The article presents the results in the scope of analysis and improvement of the galvanized wire production process with the use of Six Sigma's DMAIC cycle. The basic problem was identified - incorrect wire diameters after galvanizing and specific tools and methods were used to analyze this problem and look for its solution. The potential of Pareto analysis, SPC method, control plan, 5WHY analysis was used. As a result of the analyzes carried out, the source cause was identified - contaminated containers dispensing the preparation maintaining the temperature in the galvanizing unit. To eliminate the problem, maintenance of the machine used to cover the bare wire with zinc was carried out, which allowed to achieve the following results: standstills at the Drawing and Galvanizing Department were eliminated, the duration of the manufacturing process and the percentage of products beyond the specification were significantly reduced.
The article presents an authorship version of the analysis procedure of data set from MSA Attribute Study for the purposes related to the reduction of conformity assessment errors and improvement of production process effectiveness. The MSA manual does not include any clear guidelines on how to eliminate errors or guidelines on how to analyse data sets from attribute study to eliminate errors. The article attempts to fill the gap identified in this field. In this article (Part 1), the author outlines the key features of own methodology of analysis data from MSA attribute study. In this article, which is one of the two parts, a research problem has been identified. It was emphasised that the influence on the reduction of the effectiveness of the production process have errors committed by the controllers in the alternative assessment of the product’s conformity with the requirements, i.e. errors of I and II type, in particular, II type errors, which should be first eliminated. A traditional approach to research analysis and evaluation of alternative inspection system practised in the MSA manual was presented. Four key assumptions that were adopted for the research goal were presented. Author’s procedure for analysis of errors from the attribute study data set is to point to the direction of activities in the field of error analysis, emphasise intolerance to any error, assume to use the root causes analysis and the coaching sessions to reach the root causes of conformity errors. In the second, final article in the series (Part 2), the author illustrates how, step by step, the procedure could be used in practice. It also presents the advantages and limitations of its own procedure.
In the first article in this series, the research methodology concerning the analysis of inspection errors based on MSA attribute study data set for the improvement purposes was presented. In the final article in the series, applying the methodology in practice step by step was presented. Instructions for correct performance of the analysis, in compliance with the author’s procedure, were determined. Both advantages and disadvantages of the developed approach were underlined.
The article presents the results of the use of SPC tools, i.e. control charts and indicators of the qualitative capability to assess the stability and capability of the production process of rolled products - I-sections. Statistical analysis of the collected data regarding the selected feature of the analysed product - the width of the foot, and the normality of the distribution were done, which showed that the obtained distribution of measurement results is not a normal distribution. As a result, appropriate SPC procedures for non-normal distribution were used. The Pareto-Lorenzo diagram and FMEA method were also used to obtain information about the structure of non-conformities of the analysed product and the level of risk associated with them. This information was used to propose corrective actions and improve the production process of rolled products.
The article presents the results regarding the elimination of constraints in the production process of a power equipment subassembly, a boiler chamber, together with an analysis of the benefits resulting from this, both financial and non-financial. The significance of bottlenecks in the production process, ways of its identification and limitations - in general - are presented. The article is a case-study of an attempt to eliminate the bottleneck in the production process of the boiler chamber, which turned out to be the process of drilling and marking-off, and work stations representing these processes. In order to eliminate the limitation, it was decided to replace the existing tracing and drilling work with a numerically controlled device - a boring machine moved from the liquidated department.. As a result, labor-intensive, manual chambers marking-off and the process of drilling holes with a smaller diameter drill have been eliminated. A number of benefits has been demonstrated resulting from the elimination of the bottleneck in the process, first of all, it was possible to reduce the duration of the marking-off and drilling operations and reduce the costs of the boiler chamber production process.
The multitude of concepts and methods of management and control related to the word “visual” in the area of production and quality management may cause difficulties with their perception, proper understanding and use of these terms by researchers from various backgrounds (not necessarily related to production) and countries, including Poland. In particular, the noticed inaccuracies in the use of terms with the word “visual” concern such terms as visual: management, control, inspection, and testing, where, for example, in the Polish language the first three different terms in English are named with the same phrase, which sometimes causes some confusion. The aim of the article was an attempt to distinguish, sometimes “troublesome” definitions, to indicate the area of their application, to define possible relations between them, which is a peculiar novelty. The article is an analysis of the literature related to these concepts, systematizes the types of visual concepts and methods in the area of production and quality. It defines in what context the indicated terms should be used by researchers and what is the relationship between them, and under what conditions they can be used separately or jointly. The article is an attempt to indicating and analysis of the interrelation between concepts in which the word “visual” appears concerning production practice. Concepts visual: management, control, inspection, and testing, as the author proves in the article, they should be translated into English with due diligence, due to the differences between them. It has been shown that there is a strong relationship between type definition pairs as visual management & visual control and visual inspection & visual testing, where it is not a mistake to use them interchangeably, and cases, where all these concepts can intertwine, are also given.
The article presents the results of the assessment of the level of work safety, the level of modernity and the efficiency of the use of machines on the labelling and packaging line. The assessment of the level of occupational safety was made on the basis of an interview conducted with machine operators, by direct observation and analysis of historical data. The basis for assessing the level of modernity was the ABC technology method and the 5-stage Parker scale, while the OEE indicator was used to assess the level of efficiency of the use. An assessment of the level of safety, modernity, efficiency and other aspects such as cleanliness, completeness, maintenance, improvements for machines in the line with the use a scale of 0-5 was included and next, based on the validity index, the overall result was calculated. Modified McKinsey matrix was used to evaluate these factors and comparison the obtained results with other lines in the company. As a result of the conducted analyzes, it was pointed out that it is necessary to take improvement measures in the area of the worst-assessed factors.
The article discusses the quality improvement concept in terms of companies’ competitiveness and its operations. The research object is a production company located in Silesia province. We analyzed the quality problems occurring in the company based on the selected quality management tools: Ishikawa diagram and the Pareto-Lorenz. It was presented and discussed basic types of waste occurring in the enterprise. It was proposed improvement actions and highlights the importance of immaterial resources - the company's workers.
The article presents the results of risk analysis associated with nonconformities of aluminium profiles in the process of coating and quality inspection methods used to their detection. Analysis of risk was done based on results of FMEA method. Evaluated quality inspection methods were distinguished based on the term of inspection in the ISO 9000:2005 norm. Manufacturing process of aluminium profile in micro-technological approach was presented. Triple quantification of nonconformities risk based on the FMEA method by using three different approaches was conducted. Analysis of nonconformities risks associated with the use of specific quality inspection methods was done. In the last part the analysis of causes of critical nonconformities, proposals for improvement actions reducing the risk of the critical nonconformities and applied critical quality inspection method were showed.