Statistical process control (SPC) in a high volume machining center : gage repeatability and reproducibility study
Name
939919071-MIT.pdf
Description
Full printable version
Size
9.73 MB
Format
Adobe PDF
Checksum (MD5)
3f4641d9a2197ab618d08f6cee7be6dd
Author(s)
Zhang, Shaozheng, M. Eng Massachusetts Institute of Technology
Advisor(s)
David E. Hardt and Duane S. Boning.
Date Issued
2015
Publisher
Massachusetts Institute of Technology
Abstract
The purpose of this project is to set up a statistical process control (SPC) system in a high volume machining center to reduce the scrap rate and improve the manufacturing quality. The system is demonstrated on a machining center at Waters Corporation as part of a team internship project. This thesis focuses on the gage repeatability and reproducibility study (Gage R&R study) for the implementation of the SPC system. Based on the knowledge about the machining processes and the gages available, we select the proper gages for different dimensions to conduct the Gage R&R study. Gage capabilities are analyzed and root-cause analysis for incapable gages is performed. Related reaction plans are developed and implemented in order to improve the gage capabilities. Discussion about tolerance redesign leads to the adjustment of specifications in the manufacturing area. As a result of these efforts, we find that the existing measurement system is capable for the SPC real time inspection system. As for the final result for this entire project, we demonstrated that with the SPC system, we successfully reduce the scrap rate by half and thus offer substantial cost savings as well as improved product quality.
Description
Thesis: M. Eng. in Manufacturing, Massachusetts Institute of Technology, Department of Mechanical Engineering, 2015.
Cataloged from PDF version of thesis.
Includes bibliographical references (pages 80-81).
Subjects
Mechanical Engineering.
MIT Department
Massachusetts Institute of Technology. Department of Mechanical Engineering
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