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1

Effective data usage for the proper and beneficial automotive production cost improvement

Krzesniak G.

Journal of Achievements in Materials and Manufacturing Engineering

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2023

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Vol. 119, nr 1

27-34

EN

Purpose The article aims to present a proposal and discuss the investment cost calculation procedures based on data collected during the manufacturing process, according to standard SPC control chart evaluation and standard PDCA. It is applied as a tool to support the process of continuous improvement of the manufacturing process and improve profitability by proper allocation the cost of investment and resources. Design/methodology/approach The study uses the results of a literature review on the issue of cost analysis and their modelling. Key elements are the main cost components, but also those that are considered less important and maybe overall decisive. Application cost to benefit relations – as a method of data evaluation for cost modelling to improve overall cost structure is proposed. Findings The relationship between return on investment and amortisation time allows to easily visualise which of the proposed changes are the most cost-effective over time. Based on the analysis conducted the results, the change is proposed below, in order from the most cost-effective. Research limitations/implications Further research should focus on the impact if a decision were based on the findings and proposals defined. Practical implications Each production process is based on the use of resources. This applies to both production plants and other activities. A resource can be anything that will be used in the manufacturing process. Of key importance for the success of the project is their proper use and not only effective but most of all efficient. Originality/value The considerations presented in the study may be the basis for determining the key factors of the cost of production and investment. The proposed simulation model allows for determining the efficient direction for investment. This, in turn, should enable us to define the main directions of searching for the optimisation of the product cost to achieve the expected cost and quality level.

2

Production cost calculation approach based on data collected during manufacturing process

Krześniak Grzegorz

System Safety : Human - Technical Facility - Environment

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2022

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Vol. 4, nr 1

19-27

EN

The aim of the article is to present a proposal and discuss the production cost calculation procedures based on data collected during manufacturing process, according to standard SPC control chart evaluation. It is applied as a tool to support the process of continuous improvement of the manufacturing process and improve profitability by reducing the cost of production. Research methodology - the study uses the results of a literature review on the issue of cost analysis and their modeling. Key elements are the main cost components, but also those that are considered less important and may be overall decisive. Application of Statistical Process Control - as a method of data collection for cost modeling to improve overall cost structure is proposed. Originality/value - the considerations presented in the study may be the basis for determining the key components of the cost of production. The proposed simulation model allows for the determination of the main quality cost factors. This, in turn, should allow to define the main directions of searching for the optimization of the product cost in order to achieve the expected level of cost and quality.

3

Assessing the representative elementary volume of rock types by X-ray computed tomography (CT) – a simple approach to demonstrate the heterogeneity of the Boda Claystone Formation in Hungary

Abutaha Saja M., Geiger János, Gulyás Sándor, Fedor Ferenc

Geologos

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2021

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Vol. 27, No. 3

157--172

EN

X-ray computed tomography (CT) can reveal internal, three-dimensional details of objects in a non-destructive way and provide high-resolution, quantitative data in the form of CT numbers. The sensitivity of the CT number to changes in material density means that it may be used to identify lithology changes within cores of sedimentary rocks. The present pilot study confirms the use of Representative Elementary Volume (REV) to quantify inhomogeneity of CT densities of rock constituents of the Boda Claystone Formation. Thirty-two layers, 2 m core length, of this formation were studied. Based on the dominant rock-forming constituent, two rock types could be defined, i.e., clayey siltstone (20 layers) and fine siltstone (12 layers). Eleven of these layers (clayey siltstone and fine siltstone) showed sedimentary features such as, convolute laminations, desiccation cracks, cross-laminations and cracks. The application of the Autoregressive Integrated Moving Averages, Statistical Process Control (ARIMA SPC) method to define Representative Elementary Volume (REV) of CT densities (Hounsfield unit values) affirmed the following results: i) the highest REV values corresponded to the presence of sedimentary structures or high ratios of siltstone constituents (> 60%). ii) the REV average of the clayey siltstone was (5.86 cm3) and (6.54 cm3) of the fine siltstone. iii) normalised REV percentages of the clayey siltstone and fine siltstone, on the scale of the core volume studied were 19.88% and 22.84%; respectively. iv) whenever the corresponding layer did not reveal any sedimentary structure, the normalised REV values would be below 10%. The internal void space in layers with sedimentary features might explain the marked textural heterogeneity and elevated REV values. The drying process of the core sample might also have played a significant role in increasing erroneous pore proportions by volume reducation of clay minerals, particularly within sedimentary structures, where authigenic clay and carbonate cement were presumed to be dominant.

4

Application of X-S Control Cards to Parameter Control in the Machining Process of Piston Castings for Internal Combustion Engines

Krępa Adam, Piątkowski J.

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 4

116--120

EN

This article discusses the possibility of using a two-track X-S control card on a Mesas device to control the production process parameters of piston castings for combustion engines. The research was carried out at the Federal-Mogul Gorzyce company. The basis for estimating the variability of the process results from the mean value (X) is the standard deviation (S). Thanks to specially designed measuring stations that use algorithms to calculate process indicators (Cp and/or Cpk) and their visualization, the cost of manufacturing products and the number of non-compliant products (scraps) are reduced. The process stability was investigated by measuring the key dimensions of the piston casting in a specific population and a given measurement cycle. Taking into account the precision of details, their technical condition, and surface quality, the production machines and cutting tools were optimally selected. It has been found that an important element of the effective use of Statistical Process Control (SPC) are trained/experienced operators who can correctly interpret the resulting control chart forms.

5

Implementation of Statistical Process Control (SPC) in the Sewing Section of Garment Industry for Quality Improvement

Abtew M. A., Kropi S., Hong Y., Pu L.

Autex Research Journal

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2018

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Vol. 18, no. 2

160--172

EN

The main aim of this research was to implement appropriate Statistical Process Control (SPC) techniques for quality characteristics on sewing floor of garment Industry. Among different SPC quality improvements tools, control charts have been selected. After analyzing and selecting different critical parameters based on company and customer requirements, the X-bar and R charts for variable and c-charts for attribute quality characteristics have been identified and implemented in the trouser sewing lines for quality improvement. The check points for selected control chart implementation have also been designed. Remedial action plans for the occurred special cause variations and process stability were developed. The project incorporated theoretical and on-job training schemes for different quality team members, to understand the SPC concept and its implementation procedure. After implementation, significant improvements in the sewing section were achieved. The four months analysis before and after implementation of the SPC tools showed that the rejection percentage was reduced from 9.141% to 6.4%. Successful implementation of the result of this project can significantly improve process performance of other similar manufacturing units with appropriate modification.

6

The statistical control of the measuring process capability of vertical displacement of the head restraint - The second part: Case study

Paprocka I., Dzięgiel A.

Selected Engineering Problems

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2015

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nr 6

71--76

EN

In the paper, two techniques of the statistical process control, namely: histogram and process capability are applied to examine whether a process is statistically controllable and to identify disturbances that occur in the process. The objective is to evaluate the capability of the measuring process of vertical displacement of the head restraint. In the measuring process, forces that are used to displace the head restraint up and down are recorded. The analysis consists of checking whether the lifting and lowering forces of the head restraint belong to the required ranges of forces. The processes of displacement of the head restraint up and down are characterised by a high potential, but a poor centering. In order to improve the centering of the process, causes of defects are identified.

7

Application of the statistical control of the production processes in organisation

Žarnovský J., Drlička R., Kováč I., Petruš M.

Management Systems in Production Engineering

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2014

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nr 3 (15)

135--139

EN

All recent experiences confirm the fact that the main tasks of quality management are guaranteed only with the high skilled employees. Employees are responsible for the production plan and development, services and processes. The series of standards called ISO 9000 help to establish quality management in organization. Usage of the quality management with statistical process control is also very important for the company. Companies are spending all human, material and financial resources to improve quality management. The objective of the paper is to outline the statistical process control in production company Finalcast Ltd. Žiar nad Hronom.

PL

Wszystkie ostatnie doświadczenia potwierdzają fakt, że główne zadania zarządzania jakością są gwarantowane tylko z wysoko wykwalifikowanymi pracownikami. Pracownicy są odpowiedzialni za plan produkcji i rozwoju, usług i procesów. Seria norm ISO 9000 jest pomocna w celu ustalenia zarządzania jakością w organizacji. Korzystanie w zarządzaniu jakością ze statystycznej kontroli procesu jest również bardzo ważne dla firmy. Firmy wykorzystują wszystkie zasoby ludzkie, materialne i finansowe w celu poprawy jakości zarządzania. Celem pracy jest określenie statystycznego sterowania procesem w produkcji firmy Finalcast Ltd. Žiar nad Hronom.

8

Testing hypothesis on stability of expected value and variance

Kończak G., Wywiał J.

Badania Operacyjne i Decyzje

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2006

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nr 1

73-83

EN

The simple samples are independently taken from normal distribution. The two functions of the sample means and sample variances are considered. The density functions of these two statistics have been derived. These statistics can be applied for verifying the hypothesis on stability of expected value and variance of normal distribution considered, e.g., in statistical process control. The critical values for these statistics have been found using numerical integration. The tables with approximated critical values of these statistics have been presented.

PL

W pracy jest rozwa.ane zagadnienie jednoczesnej stabilno.ci warto.ci przeci.tnej i wariancji. Proby proste s. pobierane niezale.nie z populacji o rozk.adzie normalnym. Rozwa.a si. dwie funkcje .redniej i wariancji z proby. Dla rozwa.anych statystyk zosta.y wyprowadzone funkcje g.sto.ci. Proponowane statystyki mog. by. wykorzystane do weryfikacji hipotezy o stabilno.ci warto.ci oczekiwanej i wariancji dla rozk.adu normalnego. Hipoteza taka mo.e by. rozwa.ana np. w statystycznym sterowaniu procesem przy konstrukcji kart kontrolnych. Bardzo trudne jest dok.adne wyznaczenie kwantyli rozwa.anych statystyk. Dlatego warto.ci krytyczne dla tych statystyk zosta.y wyznaczone dla trzech zwykle u.ywanych poziomow istotno.ci (�ż = 0,01, 0,05 i 0,1) dla prob o liczebno.ciach od 4 do 30 z wykorzystaniem ca.kowania numerycznego. Zaprezentowano tablice warto.ci krytycznych dla tych statystyk. Zaproponowane statystyki i wyznaczone warto.ci krytyczne mog. by. rownie. przydatne do wykrywania zmian w procesach produkcyjnych.