Financial justification of nondestructive testing : cost of quality in manufacturing

Financial Justification of Nondestructive Testing: Cost of Quality in Manufacturing......Page 2
Preface......Page 4
Introduction......Page 5
Notes on How To Use This Book......Page 10
Author......Page 12
Acknowledgments......Page 13
Contents......Page 15
Related Titles......Page 20
1.1 What Quality Means to People......Page 21
1.2 Trying To Manage Quality......Page 23
1.3 ISO-9000 as the Management Standard for Quality (Revised 2000)......Page 24
1.3.1 Five Tiers of Quality Management per ISO-9000......Page 25
References......Page 0
2.1 Early Philosophy of Manufacturing......Page 28
2.2.1 TaylorÌs System of Scientific Management......Page 32
2.2.2 Ford\'s Extensions and Changes......Page 40
2.2.3 Further Notes on Taylor and Ford......Page 43
2.3 Quality Degradation under Taylor Management......Page 48
2.4 The Inspector as the Methodology To Rectify Quality......Page 49
2.6 Ineffectuality of Inspector To Improve Quality......Page 51
2.7 The \"Perfect\" Inspector: Automated 100% Inspection by Electronics......Page 52
2.8 Fallacies of Early Implementation of 100% Inspection......Page 53
2.9 The Root Problem: Out- of- Control Processes......Page 55
3.1 Out of Control as a Question of Information......Page 56
3.2 Statistical Process Control ( SPC) To Get Information......Page 58
3.3 A Review of Statistical Process Control......Page 59
3.4 Automated Run Rules with Computers......Page 64
3.5 Statistical Process Control Results as Statistics......Page 65
3.6 Out- of- Control Quarantining vs. Just- in- Time Inventory......Page 66
4.1 Total Quality Management and DemingÌs Fourteen Points......Page 67
4.2.1 Point 1 Key Words: Decision: Improvement......Page 69
4.2.3 Point 3 Key Words: Inspection: Taboo......Page 71
4.2.4 Point 4 Key Words: Suppliers: Good, Not Cheap......Page 74
4.2.5 Point 5 Key Words: Improvements: Pinpointing......Page 79
4.2.6 Point 6 Key Words: Training: Modern......Page 80
4.2.7 Point 7 Key Words: Supervision: Modern......Page 84
4.2.8 Point 8 Key Words: Fear: Taboo......Page 86
4.2.9 Point 9 Key Words: Teams, Not Barriers......Page 87
4.2.10 Point 10 Key Words: Slogans: Counterproductive......Page 91
4.2.11 Point 11 Key Words: Quotas: Taboo......Page 92
4.2.12 Point 12 Key Words: Workmanship: Pride ( Remove Barriers That Hinder the Hourly Worker)......Page 93
4.2.13 Point 13 Key Words: Education and Training......Page 94
4.2.14 Point 14 Key Words: Implementation: Staffing......Page 95
4.3 Summary......Page 96
5.1 Background......Page 97
5.3 Statistical Process Control and Statistics within ISO Philosophy in the 1990 Version......Page 99
5.4 Inspection in ISO- 9000 Ò 1990......Page 100
5.5.1 Philosophy......Page 103
5.5.3 Additions......Page 104
5.5.4 Applied to Organizations......Page 105
5.6.4 Section 7: Product Realization......Page 106
5.7.1 Potential Risk- Avoidance Planning......Page 107
5.8 How Does NDT Fit into ISO- 9000 Ò 2000?......Page 108
5.9 Summary......Page 110
6.1 Recapitulation of Statistical Process Control......Page 112
6.2.2 Detrimental Costs of Nonconformities......Page 113
6.2.3 Costs of Inspection......Page 115
6.2.4 Time until Improvement Lowers Nonconformities......Page 116
6.3 The Costs of Inspection and the Detrimental Costs of Not Inspecting......Page 117
6.4 Summary......Page 118
7.1.1 The Deming Inspection Criterion ( DIC) Method......Page 119
7.1.3 The Productivity, Profitability, and Revenue Method......Page 120
7.2 DIC: Low Investment......Page 121
7.3 TARR or IRR: High Investment and Long- Term Usage......Page 122
7.4 Productivity, Profitability, and Revenue Method: Nano- Economics......Page 123
8.1.1 Documentation and Methods......Page 126
8.1.2 Definition and Outlook......Page 131
8.2.1.2 Production and Reception of Ultrasound......Page 133
8.2.1.3.1 The Generic Ultrasonic Instrument......Page 136
8.2.1.3.3 The Commercial Instrument......Page 137
8.2.1.4.1.1 The System......Page 140
8.2.1.4.1.2 Probability of Detection......Page 141
8.2.1.4.2.1 Strength and Graphite Shape......Page 143
8.2.1.4.2.2 Generic Velocity Tank Diagram......Page 144
8.2.1.4.2.3 Strength vs. Velocity......Page 145
8.2.1.4.2.4 Reject Limit and Equivalent POD......Page 146
8.2.1.4.2.5 Large Practical Tank......Page 147
8.2.1.4.2.6 The Electronics for the Tank......Page 148
8.2.1.4.3.1 Flaw Detection Instrument......Page 149
8.2.1.4.3.2 Spot Welds......Page 150
8.2.1.4.3.3 Spot Weld Transducer......Page 151
8.2.1.4.4.1 The Forward Extrusion Process......Page 152
8.2.1.4.4.3 Ultrasonic Test for Chevrons......Page 154
8.2.2.1 General View of AE in NDT......Page 155
8.2.2.4.1 Instruments......Page 156
8.2.2.4.2 An Experiment......Page 157
8.2.3.1 General View of Eddy Currents in NDT......Page 159
8.2.3.2 Production and Reception of Eddy Currents......Page 160
8.2.3.4.1 Gray Iron Hardness......Page 162
8.2.3.4.2 Case Depth of Steel Axles......Page 166
8.2.4.2 X- Ray Fluoroscopy on Connecting Rods......Page 169
8.2.5.1 General View of Sonic Resonance......Page 170
8.2.5.2 Sonic Resonance for Automotive Crankshafts......Page 172
8.2.6.2 Infrared Assurance of Friction Welds......Page 179
8.2.6.3 Other Examples of IR......Page 181
8.2.7 Evanescent Sound Transmission......Page 182
8.3.2.1 Is There a Relationship?......Page 183
8.3.2.2 The Need for Relationship......Page 184
8.3.3.1 The Underlying Function......Page 185
8.3.3.2 Origin of Perturbations to the Underlying Function......Page 188
8.3.4 Experiments with Correlations......Page 190
8.3.5 Generic Curve for Reject Limits......Page 191
8.3.7 Philosophy of the Scientist and the Engineer......Page 193
8.3.8 Conclusions Concerning Correlations......Page 195
9.1 General......Page 197
9.2.1 A Process with Each Part Unique: Instant Nodular Iron......Page 198
9.2.2 Adhesively Bonded Truck Hoods: Sheet Molding Compound-Type Fiber-Reinforced Plastic (FRP)......Page 201
9.2.3 A Safety-Related Part: Front Wheel Spindle Support......Page 206
9.2.4 Several Identical Parts in One Subassembly: Connecting Rods......Page 207
9.2.5 Intermediate Inspection of a Machined Part: Engine Block......Page 208
9.3 Examples of TARR and IRR Methods......Page 209
9.3.1 Didactic Example: Hypothetical Data......Page 210
9.3.2 Intermediate Inspection of a Machined Part......Page 211
9.3.3 Aircraft Engine Discs......Page 213
9.4.1 New Metal for Automotive Connecting Rods......Page 218
9.4.1.1 The Baseline Calculation......Page 219
9.4.1.2 The Real Situation with No Inspection......Page 220
9.4.1.3 The Real Situation with Inspection......Page 221
9.4.2 Aircraft Engine Discs......Page 223
9.5 Summary......Page 225
10.2 Chronological Progression......Page 227
10.3 A Final Anecdote......Page 228