Use of Capability Indices to Drive Part Quality（PD

46thAnnualFallTechnicalConferenceUseofCapabilityIndicestoDrivePartQualityBettyRoseXeroxOfficePrintingBusinessPOBox1000/MS60-600Wilsonville,[e-mail]•Technology•TheSevenStepsofQualityManagementII.Examplesofhowcapabilityindicesareused•WiperBlade:Qualificationsteps&QualityPlan•ReclaimAssembly:Supplierselection•PivotArm:Correctiveactions•FoamRoller:Qualification&trendchartingIII.ConclusionXeroxOfficePrintingBusinessWilsonvilleORMotivation:LargepercentageofpurchasedpartsSupplychainmanagement•managingpartquality•meetdesignintent&specificationsPhaser8200introducedSpring2002OfficeNetworkPrinter,TektronixbyXerox16ppmFullColor,1200dpiPhotoModeTheSevenStepsofQualityManagementStep1:SupplierSelection.Identify,evaluateandselectsuppliersthatmeetXeroxOPB’stechnology,quality,serviceandtotalcostobjectives.Step2:ManufacturingProcessDevelopment.Step3:ToolingManufacturing.Developtoolingandfixturesforcustomdesignedpartsandmodules.Step4:ProcessQualification&Control.Step5:QualityPlan.Step6:ReleasetoProduction.Ensurethatallqualitymanagementrequirementshavebeensatisfiedpriortoproduction.Step7:ContinuousImprovement.Improvequalityandlowercostoverproductlife.Step2:ManufacturingProcessDevelopmentDevelopmentofcapableprocesses(forcevisibilityofprocesscapabilitymismatcheswithdesignrequirements);occursconcurrentwithdesigndevelopmentKeyelements:CommunicationofdesignrequirementsintheformofCriticalToFunction(CTF)featuresIdentificationofcriticalmanufacturingprocessesandestimatesoftheircapabilityFlowchartsofproposedmanufacturingprocessesProcesscharacterizationandprocessbasedcostmodelingStep4:ProcessQualification&ControlEstablishmanufacturingprocess&toolingcapabilitypriortoreleaseforproductionKeyelements:CapabilitystudiesonallCTF/CTPpartdimensions&featuresFirstarticleinspectionSelectionofCTF/CTPdimensionsforongoingSPCandVOESetsamplingmethodologyandcontrollimitsforSPCStep5:QualityPlanDevelopQualityPlanwithsuppliertoensuredesignrequirementsaremetthroughoutproductlifeKeyelements:Qualitygoals(Cp,Cpk,ppm)CTF/CTPdimensionsandfeaturestobereportedMeasurementandinspectionmethodsReportingrequirementsforSPCandVOESamplePPMChart010002000300040005000OctNovDecJanFebMarAprMayJunJulAugSepPPMgoalppm12MonthRollingDataOctNovDecJanFebMarAprMayJunJulAugSepTotalQtyReceived66,34427,21064,63930,65449,72729,52755,868101,12644,95430,52021,46880,978TotalQtyRejected96332809001304222040SupplierPPM1,4471,21343301,810023309347210494On-TimePerformance100%100%100%100%100%100%100%100%100%100%98%100%Part#'sRejected000-0000-006816000-0000-001415000-0000-00234022000-0000-004210131520000-0000-002116000-0000-0013000-0000-004000-0000-00719000-0000-0013000-0000-0027SolidInkPrintingProcessDrumMaintenancePartsDrumMaintenanceWiperBladeQualificationSteps&QualityPlanCapabilityStudiesforWiperBladeLength,trial1Samples:30Mean:9.31399StdDev:.00582Cpk:.1722Cp:.85913spLim:(9.2965,9.3315)Target:9.302SpecLim:(9.287,9.317)MeanLSLUSL+3sp-3spTarget02468109.2859.299.2959.39.3059.319.3159.329.3259.339.335CapabilityStudiesforWiperBladeLength,trial2Samples:30Mean:9.31123StdDev:.0039886Cpk:.4819Cp:1.2543spLim:(9.2993,9.3232)Target:9.302SpecLim:(9.287,9.317)MeanLSLUSL+3sp-3spTarget02468109.2859.299.2959.39.3059.319.3159.329.325CapabilityStudiesforWiperBladeLength,trial3Samples:30Mean:9.30577StdDev:.0021444Cpk:1.746Cp:2.3323spLim:(9.2993,9.3122)Target:9.302SpecLim:(9.287,9.317)MeanLSLUSL+3sp-3spTarget0246810129.2859.299.2959.39.3059.319.3159.32•3ManufacturingTrials•Atleast1monthapart•#1disappointing•#3passestheindicescriteria…butthere’saproblem!CapabilityStudiesforWiperBladeLegHeight,left,1sttrailSamples:30Mean:2.39309StdDev:.0048958Cpk:.743Cp:1.3623spLim:(2.3784,2.4078)Target:2.384SpecLim:(2.364,2.404)MeanLSLUSL+3sp-3spTarget024682.362.3652.372.3752.382.3852.392.3952.42.4052.41CapabilityStudiesforWiperBladeLegHeight,left,2ndtrialSamples:30Mean:2.38307StdDev:.0081998Cpk:.7751Cp:.8133spLim:(2.3585,2.4077)Target:2.384SpecLim:(2.364,2.404)MeanLSLUSL+3sp-3spTarget02468102.352.362.372.382.392.42.41CapabilityStudiesforWiperBladeLegHeight,left,3rdtrialSamples:30Mean:2.3828StdDev:.0055174Cpk:1.136Cp:1.2083spLim:(2.3662,2.3994)Target:2.384SpecLim:(2.364,2.404)MeanLSLUSL+3sp-3spTarget024681012142.362.3652.372.3752.382.3852.392.3952.42.405•#2:isthisanoutlyerormeasurementproblem?•#3:sameevidenceofsortCapabilityStudiesforWiperBladeLegHeight,right,1sttrialSamples:30Mean:2.39109StdDev:.0033532Cpk:1.283Cp:1.9883spLim:(2.381,2.4012)Target:2.384SpecLim:(2.364,2.404)MeanLSLUSL+3sp-3spTarget02468102.362.3652.372.3752.382.3852.392.3952.42.405CapabilityStudiesforWiperBladeLegHeight,right,2ndtrialSamples:30Mean:2.38337StdDev:.0062228Cpk:1.037Cp:1.0713spLim:(2.3647,2.402)Target:2.384SpecLim:(2.364,2.404)MeanLSLUSL+3sp-3spTarget051015202.362.3652.372.3752.382.3852.392.3952.42.405CapabilityStudiesforWiperBladeLegHeight,right,3rdtrialSamples:30Mean:2.38647StdDev:.0049252Cpk:1.187Cp:1.3543spLim:(2.3717,2.4012)Target:2.384SpecLim:(2.364,2.404)MeanLSLUSL+3sp-3spTarget05101