Assignment No.3
Title : Blue in Green Recycling and Manufacturing Company
Author: Worapol Puaratanaaroonkorn
Class code: IE673101 live
Date: Nov-1-2014
eLearning Pack ID: IE673-Fall-2014-63-63
Statement: All contents of this assignment have been completed by Worapol Puaratanaaroonkorn.
Author: Worapol Puaratanaaroonkorn
Class code: IE673101 live
Date: Nov-1-2014
eLearning Pack ID: IE673-Fall-2014-63-63
Statement: All contents of this assignment have been completed by Worapol Puaratanaaroonkorn.
Content:
- Introduction and Objectives of the Project
- A brief description of the methodologies applied
- The Main Body of The Project
- Social Networking
- Summary
- Further work needed / proposed
- References and Bibliography
- Appendix (- if necessary, e.g. drawings, diagrams)
Introduction and Objectives of the Project
The objectives of the Assignment No.3 focusing on Process Control Charts by applying the monitoring tool an a critical process with in the Blue in Green Recycling and Manufacturing Company. The next step, the company will analyze its critical process in or order to control statistically Control charts can help us to maintain smooth production. To accomplish this objective, we will use one Process Control Chart for Variables, and two control charts for Attributes. We will also show how our company can collaborate in designing green and sustainable TQM processes with our four collaborative companies.
The Blue in Green Recycling and Manufacturing Company, BGRM, is the expert plastic manufacturing company that supplies that focusing on the premium grade products and concerning to preserve the environment. Regarding to protect the ecosystem and concerning global warming issue, The BGRM company has planned to process the high quality plastic from recycle products with automation process.
A Brief Description of the Methodologies Applied
Statistical methods, discussed in this Chapter, represent an important, nevertheless not the only methods, that lead to process improvement. We use statistical tools to detect out-of-control processes, as well as for trend analysis, to capture processes before they go out-of-control. This is because out-of-control proceses are in most cases not sustainable, therefore our continuous process improvement efforts must focus on making processes to be in-control. We use the Control Charts for Variables and Attributes in our new 'Ranky-Stat_Library’ folder in this 3D eBook.
These things can be accomplished by the use of control charts for variables or attributes. The construction of a control chart is typically performed in three main steps:Collect data, Plot data and Compute the central lines and control limits (which are automatically obtained after the data fed in the spreadsheet)
The Main Body of The Project
The main purpose of this assignment is to focus on the quality of the final product, so on this project, the company will concentrate on the Manufacturing Process, As you can see from Assignment No.1, CIMPgr Model, in Figure 3: Child Process, A4: Manufacturing. That creates air pollution from melting and boiling the recycled plastic before the plastic would be injected to the molding. The boiling systems and molding machines had created a lot of pollution from plastic melting that needs to fix it as soon as possible.
Regarding to the green engineering and sustainable environment, the Blue in Green Recycling and Manufacturing Company extremely concern about the clean production that will not pollute the environment and ecosystem. Moreover, according to the CORA Spreadsheet in Assignment No.2, one of the most important process is Total Quality Management that focused on using Green Energy, Eco-friendly and Compliance standards that will play a main roles on this assignment.
As a result of this problem, the engineering team was measuring the amount of Carbon Dioxide, (CO2) that was created from the boiler from the process of plastic melting. To measure the amount of carbon dioxide in the factory we will measure in the indoor air quality by using Nondispersive Infrared (NDIR) CO2 Sensors. As you can see in the charts below, the 5 processing machines, a sample size of five, had been measure for 24 weeks to detect the gas emission. And, finding the solution to improve the production system. The first figure, X-bar-chart, shows the average of carbon dioxide emission index over time. The second plot is the r-chart, which shows the changes in each week’s range over time.
The objectives of the Assignment No.3 focusing on Process Control Charts by applying the monitoring tool an a critical process with in the Blue in Green Recycling and Manufacturing Company. The next step, the company will analyze its critical process in or order to control statistically Control charts can help us to maintain smooth production. To accomplish this objective, we will use one Process Control Chart for Variables, and two control charts for Attributes. We will also show how our company can collaborate in designing green and sustainable TQM processes with our four collaborative companies.
The Blue in Green Recycling and Manufacturing Company, BGRM, is the expert plastic manufacturing company that supplies that focusing on the premium grade products and concerning to preserve the environment. Regarding to protect the ecosystem and concerning global warming issue, The BGRM company has planned to process the high quality plastic from recycle products with automation process.
A Brief Description of the Methodologies Applied
Statistical methods, discussed in this Chapter, represent an important, nevertheless not the only methods, that lead to process improvement. We use statistical tools to detect out-of-control processes, as well as for trend analysis, to capture processes before they go out-of-control. This is because out-of-control proceses are in most cases not sustainable, therefore our continuous process improvement efforts must focus on making processes to be in-control. We use the Control Charts for Variables and Attributes in our new 'Ranky-Stat_Library’ folder in this 3D eBook.
These things can be accomplished by the use of control charts for variables or attributes. The construction of a control chart is typically performed in three main steps:Collect data, Plot data and Compute the central lines and control limits (which are automatically obtained after the data fed in the spreadsheet)
The Main Body of The Project
The main purpose of this assignment is to focus on the quality of the final product, so on this project, the company will concentrate on the Manufacturing Process, As you can see from Assignment No.1, CIMPgr Model, in Figure 3: Child Process, A4: Manufacturing. That creates air pollution from melting and boiling the recycled plastic before the plastic would be injected to the molding. The boiling systems and molding machines had created a lot of pollution from plastic melting that needs to fix it as soon as possible.
Regarding to the green engineering and sustainable environment, the Blue in Green Recycling and Manufacturing Company extremely concern about the clean production that will not pollute the environment and ecosystem. Moreover, according to the CORA Spreadsheet in Assignment No.2, one of the most important process is Total Quality Management that focused on using Green Energy, Eco-friendly and Compliance standards that will play a main roles on this assignment.
As a result of this problem, the engineering team was measuring the amount of Carbon Dioxide, (CO2) that was created from the boiler from the process of plastic melting. To measure the amount of carbon dioxide in the factory we will measure in the indoor air quality by using Nondispersive Infrared (NDIR) CO2 Sensors. As you can see in the charts below, the 5 processing machines, a sample size of five, had been measure for 24 weeks to detect the gas emission. And, finding the solution to improve the production system. The first figure, X-bar-chart, shows the average of carbon dioxide emission index over time. The second plot is the r-chart, which shows the changes in each week’s range over time.
Click here to see BGRM Variable Control Chart: Out-of-Control Spreadsheet
Regarding to the two charts above, These charts illustrate the result of carbon dioxide emission that it could be concluded that the operation was out of control. According to the X bar-chart, it shows that the carbon emission in week 11th, x-bar index was 8.92 points, was above the upper control limit that was 8.52 points. The result from the NDIR Sensor was over the limitation and wasn't acceptable. Similarly, according to the R-chart, the graph indicate that the week 11th index was 2.30, above the upper control limit that was 2.06. It also can support that the gas emission from plastic boiler was out of control. As a result of the two chart that show above, it can conclude that the engineering team need to solve the problem and improve the process to in control.
Collaboration with 4 Partner Companies
SONY HANDYCAM: This company will be the main customer who determine the requirement to compliant the sustainable and green engineering standards. Sony is not only focusing on the quality of the final product, it also helped the BGRM to develop the production process and gave the suggestion from the full of experience of technology developer.
PENTAX A RICOH COMPANY: Pentax was playing the role that similar to Sony since it also will be the main customer. One of the most important thing that is the sustainable environment since the company claim to the customers that the whole production processes of its product are not pollute the ecosystem and green environment.
SEW EURODRIVE: This company helped BGRM to develop and redesign the plastic processing machines to reduce the carbon dioxide emission. A large number of experienced engineers from SEW Eurodrive were sent to work with BGRM engineering team to detect the gas emission and solving the problem of the plastic melting.
ASSOCIATION FOR MANUFACTURING TECHNOLOGY (AMT): AMT are widely known in the field of engineering and technician, so this company provided the list of company to supply NDIR sensors to detect the gas emission problem.
All of the collaborative companies helped BGRM to solve the problem, and after working with the experts in different experience and various knowledge bases. The new result came and satisfied the project manager and the customers, that shows in the chart below. The amount of carbon dioxide emission had been decreased and became to in-control result.
Collaboration with 4 Partner Companies
SONY HANDYCAM: This company will be the main customer who determine the requirement to compliant the sustainable and green engineering standards. Sony is not only focusing on the quality of the final product, it also helped the BGRM to develop the production process and gave the suggestion from the full of experience of technology developer.
PENTAX A RICOH COMPANY: Pentax was playing the role that similar to Sony since it also will be the main customer. One of the most important thing that is the sustainable environment since the company claim to the customers that the whole production processes of its product are not pollute the ecosystem and green environment.
SEW EURODRIVE: This company helped BGRM to develop and redesign the plastic processing machines to reduce the carbon dioxide emission. A large number of experienced engineers from SEW Eurodrive were sent to work with BGRM engineering team to detect the gas emission and solving the problem of the plastic melting.
ASSOCIATION FOR MANUFACTURING TECHNOLOGY (AMT): AMT are widely known in the field of engineering and technician, so this company provided the list of company to supply NDIR sensors to detect the gas emission problem.
All of the collaborative companies helped BGRM to solve the problem, and after working with the experts in different experience and various knowledge bases. The new result came and satisfied the project manager and the customers, that shows in the chart below. The amount of carbon dioxide emission had been decreased and became to in-control result.
Click here to see BGRM Variable Control Chart: In-Control Spreadsheet
Control Charts for Attributes
These charts will go for measuring the attributes. BGRM will apply p chart to detect defective products in the batch. To satisfy the customer, this quality checking process must be done before the product launching The team has measured the product defection to control the quality from the collaborative customers, Sony Handycam and Pentax-Ricoh company. If the product sample did not compliant the standard and meet the customer requirement from the CORA Spreadsheet in Assignment 2, it would be assessed as nonconforming. The test spent 25 days of collecting the sample products.The result from the p-chart, from the picture below was out-of-control. We could assume that the operating needed to be fixed.
More Analysis (Variables)
In this part, 3D Printing Corporation fixed the data from the two charts above and come up with the new R-chart and X-bar chart, which will be in control. The engineers found that the problem were the less frequency of calibration of the Printing Machine. A solution was generated by the engineering department in order to increase the precision, also call for one of our collaborating company who mainly do machine calibration. Moreover they decided to do a 100% inspection with our collaborating company. Parts were inspected utilizing go-no go gauges to ensure the product meets the required specification. All units not meeting the acceptable requirements were taken out, checked by our engineers, in order to meet specifications and then returned machines back to the process. To ensure this process is in control.
The observed data was transformed to the chart. As we can see from the new chart there is no point outside the control limit in the R-chart and there is no other reason to say the chart is out of control. Therefore, we can then proceed to analyze the X-bar chart. Looking at the X-bar chart, first there are no points outside the control limits and secondly there is no trend anomaly that is 7 consecutive points above or below the central line.
We calculated the average voltage, Upper Control Limit (UCL) and Lower Control Limit (LCL) of the samples. After plotting the mean data of the samples we noticed that each data point was within the LCL and UCL, this demonstrates that after inspection and calibration of printing machines.
These charts will go for measuring the attributes. BGRM will apply p chart to detect defective products in the batch. To satisfy the customer, this quality checking process must be done before the product launching The team has measured the product defection to control the quality from the collaborative customers, Sony Handycam and Pentax-Ricoh company. If the product sample did not compliant the standard and meet the customer requirement from the CORA Spreadsheet in Assignment 2, it would be assessed as nonconforming. The test spent 25 days of collecting the sample products.The result from the p-chart, from the picture below was out-of-control. We could assume that the operating needed to be fixed.
More Analysis (Variables)
In this part, 3D Printing Corporation fixed the data from the two charts above and come up with the new R-chart and X-bar chart, which will be in control. The engineers found that the problem were the less frequency of calibration of the Printing Machine. A solution was generated by the engineering department in order to increase the precision, also call for one of our collaborating company who mainly do machine calibration. Moreover they decided to do a 100% inspection with our collaborating company. Parts were inspected utilizing go-no go gauges to ensure the product meets the required specification. All units not meeting the acceptable requirements were taken out, checked by our engineers, in order to meet specifications and then returned machines back to the process. To ensure this process is in control.
The observed data was transformed to the chart. As we can see from the new chart there is no point outside the control limit in the R-chart and there is no other reason to say the chart is out of control. Therefore, we can then proceed to analyze the X-bar chart. Looking at the X-bar chart, first there are no points outside the control limits and secondly there is no trend anomaly that is 7 consecutive points above or below the central line.
We calculated the average voltage, Upper Control Limit (UCL) and Lower Control Limit (LCL) of the samples. After plotting the mean data of the samples we noticed that each data point was within the LCL and UCL, this demonstrates that after inspection and calibration of printing machines.
Click here to see BGRM p-chart Spreadsheet, Variable for Sample Size
Since the control chart illustrated that the system was still need to resolve to improve the number of error parts. Consequently, the process will need to be resolved and make a new measurement. The mistake of production can cause the overwhelm budget and waste the plastic raw material. Moreover, the customer will not trust the company brand and complain about the product. So, if we can improve the operating system it will make the company being more valuable and make customer more satisfy. The engineering team and project manager had improved the operating process until the result was acceptable. For the new measurement, we used the constant chart, the sample size is 100 and the sample number is 26. The constant chart below illustrates is back in control since the number of defective product were decreased.
More Analysis (Variables)
In this part, 3D Printing Corporation fixed the data from the two charts above and come up with the new R-chart and X-bar chart, which will be in control. The engineers found that the problem were the less frequency of calibration of the Printing Machine. A solution was generated by the engineering department in order to increase the precision, also call for one of our collaborating company who mainly do machine calibration. Moreover they decided to do a 100% inspection with our collaborating company. Parts were inspected utilizing go-no go gauges to ensure the product meets the required specification. All units not meeting the acceptable requirements were taken out, checked by our engineers, in order to meet specifications and then returned machines back to the process. To ensure this process is in control.
The observed data was transformed to the chart. As we can see from the new chart there is no point outside the control limit in the R-chart and there is no other reason to say the chart is out of control. Therefore, we can then proceed to analyze the X-bar chart. Looking at the X-bar chart, first there are no points outside the control limits and secondly there is no trend anomaly that is 7 consecutive points above or below the central line.
We calculated the average voltage, Upper Control Limit (UCL) and Lower Control Limit (LCL) of the samples. After plotting the mean data of the samples we noticed that each data point was within the LCL and UCL, this demonstrates that after inspection and calibration of printing machines.
More Analysis (Variables)
In this part, 3D Printing Corporation fixed the data from the two charts above and come up with the new R-chart and X-bar chart, which will be in control. The engineers found that the problem were the less frequency of calibration of the Printing Machine. A solution was generated by the engineering department in order to increase the precision, also call for one of our collaborating company who mainly do machine calibration. Moreover they decided to do a 100% inspection with our collaborating company. Parts were inspected utilizing go-no go gauges to ensure the product meets the required specification. All units not meeting the acceptable requirements were taken out, checked by our engineers, in order to meet specifications and then returned machines back to the process. To ensure this process is in control.
The observed data was transformed to the chart. As we can see from the new chart there is no point outside the control limit in the R-chart and there is no other reason to say the chart is out of control. Therefore, we can then proceed to analyze the X-bar chart. Looking at the X-bar chart, first there are no points outside the control limits and secondly there is no trend anomaly that is 7 consecutive points above or below the central line.
We calculated the average voltage, Upper Control Limit (UCL) and Lower Control Limit (LCL) of the samples. After plotting the mean data of the samples we noticed that each data point was within the LCL and UCL, this demonstrates that after inspection and calibration of printing machines.
Click here to see BGRMSpreadsheet, Contsant for Sample Size
More Analysis (Constant)
In this part, 3D Printing Corporation fixed the data from the two charts above and come up with the new R-chart and X-bar chart, which will be in control. The engineers found that the problem were the less frequency of calibration of the Printing Machine. A solution was generated by the engineering department in order to increase the precision, also call for one of our collaborating company who mainly do machine calibration. Moreover they decided to do a 100% inspection with our collaborating company. Parts were inspected utilizing go-no go gauges to ensure the product meets the required specification. All units not meeting the acceptable requirements were taken out, checked by our engineers, in order to meet specifications and then returned machines back to the process. To ensure this process is in control.
The observed data was transformed to the chart. As we can see from the new chart there is no point outside the control limit in the R-chart and there is no other reason to say the chart is out of control. Therefore, we can then proceed to analyze the X-bar chart. Looking at the X-bar chart, first there are no points outside the control limits and secondly there is no trend anomaly that is 7 consecutive points above or below the central line.
In this part, 3D Printing Corporation fixed the data from the two charts above and come up with the new R-chart and X-bar chart, which will be in control. The engineers found that the problem were the less frequency of calibration of the Printing Machine. A solution was generated by the engineering department in order to increase the precision, also call for one of our collaborating company who mainly do machine calibration. Moreover they decided to do a 100% inspection with our collaborating company. Parts were inspected utilizing go-no go gauges to ensure the product meets the required specification. All units not meeting the acceptable requirements were taken out, checked by our engineers, in order to meet specifications and then returned machines back to the process. To ensure this process is in control.
The observed data was transformed to the chart. As we can see from the new chart there is no point outside the control limit in the R-chart and there is no other reason to say the chart is out of control. Therefore, we can then proceed to analyze the X-bar chart. Looking at the X-bar chart, first there are no points outside the control limits and secondly there is no trend anomaly that is 7 consecutive points above or below the central line.
Social Networking
1.Is Tesla Overreaching With Gigafactory Tactics?
http://cleantechnica.com/2014/09/03/tesla-overreaching-gigafactory-tactics/?utm_source=Cleantechnica+News&utm_medium=email&utm_campaign=c432f80b90-RSS_EMAIL_CAMPAIGN&utm_term=0_b9b83ee7eb-c432f80b90-331250377
Having this gigafactory creates two important points. Firstly, this is a great example of two companies collaborating, sharing resources to achieve a common goal. if this deal does follow through, it will allow great advancements in the battery industry, further allowing innovation along alternative fuel vehicles. The second point is that this deal is only viable to Tesla and Panasonic due to major government subsidies in place. this means that while the cost of the product is going down, the taxpayers are paying for it by affording the subsidies.
2.300 MW Of New Solar PV Power Plants Being Developed In Burma, With US Backing
http://cleantechnica.com/2014/09/04/300-mw-new-solar-pv-power-plants-developed-burma-us-backing/?utm_source=Cleantechnica+News&utm_medium=email&utm_campaign=c432f80b90-RSS_EMAIL_CAMPAIGN&utm_term=0_b9b83ee7eb-c432f80b90-331250377
Two Solar Power Plant Projects of 150 MV each brings happiness in itself. Its for the benefit green concept(ecosystem) unlike to the use of the conventional power production sourcesAs discussed in our previous assignment about how/why collaborations adds value to a product. Here,we see two countries coming together to proper financially (U.S.A) and development a legacy of development for people(Burma) which indeed benefits our nature.i like the fact the U.S investors are investing in sustainable finance rather than. Burma has always engaged itself in being being green and sustainable like the implementation of hydroelectric power plants.This project is way to go.
3.First Tesla Battery Swap Station Online Soon
http://cleantechnica.com/2014/10/17/first-tesla-battery-swap-station-online-soon/
Tesla will bring online its first battery swapping station in the next two months after remaining mum on the subject since last year’s debut. That mandate never made it into law though, and battery swapping seemed to be put on the back burner as Tesla focused on the Model X launch and the all-wheel drive system. Rather, owners will be charged for the electricity, and either have to return and pick up their original battery or pay for the brand new battery based on the mileage of their original pack.
1.Is Tesla Overreaching With Gigafactory Tactics?
http://cleantechnica.com/2014/09/03/tesla-overreaching-gigafactory-tactics/?utm_source=Cleantechnica+News&utm_medium=email&utm_campaign=c432f80b90-RSS_EMAIL_CAMPAIGN&utm_term=0_b9b83ee7eb-c432f80b90-331250377
Having this gigafactory creates two important points. Firstly, this is a great example of two companies collaborating, sharing resources to achieve a common goal. if this deal does follow through, it will allow great advancements in the battery industry, further allowing innovation along alternative fuel vehicles. The second point is that this deal is only viable to Tesla and Panasonic due to major government subsidies in place. this means that while the cost of the product is going down, the taxpayers are paying for it by affording the subsidies.
2.300 MW Of New Solar PV Power Plants Being Developed In Burma, With US Backing
http://cleantechnica.com/2014/09/04/300-mw-new-solar-pv-power-plants-developed-burma-us-backing/?utm_source=Cleantechnica+News&utm_medium=email&utm_campaign=c432f80b90-RSS_EMAIL_CAMPAIGN&utm_term=0_b9b83ee7eb-c432f80b90-331250377
Two Solar Power Plant Projects of 150 MV each brings happiness in itself. Its for the benefit green concept(ecosystem) unlike to the use of the conventional power production sourcesAs discussed in our previous assignment about how/why collaborations adds value to a product. Here,we see two countries coming together to proper financially (U.S.A) and development a legacy of development for people(Burma) which indeed benefits our nature.i like the fact the U.S investors are investing in sustainable finance rather than. Burma has always engaged itself in being being green and sustainable like the implementation of hydroelectric power plants.This project is way to go.
3.First Tesla Battery Swap Station Online Soon
http://cleantechnica.com/2014/10/17/first-tesla-battery-swap-station-online-soon/
Tesla will bring online its first battery swapping station in the next two months after remaining mum on the subject since last year’s debut. That mandate never made it into law though, and battery swapping seemed to be put on the back burner as Tesla focused on the Model X launch and the all-wheel drive system. Rather, owners will be charged for the electricity, and either have to return and pick up their original battery or pay for the brand new battery based on the mileage of their original pack.
Summary
This assignment show the measurement of product quality and the operating process quality that relate to the Assignment No.1 and Assignment No.2. As you can see, these process need to improve based on customer satisfaction and the total quality management. Statistical process control charts help to establish mistake proof processes, develop upstream process controls, contribute to process and product redesign, and as a result, help to monitor, and keep the processes under continuous control. A process out-of-control must always be investigated properly. Moreover, We need to continually improve, which requires continuous monitoring of our processes to make sure they are in control.
Further Work Needed/ Proposed
To control the final product toward to satisfy the customers, it is extremely necessary to continuously detect and measure the quality of product and operating efficiency. The tool and the process that were provided from the ebook will be helpful to control the process.
References and Bibliography:
1. Ranky P.G. PhD, eLearning Pack ID: IE673-Fall-2014-63-63
2. Total Quality Management 3D eBook, CIMpgr USA, Inc.
3. Ranky, Paul. “Professor Ranky's Sustainable Green Design and Manufacturing Engineering Presentation”, http://www.cimwareukandusa.com/All-Green/Ranky-GreenEngineering.html
4. http://www.wikipedia.org/
Grade Myself
I believe that I deserve the point 10/10, in order to completing all requirements from the assignment direction and creating the process models that meets the assignment's objectives.
This assignment show the measurement of product quality and the operating process quality that relate to the Assignment No.1 and Assignment No.2. As you can see, these process need to improve based on customer satisfaction and the total quality management. Statistical process control charts help to establish mistake proof processes, develop upstream process controls, contribute to process and product redesign, and as a result, help to monitor, and keep the processes under continuous control. A process out-of-control must always be investigated properly. Moreover, We need to continually improve, which requires continuous monitoring of our processes to make sure they are in control.
Further Work Needed/ Proposed
To control the final product toward to satisfy the customers, it is extremely necessary to continuously detect and measure the quality of product and operating efficiency. The tool and the process that were provided from the ebook will be helpful to control the process.
References and Bibliography:
1. Ranky P.G. PhD, eLearning Pack ID: IE673-Fall-2014-63-63
2. Total Quality Management 3D eBook, CIMpgr USA, Inc.
3. Ranky, Paul. “Professor Ranky's Sustainable Green Design and Manufacturing Engineering Presentation”, http://www.cimwareukandusa.com/All-Green/Ranky-GreenEngineering.html
4. http://www.wikipedia.org/
Grade Myself
I believe that I deserve the point 10/10, in order to completing all requirements from the assignment direction and creating the process models that meets the assignment's objectives.