Controlling Quality Through Metal Fabrication Process Control
Maintaining product quality is necessary to any organization. Taking a broader approach, maintaining product quality can be done via controlling the quality of the processes that it takes to make that product. An instance of process control would be to take calculations of something when it is operating at its best so that the calculations can be compared to measurements in the future, to make sure that optimum quality functions are still in place. For instance, strain on the frames of machines can be assessed via a strain monitor to rate quality. The machine’s frame strain must have been assessed when it was working at its best and producing quality parts so that measurements from that assessment may be employed as a control to measure against when the machine starts operating in a way that is not best. This can assist in measuring the entire production process. Monitoring processes for discrepancies is a revolutionary new way of looking at quality assurance rather than looking for defects in parts. If a process makes quality parts and is able to be repeated, this is an ideal scenario for a manufacturing environment.
Process Valuation Monitoring
The traits of process variation monitoring involve overseeing all of the production but not needing to add any extra steps in the process. Also, if a piece is discovered to be abnormal, processing is ceased so that there is no misusing of time in manufacturing bad parts and the defective parts do not lead to squandered materials. When process variation monitoring is put in place, maintenance staff do not have to insist that machines are shut down at periodic times so that they can accomplish their supportive tasks or worry about not accomplishing their maintenance often enough, and the machines don’t perform. In this environment, the maintenance occurs only when it is needed. Maintenance costs will therefore go down and efficiency in machine operation and operation as a whole will increase.
Tooling will only be swapped on when necessary in this environment so money will be saved because the tooling will not be replaced too soon or too late. The final trait is that all staff in the company will focus on process instead of the actual pieces being produced so gains will be found in many places including the quality of the end product.
For process control to be useful in any setting, it must have a goal that is narrow and comprehensive. There needs to also be a method of measurement in place so that it can be discovered if the purpose is attainable or at what point it will have been attained. There should also be a set of procedures with responses that are anticipated to operate, so that effectiveness can be assessed.
Process Control: Case Study
At Maloya, they put in place process control in their manufacturing environment. They utilized it as part of their regular maintenance of machinery which involved regular calibration of the machines. Their laser machines were adorned with test elements and these would be assessed and the results recorded to make sure that the machine was giving precise results within the original equipment manufacturer (OEM) specifications. This afforded Maloya with a proven process capability to guarantee that their methods are working optimally which then transforms to their quality levels and standards. This process can also be duplicated in areas such as machining and welding, as well as in forming work centers.
By implementing process controls, you will find it an effective way of continuing quality management in a metal production environment. Rather than concentrate on the parts, focus on the processes and everything will fall into place if performed effectively.
Roger Hug is the VP of Sales Engineering of Maloya Laser, leaders in <A href=”http://www.MaloyaLaser.com”>contract manufacturing</a> and <A href=”http://www.maloyalaser.com/turnkey_products.php”>turnkey manufacturing</a> servicing medical, aerospace, scientific and transportation needs with Laser Cutting systems.