمان آن را یکبار و آن هم در زمان بروز مشکل از آن استفاده کند و هنگامیکه مشکل برطرف شد کنار گذاشته شود. لازم به ذکر است که, عناصر موثر در اجرای موفقیت آمیز SPC عبارتند از رهبری مدیریت, نگرش تیمی, آموزش پرسنل در کلیه سطوح , مکانیزمی برای تشخیص موفقیت و تأکید بر بهبود مستمر. هدف اولیه استفاده از مطالعات قابلیت فرآیند اینستکه اطلاعاتی درباره فرآیند کسب کنیم. این اطلاعات یک پایهای را برای بهبود فرآیندها شکل میدهند که به فرآیندهای تواناتر منجر میشوند. . اگر شاخصهای قابلیت فرآیند بطور مناسب مورد استفاده قرار گیرند، اطلاعات با ارزشی در مورد قابلیت یک فرآیند در اختیار قرار میدهند. این اطلاعات برای بهبود عملکرد فرآیندها مفید هستند و باعث کاهش هزینههای تولید و رضایت بیشتر مشتریان میشوند. در این مقاله, شاخصهای قابلیت فرآیند ارائه و مراحل جامع پیاده سازی کنترل فرآیند آماری با در نظر گرفتن مطالعات قابلیت فرآیند بیان شده و در فرآیند نصب شیشه یک شرکت خودروسازی پیاده و نتایج آن نیز بیان گردیده است. به منظور اندازهگیری بهرهوری اجرای کنترل فرآیند آماری شاخصی تعریف شده است. بوسیله این شاخص، تیم اجرایی بطور کمی مشخص میکند که در شروع کار چه وضعیتی داشته و مدتی پس از اجرا چه پیشرفتی صورت گرفته است. اندازه گیری این شاخص بهبود را نشان داد. | ||
کلیدواژهها [English] | ||
کنترل آماری فرآیند, مطالعات قابلیت فرآیند, شاخصهای قابلیت فرآیند, تجهیزات مونتاژ خودرو, فرآیند نصب شیشه جلو | ||
مراجع | ||
Abbasi Ganji, Z., & Sadeghpour Gildeh, B. (2016). A class of process capability indices for asymmetric tolerances. Quality Engineering, 28(4), 441–454. Ahmad, L., Aslam, M., & Jun, C.-H. (2014). Designing of X-bar control charts based on process capability index using repetitive sampling. Transactions of the Institute of Measurement and Control, 36(3), 367–374. Aslam, M. (2018). Statistical monitoring of process capability index having one sided specification under repetitive sampling using an exact distribution. IEEE Access, 6, 25270–25276. Avinadav, T., Perlman, Y., & Cheng, T. C. E. (2016). Economic design of control charts for monitoring batch manufacturing processes. International Journal of Computer Integrated Manufacturing, 29(2), 212–221. Bahria, N., Chelbi, A., Bouchriha, H., & Dridi, I. H. (2019). Integrated production, statistical process control, and maintenance policy for unreliable manufacturing systems. International Journal of Production Research, 57(8), 2548–2570. Balamurali, S., & Usha, M. (2014). Optimal designing of variables quick switching system based on the process capability index C pk . Journal of Industrial and Production Engineering, 31(2), 85–94. Bazhenova, E., Zerbato, F., Oliboni, B., & Weske, M. (2019). From BPMN process models to DMN decision models. Information Systems, 83, 69–88. Besseris, G. J. (2019). Evaluation of robust scale estimators for modified Weibull process capability indices and their bootstrap confidence intervals. Computers & Industrial Engineering, 128, 135–149. Burr, I. W. (2018). Statistical quality control methods. Routledge. Cakmakci, M., & Demirel-Ortabas, N. (2019). Performance measurement of SMED improved plastic injection molding production by using process capability analysis for attribute data. In A. Hamrol, A. Kujawińska, & M. F. S. Barraza (Eds.), Advances in Manufacturing II (pp. 188–205). Springer International Publishing. Process Capability Studies in an Automated Flexible Assembly Process … 31 Cano, E. L., Moguerza, J. M., & Corcoba, M. P. (2015). Quality specifications and process capability analysis with R. In E. L. Cano, J. Martinez Moguerza, & M. Prieto, Quality Control with R (pp. 221–236). Springer International Publishing. Chakraborty, A. K., & Chatterjee, M. (2016). Univariate and multivariate process capability analysis for different types of specification limits. In H. Pham (Ed.), Quality and Reliability Management and Its Applications (pp. 47–81). Springer. Chao, M.-T., & Lin, D. K. J. (2006). Another look at the process capability index. Quality and Reliability Engineering International, 22(2), 153–163. Chen, C.-C., Lai, C.-M., & Nien, H.-Y. (2010). Measuring process capability index C pm with fuzzy data. Quality & Quantity, 44(3), 529–535. Cohen, A., Tiplica, T., & Kobi, A. (2016). Design of experiments and statistical process control using wavelets analysis. Control Engineering Practice, 49, 129–138. Crowder, S. V. (1992). An SPC model for short production runs: Minimizing expected cost. Technometrics, 34(1), 64–73. Cui, Y., Yang, J., & Huang, S. (2018). Interval estimation of process capability indices based on the quality data of supplied products. In [Randall Bilof] 2018 12th International Conference on Reliability, Maintainability, and Safety (ICRMS), 400–404. Dalalah, D., & Hani, D. B. (2016). On the actual and observed process capability indices: A signal-to-noise ratio model. Measurement, 81, 241–250. Daniels, L., Edgar, B., Burdick, R. K., & Hubele, N. F. (2004). Using confidence intervals to compare process capability indices. Quality Engineering, 17(1), 23–32. de-Felipe, D., & Benedito, E. (2017). A review of univariate and multivariate process capability indices. The International Journal of Advanced Manufacturing Technology, 92(5–8), 1687–1705. Dianda, D. F., Quaglino, M. B., & Pagura, J. A. (2016). Performance of multivariate process capability indices under normal and non-normal distributions: Performance of multivariate process 32 (IJMS) Vol. 14, No. 1, Winter 2021 capability indices. Quality and Reliability Engineering International, 32(7), 2345–2366. Dovich, R. (1991). Statistical terrorists II- It’s not safe yet, Cpk is out there. MS, Ingersoll Cutting Tools Co. Flaig, J. J. (1999). Process capability sensitivity analysis. Quality Engineering, 11(4), 587–592. Flaig, J. J. (2002). Process capability optimization. Quality Engineering, 15(2), 233–242. Fuentes-García, M., Maciá-Fernández, G., & Camacho, J. (2018). Evaluation of diagnosis methods in PCA-based multivariate statistical process control. Chemometrics and Intelligent Laboratory Systems, 172, 194–210. Gaikwad, L. M., Sunnapwar, V. K., Teli, S. N., & Parab, A. B. (2019). Application of DMAIC and SPC to improve operational performance of manufacturing industry: A case study. Journal of The Institution of Engineers (India): Series C, 100(1), 229–238. Geng, Z., Wang, Z., Peng, C., & Han, Y. (2016). A new fuzzy process capability estimation method based on Kernel function and FAHP. IEEE Transactions on Engineering Management, 63(2), 177–188. George, S., & Sasi, A. (2017). Bootstrap lower confidence limits of superstructure process capability indices for Esscher-Transformed Laplace Distribution. Stochastics and Quality Control, 32(2). Geramian, A., Shahin, A., Minaei, B., & Antony, J. (2020). Enhanced FMEA: An integrative approach of fuzzy logic-based FMEA and collective process capability analysis. Journal of the Operational Research Society, 71(5), 800-812. Guarnieri, J. P., Souza, A. M., Jacobi, L. F., Reichert, B., & da Veiga, C. P. (2019). Control chart based on residues: Is a good methodology to detect outliers? Journal of Industrial Engineering International, 15(1), 119–130. Hadian, H., & Rahimifard, A. (2019). Multivariate statistical control chart and process capability indices for simultaneous monitoring of project duration and cost. Computers & Industrial Engineering, 130, 788–797. Process Capability Studies in an Automated Flexible Assembly Process … 33 He, Q. P., & Wang, J. (2018). Statistical process monitoring as a big data analytics tool for smart manufacturing. Big Data: Data Science for Process Control and Operations, 67, 35–43. Hesamian, G., & Akbari, M. G. (2018). Fuzzy process capability indices based on imprecise observations induced from non-normal distributions. Computational and Applied Mathematics, 37(5), 5715–5726. Ile, C. (2014). The implemenation of process capability: A case study in a wood industry company. IN [Liviu Miclea; Ioan Stoian; Szilard Enyedi], 2014 IEEE International Conference on Automation, Quality and Testing, Robotics, ( pp. 1–5). Jin, X., Fan, J., & Chow, T. W. S. (2019). Fault detection for rolling-element bearings using multivariate statistical process control methods. IEEE Transactions on Instrumentation and Measurement, 68(9), 3128–3136. Kahraman, C., Parchami, A., Cevik Onar, S., & Oztaysi, B. (2017). Process capability analysis using intuitionistic fuzzy sets. Journal of Intelligent & Fuzzy Systems, 32(3), 1659–1671. Kaya, İ., & Kahraman, C. (2011). Process capability analyses with fuzzy parameters. Expert Systems with Applications, 38(9), 11918–11927. Kodamana, H., Huang, B., Ranjan, R., Zhao, Y., Tan, R., & Sammaknejad, N. (2018). Approaches to robust process identification: A review and tutorial of probabilistic methods. Journal of Process Control, 66, 68–83. Kotz, S., & Johnson, N. L. (2002). Process capability indices—A Review, 1992–2000. Journal of Quality Technology, 34(1), 2–19. Kulkarni, S., Kulkarni, C., Vimal, K. E. K., & Jayakrishna, K. (2019). Statistical quality control of torque wrenches used in automotive assembly separtment. In S. S. Hiremath, N. S. Shanmugam, & B. R. R. Bapu (Eds.), Advances in Manufacturing Technology (pp. 199–208). Springer Singapore. Kumar, S., Dey, S., & Saha, M. (2019). Comparison between two generalized process capability indices for Burr XII distribution using bootstrap confidence intervals. Life Cycle Reliability and Safety Engineering, 8(4), 347–355. 34 (IJMS) Vol. 14, No. 1, Winter 2021 Littig, S. J., & Lam, C. T. (1993). Case studies in process capability measurement [Technical report]. Luan, H., Post, B. K., & Huang, Q. (2017). Statistical process control of in-plane shape deformation for additive manufacturing. IN [Xiaohong Guan and Qianchuan Zhao], 2017 13th IEEE Conference on Automation Science and Engineering (CASE), (pp. 1274–1279). Mezouar, H., El Afia, A., Chiheb, R., & Ouzayd, F. (2016). Proposal of a modeling approach and a set of KPI to the drug supply chain within the hospital. IN [Ahmed El Hilali Alaoui, Youssef Benadada and Jaouad Boukachour,], 2016 3rd International Conference on Logistics Operations Management (GOL) (pp. 1–6). Nikzad, E., Amiri, A., & Amirkhani, F. (2018). Estimating total and specific process capability indices in three-stage processes with measurement errors. Journal of Statistical Computation and Simulation, 88(15), 3033–3064. Onggo, B. S. S., Proudlove, N. C., D’Ambrogio, S. A., Calabrese, A., Bisogno, S., & Levialdi Ghiron, N. (2018). A BPMN extension to support discrete-event simulation for healthcare applications: An explicit representation of queues, attributes and data-driven decision points. Journal of the Operational Research Society, 69(5), 788–802. Palmer, K., & Tsui, K.-L. (1999). A review and interpretations of process capability indices. Annals of Operations Research, 87(1), 31–47. Pearn, W. L., & Chen, K. S. (1997). A practical implementation of the process capability index Cpk. Quality Engineering, 9(4), 721–737. Peruchi, R. S., Rotela Junior, P., Brito, T. G., Largo, J. J. J., & Balestrassi, P. P. (2018). Multivariate process capability analysis applied to AISI 52100 hardened steel turning. The International Journal of Advanced Manufacturing Technology, 95(9–12), 3513–3522. Piña-Monarrez, M. R., Ortiz-Yañez, J. F., & Rodríguez-Borbón, M. I. (2016). Non-normal capability indices for the weibull and lognormal distributions: Weibull and Lognormal capability Process Capability Studies in an Automated Flexible Assembly Process … 35 indexes. Quality and Reliability Engineering International, 32(4), 1321–1329. Price, F. (2017). Right first time: Using quality control for profit. Routledge. Rezaye Abbasi Charkhi, M., Aminnayeri, M., & Amiri, A. (2016). Process capability indices for logistic regression profile: Process capability indices for logistic regression profile. Quality and Reliability Engineering International, 32(5), 1655–1661. Roberto Jose, H. A., Adel Alfonso, M. M., & Juan Carlos, C. R. (2018). Robust multivariate process capability indices. Contemporary Engineering Sciences, 11(83), 4139–4146. Salazar-Alvarez, M. I., Temblador-Pérez, C., Conover, W. J., Tercero-Gómez, V. G., Cordero-Franco, A. E., & Beruvides, M. G. (2016). Regressing sample quantiles to perform nonparametric capability analysis. The International Journal of Advanced Manufacturing Technology, 86(5–8), 1347–1356. Selmi, S., Ben Amara, S., Ben Fredj, N., Kobi, A., & Ben Salah, I. (2018). Process capability indices and X¯$$ \overline{X} $$, R control chart limit adjustments by taking into account measurement system errors. The International Journal of Advanced Manufacturing Technology, 95(5–8), 1919–1930. Senvar, O., & Akburak, D. (2019). Implementation of Lean Six Sigma for airline ground handling processes. In F. Calisir, E. Cevikcan, & H. Camgoz Akdag (Eds.), Industrial engineering in the big data era (pp. 53–66). Springer International Publishing. Sharma, R., Singh, R., & Batish, A. (2020). On multi response optimization and process capability analysis for surface properties of 3D printed functional prototypes of PVC reinforced with PP and HAp. materialstoday: PROCEDINGS, 28(2), 1115-1122. Shi, L., Ma, H., & Lin, D. K. J. (2016). Process capability analysis via continuous ranked probability score: PCA via CRPS. Quality and Reliability Engineering International, 32(8), 2823–2834. Silva, A. F., Sarraguça, M. C., Fonteyne, M., Vercruysse, J., De Leersnyder, F., Vanhoorne, V., Bostijn, N., Verstraeten, M., Vervaet, C., Remon, J. P., De Beer, T., & Lopes, J. A. (2017). Multivariate statistical process control of a continuous 36 (IJMS) Vol. 14, No. 1, Winter 2021 pharmaceutical twin-screw granulation and fluid bed drying process. International Journal of Pharmaceutics, 528(1–2), 242–252. Sousa, S., Rodrigues, N., & Nunes, E. (2017). Application of SPC and quality tools for process improvement. Procedia Manufacturing, 11, 1215–1222. Sousa, S., Rodrigues, N., & Nunes, E. (2018). Evolution of process capability in a manufacturing process. Journal of Management Analytics, 5(2), 95–115. Sturgeon, T., Van Biesebroeck, J., & Gereffi, G. (2008). Value chains, networks and clusters: Reframing the global automotive industry. Journal of Economic Geography, 8(3), 297–321. Townsend, J. D., & Calantone, R. J. (2014). Evolution and transformation of innovation in the global automotive industry: Innovation in the global auto industry. Journal of Product Innovation Management, 31(1), 4–7. Tsai, C.-C., & Chen, C.-C. (2006). Making decision to evaluate process capability index Cpwith fuzzy numbers. The International Journal of Advanced Manufacturing Technology, 30(3), 334–339. Tsung, F., Zhang, K., Cheng, L., & Song, Z. (2018). Statistical transfer learning: A review and some extensions to statistical process control. Quality Engineering, 30(1), 115–128. Wang, H., Yang, J., & Hao, S. (2016). Two inverse normalizing transformation methods for the process capability analysis of non-normal process data. Computers & Industrial Engineering, 102, 88–98. Wu, C.-W., Pearn, W. L., & Kotz, S. (2009). An overview of theory and practice on process capability indices for quality assurance. International Journal of Production Economics, 117(2), 338–359. Yen, C.-H., Chang, C.-H., Aslam, M., & Jun, C.-H. (2018). Multiple dependent state repetitive sampling plans based on one-sided process capability indices. Communications in Statistics - Theory and Methods, 47(6), 1403–1412. Process Capability Studies in an Automated Flexible Assembly Process … 37 Yum, B.-J., & Kim, K.-W. (2011). A bibliography of the literature on process capability indices: 2000-2009. Quality and Reliability Engineering International, 27(3), 251–268. Zhang, Y., Ma, Y., Park, C., & Byun, J.-H. (2020). Integration of the variance of quadratic loss for evaluating process performance. Quality Engineering, 32(1), 46–57. Zhao, Y., Fatehi, A., & Huang, B. (2017). A data-driven hybrid ARX and Markov chain modeling approach to process identification with time-varying time delays. IEEE Transactions on Industrial Electronics, 64(5), 4226–4236. | ||
آمار تعداد مشاهده مقاله: 2,050 تعداد دریافت فایل اصل مقاله: 1,843 |