Total manufacturing assurance : controlling product quality, reliability, and safety

Cover
Half Title
Title Page
Copyright Page
Table of Contents
Foreword
Preface
Authors
SECTION I: Introduction to TMA
	Chapter 1 The World of Manufacturing
		1.1 Industrial Revolution
		1.2 Innovation in Management and Manufacturing
		1.3 Industry 4.0
		References
	Chapter 2 Total Manufacturing Assurance
		2.1 Strategic Manufacturing Management
		2.2 Manufacturing System Control
		2.3 System Improvement Monitoring
		2.4 Summary
SECTION II: Strategic Manufacturing Management
	Chapter 3 Strategic Operations
		3.1 Strategic Planning
		3.2 Strategic Planning Path
		3.3 Product Assurance Strategy
			3.3.1 Reliability, Safety, and Quality Requirements
		3.4 Summary
		Questions
		References
	Chapter 4 Innovation and Technology Transfer
		4.1 Technology Development
			4.1.1 Technology S-Curve & Technology Life Cycle
		4.2 Strategic Implications on Technology Commercialization
		4.3 Global Technology Transfer
		4.4 Summary
		Questions
		References
	Chapter 5 Engineering Economic Analysis
		5.1 Economic Analysis
			5.1.1 Time Value of Money
			5.1.2 Selection of Alternatives
				5.1.2.1 Initial Cost
				5.1.2.2 Interest Rate
				5.1.2.3 Annual Cost or Benefit
				5.1.2.4 Economic Life
				5.1.2.5 Salvage Value
				5.1.2.6 After-Tax Cash Flow
		5.2 Proforma Development
		5.3 Investment Decision Matrix
			5.3.1 Time to Market
			5.3.2 Initial Investment
			5.3.3 Excess Present Value Index
			5.3.4 Benefit-Cost Ratio
			5.3.5 Investment Payback
			5.3.6 Internal Rate of Return
			5.3.7 Ownership
			5.3.8 Asset Value
			5.3.9 Purchase Investment Analysis
		5.4 Summary
		Questions
		References
	Chapter 6 Management Control
		6.1 Integrated Management Control
			6.1.1 Manufacturing Enterprise Focus
		6.2 Decision-Making Using Qualitative and Quantitative Tools
			6.2.1 Project Management Networking
			6.2.2 Optimization Modeling
			6.2.3 Linear Programming
		6.3 Tactical Operations
			6.3.1 Design for Manufacturing
				6.3.1.1 DFM Guidelines
			6.3.2 Computer-Integrated Manufacturing
				6.3.2.1 Computer-Aided Design
				6.3.2.2 Computer-Aided Manufacturing
				6.3.2.3 Computer-Aided Process Planning
				6.3.2.4 Flexible Manufacturing Cells and Systems
			6.3.3 Material Requirements Planning
				6.3.3.1 Master Production Schedule
				6.3.3.2 Bill of Materials
				6.3.3.3 Inventory Record File
			6.3.4 Just-In-Time Manufacturing
				6.3.4.1 Inventory Exposure
				6.3.4.2 Pull-Based Production
				6.3.4.3 JIT Implementation
				6.3.4.4 Pull-Based Startup
			6.3.5 Technology Leveraging
				6.3.5.1 Mechatronics
				6.3.5.2 Artificial Intelligence
				6.3.5.3 Machine Learning
				6.3.5.4 Automated Machining/Processes
				6.3.5.5 Additive Manufacturing
				6.3.5.6 Advanced Robotics
				6.3.5.7 Autonomous Technologies
				6.3.5.8 Man/Machine Interface
				6.3.5.9 Internet of Things
				6.3.5.10 Big Data and Analytics
				6.3.5.11 Virtual/Augmented Reality
				6.3.5.12 Supply Chain Visibility
				6.3.5.13 Block-Chaining
				6.3.5.14 Cyber-Security
		6.4 Expert Systems
			6.4.1 Expert System Definition
			6.4.2 Expert Systems versus Artificial Intelligence
			6.4.3 Expert System Structure
			6.4.4 Expert System Development
				6.4.4.1 Expert System Domain
				6.4.4.2 Domain Expert
				6.4.4.3 Knowledge Engineer
				6.4.4.4 Expert System Shell
				6.4.4.5 The Development Process
			6.4.5 Expert System Topical Application Areas
		6.5 Summary
		Questions
		References
	Chapter 7 Organizational Leadership
		7.1 Motivation
			7.1.1 Leadership Style
				7.1.1.1 Organizational Psychology
				7.1.1.2 Strategic Motivation Model
		7.2 Teaming
			7.2.1 Basic Assumption Theory
			7.2.2 Team Effectiveness
				7.2.2.1 Personality
				7.2.2.2 Team Composition
				7.2.2.3 Reactions to Group Situations Test
		7.3 Strategic Human Resource Planning
			7.3.1 Performance Appraisal
			7.3.2 Organizational Development/Training
				7.3.2.1 Stages of Development
				7.3.2.2 Technical Development Program
			7.3.3 Succession Planning
		7.4 Summary
		Questions
		References
SECTION III: Manufacturing System control
	Chapter 8 System Definition
		8.1 System Definition Activities
		8.2 Process Planning
			8.2.1 Process Planning for Specific Industries
		8.3 Plant Layout and Flow
			8.3.1 Plant Layout Analysis
				8.3.1.1 The From-To Chart
				8.3.1.2 The REL Chart
				8.3.1.3 Space-Relationship Diagram and Block Plan
			8.3.2 Plant Layout Synthesis
		8.4 Material Handling
			8.4.1 Material Handling Equations
			8.4.2 Automated Guided Vehicles
		8.5 Automation
			8.5.1 Automation Elements
		8.6 Flexible Manufacturing Systems
		8.7 Simulation
			8.7.1 Simulation Example
		8.8 Summary
		Questions
		References
	Chapter 9 Product Manufacturing Degradation Control
		9.1 Reliability Engineering and Control
			9.1.1 Reliability Fundamentals
				9.1.1.1 General Approach to Reliability Improvement
			9.1.2 Design for Reliability
				9.1.2.1 Part Selection and Control
				9.1.2.2 Part Derating
				9.1.2.3 Design Simplification
				9.1.2.4 Redundancy
			9.1.3 Reliability Prediction
			9.1.4 Growing Product Reliability Prior to Manufacture
				9.1.4.1 Test Data Collection and Analysis
			9.1.5 Manufacturing System Modeling
				9.1.5.1 Defect Removal Planning
				9.1.5.2 PRMDA Technique
		9.2 Safety Engineering and Control
			9.2.1 Safety Assessment
				9.2.1.1 Fault Tree Analysis
				9.2.1.2 Failure Mode, Effects, and Criticality Analysis
			9.2.2 Safety and the Worker
				9.2.2.1 Human Factors
				9.2.2.2 Safety Program Planning
		9.3 Quality Engineering and Control
			9.3.1 Design of Experiment
				9.3.1.1 Variable Identification
				9.3.1.2 Analysis of Variance
			9.3.2 Statistical Process Control
				9.3.2.1 The Normal Distribution
			9.3.3 Process Capability Analysis
				9.3.3.1 Process Monitoring
				9.3.3.2 Control Charts for Variables
				9.3.3.3 Control Charts for Attributes
			9.3.4 Acceptance Sampling
			9.3.5 Six-Sigma Fundamentals
			9.3.6 Cost of Quality
				9.3.6.1 Good Costs of Quality
				9.3.6.2 Bad Costs of Quality
			9.3.7 Total Quality Management
		9.4 Lean Manufacturing Fundamentals
			9.4.1 Minimize Waste
			9.4.2 Perfect First-Time Quality
			9.4.3 Flexible Production Lines
			9.4.4 Continuous Improvement
		9.5 Manufacturing System Effectiveness
			9.5.1 Components of Se
				9.5.1.1 Quality Capability
				9.5.1.2 Operational Efficiency
				9.5.1.3 Achieved Availability
			9.5.2 Performance Benchmark
				9.5.2.1 Quality Capability Data
				9.5.2.2 Operational Efficiency Data
				9.5.2.3 Operational Availability Data
			9.5.3 Business Decision-Making
		9.6 Summary
		Questions
		References
	Chapter 10 System Maintenance
		10.1 Reliability, Maintainability, and Availability
		10.2 Maintenance Program Planning
			10.2.1 Corrective and Preventive Maintenance
			10.2.2 Maintenance Planning Process
				10.2.2.1 Maintenance-Induced Problems
				10.2.2.2 Maintenance Documentation
		10.3 Maintenance Strategy
			10.3.1 Reliability-Centered Maintenance
				10.3.1.1 The RCM Process
		10.4 Maintainability Analysis
			10.4.1 Maintainability Improvement
				10.4.1.1 Automated Fault Isolation
			10.4.2 Maintainability Levels and Prediction
		10.5 Summary
		Questions
		References
SECTION IV: System improvement Monitoring
	Chapter 11 Big Data System Planning
		11.1 Data System Organization
		11.2 Data System Structure
		11.3 Data System Operation
			11.3.1 Data Collection
			11.3.2 Data Processing
			11.3.3 Data Reporting
		11.4 Data System Implementation
		11.5 Summary
		Questions
		References
	Chapter 12 Data Recording and Feedback
		12.1 Organizational Data Communications
			12.1.1 Types of Databases
				12.1.1.1 Automatic Identification Technology
				12.1.1.2 Bar Coding
				12.1.1.3 Optical Character Recognition
				12.1.1.4 Voice Entry
				12.1.1.5 Radio Frequency
				12.1.1.6 Vision
				12.1.1.7 Magnetic Stripe
			12.1.2 Programmable Logic Controller
		12.2 Failure Recording, Analysis and Corrective Action
			12.2.1 Elements of the FRACA System
				12.2.1.1 Responsibility
				12.2.1.2 Activity Architecture
				12.2.1.3 Reporting
		12.3 Summary
		Questions
		References
	Chapter 13 Performance Analytics
		13.1 Key Performance Indicators
			13.1.1 Production Analytics
			13.1.2 Financial Analytics
			13.1.3 Customer Service Analytics
		13.2 Summary
		Questions
		References
Appendix: Reactions to Group Situations Test (RGST)
Index