Table Of ContentTotal Manufacturing
Assurance
Second Edition
Total Manufacturing
Assurance
Controlling Product Quality, Reliability,
and Safety
Second Edition
Dr. Douglas Brauer and Dr. John Cesarone
Second edition published 2022
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742
and by CRC Press
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© 2022 Douglas Brauer and John Cesarone
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Library of Congress Cataloging‑in‑Publication Data
Names: Brauer, Douglas, author. | Cesarone, John, author.
Title: Total manufacturing assurance : controlling product quality, reliability, and safety /
Douglas Brauer and John Cesarone.
Description: First edition. | Boca Raton, FL : CRC Press, 2022. | Includes
bibliographical references and index.
Identifiers: LCCN 2021048082 (print) | LCCN 2021048083 (ebook) |
ISBN 9781032076362 (hbk) | ISBN 9781032076379 (pbk) | ISBN 9781003208051 (ebk)
Subjects: LCSH: Quality assurance. | Total quality control.
Classification: LCC TS156.6 .B75 2022 (print) |
LCC TS156.6 (ebook) | DDC 658.5/62—SSdc23/eng/20211109
LC record available at https://lccn.loc.gov/2021048082
LC ebook record available at https://lccn.loc.gov/2021048083
ISBN: 978-1-032-07636-2 (hbk)
ISBN: 978-1-032-07637-9 (pbk)
ISBN: 978-1-003-20805-1 (ebk)
DOI: 10.1201/9781003208051
Typeset in Times
by codeMantra
Contents
Foreword ................................................................................................................xiii
Preface......................................................................................................................xv
Authors ....................................................................................................................xix
Section i introduction to tMA
Chapter 1 The World of Manufacturing ...............................................................3
1.1 Industrial Revolution .................................................................3
1.2 Innovation in Management and Manufacturing ........................6
1.3 Industry 4.0 ................................................................................6
References ............................................................................................9
Chapter 2 Total Manufacturing Assurance .........................................................11
2.1 Strategic Manufacturing Management ....................................13
2.2 Manufacturing System Control ...............................................13
2.3 System Improvement Monitoring ............................................14
2.4 Summary .................................................................................14
Section ii Strategic Manufacturing Management
Chapter 3 Strategic Operations ...........................................................................17
3.1 Strategic Planning ...................................................................17
3.2 Strategic Planning Path ...........................................................21
3.3 Product Assurance Strategy ....................................................26
3.3.1 Reliability, Safety, and Quality Requirements ...........26
3.4 Summary .................................................................................32
Questions ............................................................................................33
References ..........................................................................................33
Chapter 4 Innovation and Technology Transfer ..................................................35
4.1 Technology Development ........................................................35
4.1.1 Technology S-Curve & Technology Life Cycle .........37
4.2 Strategic Implications on Technology Commercialization .....40
4.3 Global Technology Transfer ....................................................41
4.4 Summary .................................................................................56
v
vi Contents
Questions ............................................................................................57
References ..........................................................................................57
Chapter 5 Engineering Economic Analysis ........................................................59
5.1 Economic Analysis ..................................................................59
5.1.1 Time Value of Money .................................................59
5.1.2 Selection of Alternatives ............................................60
5.1.2.1 Initial Cost ..................................................61
5.1.2.2 Interest Rate ................................................61
5.1.2.3 Annual Cost or Benefit ...............................61
5.1.2.4 Economic Life ............................................61
5.1.2.5 Salvage Value ..............................................62
5.1.2.6 After-Tax Cash Flow ...................................62
5.2 Proforma Development ............................................................63
5.3 Investment Decision Matrix ....................................................65
5.3.1 Time to Market ...........................................................65
5.3.2 Initial Investment ........................................................65
5.3.3 Excess Present Value Index ........................................65
5.3.4 Benefit-Cost Ratio ......................................................66
5.3.5 Investment Payback ....................................................67
5.3.6 Internal Rate of Return ..............................................67
5.3.7 Ownership ..................................................................67
5.3.8 Asset Value .................................................................67
5.3.9 Purchase Investment Analysis ....................................68
5.4 Summary .................................................................................74
Questions ............................................................................................76
References ..........................................................................................76
Chapter 6 Management Control ..........................................................................77
6.1 Integrated Management Control ..............................................77
6.1.1 Manufacturing Enterprise Focus ................................78
6.2 Decision-Making Using Qualitative and Quantitative Tools .....81
6.2.1 Project Management Networking ...............................83
6.2.2 Optimization Modeling ..............................................86
6.2.3 Linear Programming ..................................................86
6.3 Tactical Operations ..................................................................91
6.3.1 Design for Manufacturing ..........................................91
6.3.1.1 DFM Guidelines .........................................92
6.3.2 Computer-Integrated Manufacturing .........................93
6.3.2.1 Computer-Aided Design .............................93
6.3.2.2 Computer-Aided Manufacturing ................94
6.3.2.3 Computer-Aided Process Planning .............95
6.3.2.4 Flexible Manufacturing Cells and Systems ...96
Contents vii
6.3.3 Material Requirements Planning .............................100
6.3.3.1 Master Production Schedule .....................100
6.3.3.2 Bill of Materials ........................................101
6.3.3.3 Inventory Record File ...............................101
6.3.4 Just-In-Time Manufacturing .....................................103
6.3.4.1 Inventory Exposure ...................................104
6.3.4.2 Pull-Based Production ..............................104
6.3.4.3 JIT Implementation ...................................105
6.3.4.4 Pull-Based Startup ....................................107
6.3.5 Technology Leveraging ............................................109
6.3.5.1 Mechatronics ............................................109
6.3.5.2 Artificial Intelligence ................................109
6.3.5.3 Machine Learning ....................................110
6.3.5.4 Automated Machining/Processes .............110
6.3.5.5 Additive Manufacturing ...........................110
6.3.5.6 Advanced Robotics ...................................111
6.3.5.7 Autonomous Technologies ........................111
6.3.5.8 Man/Machine Interface ............................111
6.3.5.9 Internet of Things .....................................112
6.3.5.10 Big Data and Analytics .............................112
6.3.5.11 Virtual/Augmented Reality ......................112
6.3.5.12 Supply Chain Visibility ............................113
6.3.5.13 Block-Chaining .........................................113
6.3.5.14 Cyber-Security ..........................................114
6.4 Expert Systems ......................................................................115
6.4.1 Expert System Definition .........................................115
6.4.2 Expert Systems versus Artificial Intelligence ..........116
6.4.3 Expert System Structure...........................................117
6.4.4 Expert System Development ....................................120
6.4.4.1 Expert System Domain .............................120
6.4.4.2 Domain Expert .........................................121
6.4.4.3 Knowledge Engineer.................................121
6.4.4.4 Expert System Shell ..................................122
6.4.4.5 The Development Process ........................122
6.4.5 Expert System Topical Application Areas ...............124
6.5 Summary ...............................................................................131
Questions ..........................................................................................131
References ........................................................................................132
Chapter 7 Organizational Leadership ...............................................................133
7.1 Motivation ..............................................................................133
7.1.1 Leadership Style .......................................................134
7.1.1.1 Organizational Psychology .......................135
7.1.1.2 Strategic Motivation Model ......................136
viii Contents
7.2 Teaming .................................................................................137
7.2.1 Basic Assumption Theory ........................................138
7.2.2 Team Effectiveness ...................................................139
7.2.2.1 Personality ................................................140
7.2.2.2 Team Composition ....................................142
7.2.2.3 Reactions to Group Situations Test ...........143
7.3 Strategic Human Resource Planning .....................................144
7.3.1 Performance Appraisal .............................................145
7.3.2 Organizational Development/Training ....................147
7.3.2.1 Stages of Development .............................148
7.3.2.2 Technical Development Program .............149
7.3.3 Succession Planning .................................................150
7.4 Summary ...............................................................................155
Questions ..........................................................................................155
References ........................................................................................156
Section iii Manufacturing System control
Chapter 8 System Definition .............................................................................161
8.1 System Definition Activities ..................................................161
8.2 Process Planning ...................................................................162
8.2.1 Process Planning for Specific Industries ..................163
8.3 Plant Layout and Flow ...........................................................164
8.3.1 Plant Layout Analysis ...............................................164
8.3.1.1 The From-To Chart ...................................165
8.3.1.2 The REL Chart .........................................166
8.3.1.3 Space-Relationship Diagram and
Block Plan .................................................167
8.3.2 Plant Layout Synthesis .............................................168
8.4 Material Handling .................................................................169
8.4.1 Material Handling Equations ...................................171
8.4.2 Automated Guided Vehicles .....................................172
8.5 Automation ............................................................................173
8.5.1 Automation Elements ...............................................174
8.6 Flexible Manufacturing Systems ...........................................176
8.7 Simulation ..............................................................................176
8.7.1 Simulation Example .................................................178
8.8 Summary ...............................................................................182
Questions ..........................................................................................183
References ........................................................................................183
Contents ix
Chapter 9 Product Manufacturing Degradation Control ..................................185
9.1 Reliability Engineering and Control .....................................186
9.1.1 Reliability Fundamentals .........................................189
9.1.1.1 General Approach to Reliability
Improvement .............................................191
9.1.2 Design for Reliability ...............................................192
9.1.2.1 Part Selection and Control ........................192
9.1.2.2 Part Derating .............................................193
9.1.2.3 Design Simplification ...............................195
9.1.2.4 Redundancy ..............................................195
9.1.3 Reliability Prediction ...............................................198
9.1.4 Growing Product Reliability Prior to Manufacture ....203
9.1.4.1 Test Data Collection and Analysis ............207
9.1.5 Manufacturing System Modeling .............................209
9.1.5.1 Defect Removal Planning .........................211
9.1.5.2 PRMDA Technique...................................211
9.2 Safety Engineering and Control ............................................217
9.2.1 Safety Assessment ....................................................218
9.2.1.1 Fault Tree Analysis ...................................219
9.2.1.2 Failure Mode, Effects, and
Criticality Analysis ...................................222
9.2.2 Safety and the Worker ..............................................224
9.2.2.1 Human Factors ..........................................225
9.2.2.2 Safety Program Planning ..........................227
9.3 Quality Engineering and Control ..........................................229
9.3.1 Design of Experiment...............................................229
9.3.1.1 Variable Identification...............................231
9.3.1.2 Analysis of Variance .................................232
9.3.2 Statistical Process Control .......................................235
9.3.2.1 The Normal Distribution ..........................237
9.3.3 Process Capability Analysis .....................................238
9.3.3.1 Process Monitoring ...................................240
9.3.3.2 Control Charts for Variables .....................244
9.3.3.3 Control Charts for Attributes ....................245
9.3.4 Acceptance Sampling ...............................................246
9.3.5 Six-Sigma Fundamentals ..........................................247
9.3.6 Cost of Quality .........................................................248
9.3.6.1 Good Costs of Quality ..............................248
9.3.6.2 Bad Costs of Quality .................................249
9.3.7 Total Quality Management .......................................249
9.4 Lean Manufacturing Fundamentals ......................................250
9.4.1 Minimize Waste .......................................................250
9.4.2 Perfect First-Time Quality ........................................251
