Manufacturing Best Practices

224 Pages·2010·6.951 MB·English

by  Bobby Hull

Manufacturing
Best Practices
Wiley & S AS Business Series
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Manufacturing
Best Practices
Optimizing Productivity and
Product Quality
Bobby Hull
John Wiley & Sons, Inc.
Copyright © 2011 by Bobby Hull. All rights reserved.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.
Published simultaneously in Canada.
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Library of Congress Cataloging-in-Publication Data:
Hull, Bobby, 1958–
Manufacturing best practices : optimizing productivity and product quality /
Bobby Hull.
p. cm. – (Wiley and SAS business series; 29)
Includes index.
ISBN 978-0-470-58214-5; ISBN 978-0-470-93198-1 (ebk);
ISBN 978-0-470-93199-8 (ebk); ISBN 978-0-470-93200-1 (ebk)
1. Manufacturing processes. 2. Quality control. 3. Industrial
productivity. I. Title.
TS183.H85 2010
670–dc22
2010031655
Printed in the United States of America
10 9 8 7 6 5 4 3 2 1
I dedicate this work to my mom and dad, who taught me
very early that perseverance, honesty, and hard work
are just as important as education. My deepest,
heartfelt thanks to you both. I love you.
A man with blinded eyes does not see, because
he cannot.
A man with a closed mind does not see, because
he will not.
To the fi rst, the light is freedom.
To the other, enlightenment is a demon.
Thus is the way of the world . . .
Bobby Hull 2010
Contents
Preface xi
Acknowledgments xvii
Chapter 1 Understanding Quality and Quality
Requirements ......................................................1
The End Result 3
Quality 3
Quality Control 5
Quality Assurance 6
The Quality System 6
Quality Requirements and Specification Review 7
Quality Requirements 9
Final Thoughts 10
Chapter 2 Testing ...............................................................11
Testing: What Is It? 11
Testing: Location, Technicians, and Training 12
Procedures 14
Final Thoughts 31
Chapter 3 Inspection and Data Handling ..........................33
Inspection 34
Plans and Procedures 34
Data, Data, Everywhere! 43
Final Thoughts 48
vii
viii ▸ CONTENTS
Chapter 4 Calibration .........................................................49
Gauge Identification 51
Calibration Standards 53
Calibration Recall and Data Management System 54
Moving beyond the Simple Recall System 55
Out-of-Tolerance Conditions 56
Final Thoughts 58
Chapter 5 Corrective and Preventative Action and
Error Proofing....................................................59
When Is Corrective Action Required? 61
Requirements for a Corrective Action System 62
Investigating and Resolving a Corrective Action Issue 63
Corrective Action Resolution 66
Error Proofing 67
Preventative Action 69
Final Thoughts 72
Chapter 6 Document Control: Ensuring Vital
Information Is Available to Those
Who Need It ......................................................73
Why Go to All This Effort? 74
Paper-Based Systems 75
Revision Control 76
Document Distribution 76
Uncontrolled Copies 79
Electronically Based Systems 80
Guidelines and Audits 81
Final Thoughts 82
Chapter 7 Process Control .................................................83
How Do I Do It? 85