Manufacturing Solutions for Consistent Quality and Reliability: The Nine-Step Problem-Solving Process

Overview

This key variable isolation approach looks at each quality and reliability problem from the standpoint of patterns of variation, and each successive test brings the investigator closer to a solution. It's a dynamic process that will locate even obscure causes of variability, as well as variability created by unforeseen interaction of materials or manufacturing methods. And because The Traver Nine-Step Problem-Solving Process can isolate multivariable causes - unlike most engineering methods, which point only to ...
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Overview

This key variable isolation approach looks at each quality and reliability problem from the standpoint of patterns of variation, and each successive test brings the investigator closer to a solution. It's a dynamic process that will locate even obscure causes of variability, as well as variability created by unforeseen interaction of materials or manufacturing methods. And because The Traver Nine-Step Problem-Solving Process can isolate multivariable causes - unlike most engineering methods, which point only to single causes - even the most randomly occurring problems affecting consistent production standards can be found and fixed. Twenty-one fast-moving, fascinating case histories covering a wide range of manufactured products provide the bulk of the information in the book, and show how the generic Traver Nine-Step Problem-Solving Process can be applied successfully in a variety of situations. These are difficult, sometimes maddening product quality and reliability problems that take the most thorough analysis to solve. The approach the author outlines is akin to detective work: Participants gather clues and zero in on "what dunnit." The result is a very effective learning vehicle, showing readers how real problems are solved, with all the blind alleys, loose ends, and contradictory information found in life, rather than in books!

For middle managers, engineers, and quality assurance and design staff members, here's how to solve real-life problems on the factory floor more quickly--often without having to shut down the production line. Twenty-one fascinating case histories, covering a wide range of manufactured products, show how the process can be applied successfully to a variety of situations.

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Editorial Reviews

Booknews
Offers middle managers and engineers a method of tracking down the cause of product variation in the manufacturing process, often without stopping production. It involves looking at each quality and reliability problem from the perspective of patterns of variation, then applying successive tests to narrow down the source of the problem and the solution. Unlike most such methods, it can isolate multiple causes that sometimes make variations seem to occur almost randomly. Annotation c. Book News, Inc., Portland, OR (booknews.com)
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Product Details

  • ISBN-13: 9780814402719
  • Publisher: AMACOM
  • Publication date: 5/16/1995
  • Pages: 224
  • Product dimensions: 7.35 (w) x 10.31 (h) x 0.87 (d)

Table of Contents

Foreword
Preface
Acknowledgment
1 Key Variable Isolation 1
2 Multi-Vari Studies 7
3 Quantification: The Initial Diagnostic Step 13
4 The Case of Out-of-Specification Coil Resistance 18
5 Interactions 22
6 The Case of the Flat Beer 25
7 Designed Experiments 32
8 The Case of Porous Decorative Rings 38
9 The Case of Scrapped Artillery Projectiles 46
10 The Case of Shorts on Dust Cover Seals 55
11 The Case of Rejects on a Multicavity Compression Molder 61
12 The Case of Varying Seat Measurements 66
13 The Case of Bore Defects on Centrifugal Castings 74
14 The Case of Weeping Stoppers 82
15 Introduction to Isoplots 91
16 The Case of the Noisy Motor 102
17 The Case of Low Yield on Solid-State Devices 112
18 The Case of Improving Aluminum Die-Casting Quality 123
19 The Case of Nondisintegrating Tablets 140
20 The Case of the Eccentric Discs 150
21 The Case of the Spline Demerits 155
22 The Case of the Mysterious Hot Crank 160
23 Variables Search 174
24 Parallel Path Experimentation 183
Epilogue 187
Appendixes: Multi-Vari Exercises 189
Appendix I. Rope Consistency 191
Appendix II. Foundry Measles Charts 201
Glossary 213
Bibliography 221
Index 223
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