Evidence from companies on the implementation of Statistical Process Control (SPC). Shewhart control charts - the main tool of SPC
Preface, Sergey P. Grigoryev:
I am often asked about examples of successful cases in the mining and processing industry, oil production and other industries. I would not like to repeat myself, but for more than thirty years Edwards Deming answered these questions in a short article: “The pointlessness of searching for examples” . Is catching up really good for you? And how can you catch up with someone who is going faster (E. Deming’s answer to American automakers to the question of how to catch up with the Japanese)? Cutting corners won't help here. If you understand theory of variability which is inevitably present in all types of activities, why do you need examples of “successful cases”? And if you don’t understand, copying “successful cases” will only worsen the situation.
“Resistance to knowledge is still strong in people. The type of transformation that Western (read, Russian – Note by S.P. Grigoryev) industry needs involves expanding knowledge, and yet people continue to resist them.
Pride is not the last factor in this struggle. After all, new knowledge that comes to the company can reveal our mistakes. The best approach is to pursue new knowledge because it can help us do better."
Many companies claim to have implemented statistical process control tools. But often their attempts to use Shewhart control charts for improvement are unsystematic and formal. With very few exceptions, companies attempting to improve quality and productivity are treading water, failing to take advantage of opportunities that represent meaningful knowledge in areas of understanding. nature of variability production processes and innovative management methods proposed Edwards Deming .
We do not evaluate the content of source documents, since the purpose of this page is to evidence some of the activities of enterprises in the field of implementing statistical process control tools, nothing more.
"Any organization planning to use control charts effectively must first break down all barriers described by Deming.
You can't just "implement statistical process control." Control charts do not work in a vacuum. Their use places certain demands on workers and management, and the organization must do everything possible to meet these demands. Once the control chart philosophy becomes part of the corporate culture or even part of the structure of the organization itself, occasional interference from workers or management will no longer be able to interfere with anything.
Statistical process control is, first of all, a whole worldview, supported by certain methods. It's a way of thinking, and that's what it's all about. Without such thinking, methods are completely useless! Only senior management can highlight the importance of control charts for continuous improvement. If senior management provides active support for this, the potential impact of implementing control charts will exceed all expectations! "
Companies on the implementation of SPC tools
"Monitoring and control of product production involves recording data not only at the key technological level, but also at every step of its production. The procedure allows us to identify defects at an early stage and guarantees the stability and uniformity of the quality of the products. The use of methods such as statistical management and data analysis led to improvements in production processes and also allowed the development of effective corrective measures."
" Perm enterprise "ODK-STAR" has developed and mass-produces automatic control systems (ACS) for the fifth-generation PD-14 gas turbine engine, intended for installation on the latest Russian MS-21 aircraft. To date, the company has mass-produced and shipped to the main manufacturer of the PD-14 engine - the company "ODK-Perm Motors" – 5 sets of self-propelled guns PD-14.
The PD-14 aircraft engine control system consists of an electronic regulator RED-14 and an executive hydromechanical part - a fuel dispenser DT-14M, a pump unit BN-14M, an engine protection unit BZD-14 and a shut-off valve of the first manifold ZK-14-1. The electronic regulator with full responsibility (FADEC type) RED-14 provides comprehensive all-mode control of an aircraft engine, limiting limit parameters, operational diagnostics and engine protection, as well as information exchange with aircraft and engine systems. The hydromechanical part of the system is responsible for fuel supply to the engine and its mechanization equipment.
The commissioning of two new automatic production lines made in Russia - chemical and galvanic metallization of printed circuit board holes - will allow "ODK-STAR" improve quality ( due to statistical control of the processes of chemical and galvanic deposition of metal coatings ) and the number of produced printed circuit boards for electronic units, in particular, for the electronic regulator RED-14; "Almost completely eliminate manual labor at this technological stage and double labor productivity."
“In the foundry industry, when producing complex-profile parts, such as turbine blades made of heat-resistant alloys, it is rare that an enterprise can boast a high level of yield of suitable castings.
A similar problem was typical for Perm Motor Plant . The situation was aggravated by the fact that the yield of suitable casting was not only low, but also constantly changed from heat to heat, even if the blocks were poured at the same time. And at the moment when it was necessary to significantly increase the number of blades delivered, a choice arose: to double the production capacity or to ensure the yield of suitable casting at a level of at least 70%.
And the choice, accordingly, settled on reducing marriage. But it cannot be said that up to this point no work had been carried out to increase the yield of suitable casting. Except that the experimental work carried out by shop technologists and service specialists did not always give the required result or provided only a short-term effect. It was necessary to change the very approach to organizing work to combat defects.
To search for fresh ideas, specialists from the workshop and the enterprise visited a number of related factories. Particularly interested in the experience NPO "Saturn" . At that time, the company was successfully implementing a project to improve quality management systems using statistical management methods , and significant results have already been obtained. And, just as importantly, this was achieved at virtually no financial cost.
For a deeper study of the topic and transfer of positive experience to PMZ specialists were invited NPO "Saturn" . Over the course of several days, shop workers became familiar with the basic techniques used at Saturn and the possibilities of using them in the PMZ foundry.
Based on the results of the training, a working group was formed from among the specialists of the enterprise and the workshop, which needed to analyze the current situation of the workshop in dealing with defects and work out the proposed methods using statistical quality management methods on experimental names of blades.
To change the current state, the working group selected the most problematic blades with the minimum yield of suitable casting and critical for production. Designed for each blade checklists (Shewhart cards) , which linked real-time process parameters and defect rates for each heat. Shewhart chart made it possible to identify points where technological process parameters exit a stable state for subsequent identification of the causes of the emerging deviation and their elimination.
Initial analysis control charts using statistical analysis methods was carried out on 10 heats (60–70 blocks). The analysis showed that out of more than 90 parameters, special attention needs to be paid to only half of them. Thus, the group with a high power of influence (with a correlation coefficient of more than 0.5) included 11 parameters, and the “risk group” (with a correlation coefficient of 0.15 to 0.5) included more than 30. A particular surprise for the group was this fact: for some critical parameters, the actual values many times exceeded or did not reach those required by the technology, but at the same time, the “correct” values were recorded in the log books.
The result of the group’s work was an increase in the yield of suitable casting to relatively constant indicators for closed control positions of the blades (from 52% to 71% for equiaxed casting, from 60% to 83% for block blades). The economic effect at the end of the year will reach more than 5 million rubles.
When summing up the results of the 6 months of operation of the working group, a decision was made to standardize the process and use statistical methods of quality management across the entire range of the foundry. And in 2016, it is planned to deploy a similar project further along the production process in the machine shop.
Rostec State Corporation held in Moscow JSC Gas Turbine Research and Production Center Salyut (part of the United Engine Corporation (UEC) of Rostec) meeting of the third quality coordinating council (QCC). Based on its results, a decision was made to expand interaction between organizations of the aviation cluster of the state corporation in the field of product quality. The press service reports this UEC .
With a report on the work UEC Sergey Antropov, director of the corporation for quality, spoke on improving the quality of products. " UEC pays great attention to improving the quality of the holding’s products,” says Sergei Antropov. – First of all, issues of working with claims from operation because Customer satisfaction primarily depends on this. A prompt response to every complaint from operation is an indicator of the work and mood of the enterprise’s quality system.”
Aviation cluster holdings (Russian Helicopters JSC, UEC JSC, KRET JSC, Tekhnodinamika JSC) in June 2017, they will present the criteria for certification of managers responsible for quality, and by the end of the year they will organize their certification.
In the third quarter of 2017 JSC "RT-Tekhpriemka" will present proposals for the formation of a corporate standard regulating the use statistical methods of analysis for research of companies' products with complaints Rostec . The main principles of quality management are reducing customer risks, increasing the effectiveness of measures to ensure product quality, and preventing deviations from the requirements specified by the customer. It is also important to reduce the costs of eliminating malfunctions, defects and failures, noted in UEC ".
"
STATISTICAL METHODS OF QUALITY MANAGEMENT
On
JSC "KnAAPO"
methods are applied
statistical analysis of the accuracy and stability of technological processes
in, as well as methods
statistical regulation and process control
in order to identify and eliminate the causes of inconsistencies. In 2011, work was carried out on the application and implementation
statistical methods for quality management of technological processes
for the Sukhoi Superjet-100, Su-27, Su-30M2, Su-30MK2, Su-35S products. In 2011, 71 audits were carried out using statistical methods. Degree of implementation of process inspections
statistical methods
, according to programs, schedules, lists, amounted to 100%."
"At the engine plant, in all technological streams of production of in-line P6 engines for K5 generation trucks, special attention is paid to ensuring stable quality and implementation of statistical process control methods . In 2019, a crankshaft processing line, turning and gear hobbing equipment was launched. In addition, as part of digitalization, they began to connect equipment in the 119th and 201st workshops in order to monitor the condition of the machines, their loading, etc.”
"Quality Department PJSC KAMAZ started launching jobs with SPC (Statistical Process Control) . The first of them appeared in the press shop at the company's press-and-frame plant. The event was attended by Quality Director - Director of the Quality Department Evgeniy Leonov, Head of the Bureau for Analysis of Stability of Technological Processes Lenar Zaripov and SPC - bureau coordinators. Implementation of IATF 16949:2016 standard on "KAMAZ" goes step by step. The peculiarity of this standard is the use of the main five tools - APQP, PPAP, FMEA, SPC, MSA – as methods of quality assurance. Of these, PPAP has already been implemented; at the current stage, implementation has begun in pilot mode MSA (Measurement System Analysis) and SPC (Statistical Process Control) .
Extensive preparatory work was carried out. Together with plant technologists, as a result of audits, we identified bottlenecks and found out that each part is determined by a large set of special characteristics. Based on the data obtained, it was decided to create four jobs with SPC at the engine plant, five at the automobile plant and two at the frame press plant, one of which has already been launched. The rest, as Lenar Zaripov noted, are 95% ready. To automate the process "KAMAZ" chose the specialized Q-DAS program, which is also used by European automakers. It allows you to quickly identify the causes of defects and constantly improve the production process.
"Launching the first workplace with SPC - this is an important moment for "KAMAZ" . System SPC позволяет уменьшить человеческий фактор при оценке качества продукции, – прокомментировал директор департамента качества Евгений Леонов. – Она облегчит работу не только контролёров ОТК по контролю ключевых характеристик, но и предоставит большую информацию по износу оборудования, штамповой оснастки. По определённым выпадам по контрольным точкам можно будет отследить, когда штамповую оснастку требуется отдать в ремонт, чтобы в дальнейшем не производить продукцию с отклонением от качества». По словам руководителя, в перспективе проектом будет охвачено производство деталей для автомобилей нового модельного ряда К5 и двигателей Р6. Параллельно ведётся работа по внедрению рабочих мест с SPC in positions for the K3 generation model range and the V8 engine."
“In 2010, the process of deploying the production system "Rosatom" was continued. Another technological stage has been added to the spacer grating manufacturing area - frame assembly, which has determined a new name - frame manufacturing area. This indicates systematic work to create a pulling production system at the enterprise.
The stock of spacer grilles in the PDB warehouse was reduced by 150 sets by the end of the year. Elements of built-in quality have been introduced – Shewhart control charts in operations: cutting blanks for cells and welding spacer grids. Monitored reproducibility indices geometric dimensions of DR Before the process control operation, the DR manufacturing process was assessed and adjusted. Output per worker continued to rise."
“But all of this (purchases, certification of suppliers, even improving the quality of packaging of delivered products), so to speak, are “near-production processes.” Does this mean that in production itself to RUSAL There is nothing left to improve, and all internal reserves for reducing costs through improving quality have already been exhausted? Unfortunately, it is not. A clear confirmation of this is the projects to improve quality in production that have already been launched in the Company or are planned to be launched in the near future. One of them is “Improving product quality at the Wagstaff foundry complex.” Its results (multiple increases in production quality and customer satisfaction, achieved at minimal cost on the part of RUSAL ) give reasons for optimism. Also, a number of similar projects are currently underway KrAZ And SAZ . However – here’s a paradox – innovations in production themselves, which seem to lead to an increase in quality, can be fraught with additional risks and increase, rather than reduce, the Company’s costs. How can this be avoided? Fortunately, the Quality Directorate has an answer to this question too! “A number of tools that we plan to implement at factories allow us to minimize risks when launching new production processes RUSAL in 2014,” says Natalya Ryabova (Director of the Quality Management Department RUSAL ). - In particular, statistical process control, measurement systems analysis, quality planning . And also FMEA analysis, which allows you to preview and calculate the entire process in advance and determine the potential risks of failures at each stage of the technology. All these tools and methods will be taught to foundry workers directly at the production site by FMEA trainers from the Quality Management Department."
Quality development strategy.
In 2020, an updated roadmap for 2019–2022 was adopted to achieve the goals of the Quality Development Strategy. The key changes were the introduction of culture
statistical process control (SPC)
at all levels of the organization and development of a corporate-wide rating management system
"RUSAL as a supplier"
.
To implement the strategy, key KPIs were identified and distributed to all levels of the Company. In 2021
RUSAL
plans to increase the planning horizon of the roadmap for a five-year perspective.
The Company operates RUSAL Quality Academy , whose task is to develop employees and personnel reserves in terms of the practical application of approaches and tools of quality and professional competencies. All newly hired employees undergo a mandatory basic quality course. Personnel are regularly trained in the requirements of ISO and IATF international standards, as well as quality tools such as failure modes and effects analysis (FMEA), statistical process control (SPC), measurement system analysis (MSA, Measurement System Analysis) , advanced product quality planning (APQP), etc. In 2020, 1,800 employees were trained on 19 topics in the field of quality. In addition, 132 employees of the Company’s non-production directorates completed a 15-hour program on the technical minimum for quality.”
“I would like to note that our company has been systematically implementing progressive methods of quality management for a long time. We were one of the first in Russia to use Statistical Process Control (SPC) , introduce a system of universal equipment maintenance and rapid changeovers. Today there are already real results. For example, the reduction in losses in the manufacture of some products reaches 34.6 kopecks per ruble of cost, and the annual savings amount to more than a million rubles.
IN "Treke" The process approach has been introduced for quite some time now. When creating new products, cross-functional teams are organized that plan and monitor all stages of the project, prepare a business case, and conduct a risk assessment. And now, when developing and launching production of new products, the following methods are used: APQP (advanced quality planning), QFD (quality function structuring), DFMEA (analysis of the modes and consequences of design failures), PFMEA (analysis of the modes and consequences of process failures), SPC (Statistical Process Control) and MSA (Measurement Systems Analysis) , which are converted into enterprise standards."
"Foundry Tikhvin Carriage Works its first audit took place in August 2016. The preparation took more than a year, and all departments of the enterprise took part in it. At this stage, work was carried out in several main areas at once: development and bringing the management system documentation into compliance with the requirements of standards, technological preparation of production and implementation of quality tools.
One of them is the use statistical methods of quality control (Statistic processing control, SPC) - has great practical benefits. Monitoring the state of technological processes using statistical methods to monitor the stability and reproducibility of production processes based on mathematically based samples is one of the mandatory requirements of the Association of American Railroads (AAR).
"We note that the closed quality cycle and the connection of QMS with ERP, PLM, MES systems is also emphasized by the MESA organization [3]. QMS integrates with the existing enterprise management system (ERP), product life cycle management system (PLM), production management system (MES ) and complements them to support risk management, providing direct access to information about the company's production and product quality. It also helps support seamless system integration and master data alignment across functions. It controls all corporate management and production processes as well. their compliance with standards, laws and other guidance materials Supports the full range of quality management methods and practices in a single consistent system, such as advanced quality planning (APQP), control plans, management audit, failure cause and effect analysis (FMEA), test plan management. (IPM), Complaints Management (CCM), statistical process control (SPC) in-process, warranty management, traceability management, incoming and outgoing product inspection and an integrated task and performer management process."
“The key focuses of the site are the launch of new capacities, the development of a new brand assortment, the implementation of measures to minimize the risks of unscheduled shutdowns and losses of useful work time (VLO); reducing losses of raw materials through the implementation of both costly and non-costly measures, achieving reference consumption standards for raw materials, energy; automation of production processes, introduction of new technologies based on the application statistical methods of analysis .
After modernization and phased digitalization of the main production facilities Tomskneftekhim LLC in 2016-2017 the necessity and focus of the development of PSS has become statistical assessment of process controllability and reproducibility . Many technological process metrics have changed and understanding the current state and making decisions on making adjustments requires statistical analysis based on the Six Sigma methodology and the selection of optimal levels of key process indicators, control in the MES system and SPC -production module, with fixation of the target value and permissible spread of shift personnel in KPIs. Statistical process evaluation plays an important role in the system of supplier-consumer relationships both within the enterprise and outside it. The assessment allows us to answer the question of how the capabilities of the supplier’s processes can satisfy the customer’s requirements, as well as plan and predict the quality of products.”
“Yuri Vasilievich Ryabov, leading expert of the continuous improvement department, shares his experience in implementing Six Sigma projects, which have allowed the company to already earn several hundred million rubles. LLC "Tomskneftekhim" .
The main task of the last stage of the project (Control) is to make the achieved improvements permanent. The solution to this problem is possible by implementing statistical process control (SPC) using control charts . It is the cards that make it possible to reduce the spread of key technological parameters, which guarantee high quality products. Greatest effect statistical process control is observed when constructing control charts in real time. This is only possible when using APCS and MES systems. This possibility will be implemented on "Tomskneftekhime" since 2015.
" Chusovsky plant OMK regularly conducts internal audits of the quality management system, technological processes and product, the requirements of the current international standard IATF 16949 are met using quality planning and product production methods: • APQP (Advanced product quality planning) – Long-term product quality planning and management plan. • PPAP (Production part approval process) – The process of approving the production of a component. • PFMEA (Failure mode and effects analysis) – Analysis of the types and consequences of potential process failures. • SPC (Statistical process control) – Statistical process control . • MSA (Measurement System Analyzes) – Analysis of measurement systems . • 8D - a method for eliminating problems, used when the consumer reports identified product inconsistencies."
"One of the main areas of cost reduction is the desire to reducing variability and optimal adjustment of average values of standardized indicators state of objects of infrastructure elements. This is ensured by achieving state stability and continuous improvement of quality using statistical management methods ".
"8.3. Statistical Process Control One of the requirements of enterprises GAZ Group - support of production processes at the supplier tools and methods of statistical management . Поставщик должен обеспечить управляемость операций воспроизводства ключевых характеристик изделия при помощи инструментов SPC . The supplier must have sufficient knowledge in this area and is obliged to ensure a stable and controlled state of technological processes with a given reproducibility in the designed production process of this product.
Minimum
requirements for process stability Cm, Cmk ≥ 1.67 – process reproducibility index for machines Cp, Cpk ≥ 1.33 – process reproducibility index,
at lower values, corrective measures are required. Before they are implemented, 100% control must be introduced into the management plan. In the absence of a normal distribution and the impossibility of applying reproducibility indices, the supplier is required to demonstrate control plans with an increased frequency of checks (the control plan is agreed separately with the consumer). The evaluation must be carried out for the key characteristics specified in the drawing, as well as those determined by the supplier during the FMEA analysis.
8.4. Measurement System Analysis (MSA) The measurement system analysis methodology must comply with the MSA version (3rd edition). Measuring equipment for monitoring key characteristics is selected from the condition that the error is no more than 10% of the tolerance for the controlled parameter."
"Several years ago, the company made a strategic decision - to introduce the principles of quality management of processes, both technological and production, using methods Statistical process control And lean manufacturing .
The idea is as follows: in order to obtain a high-quality and competitive product, it is necessary to stabilize and improve the processes as a result of which this product is obtained, that is, to combat the cause of possible deviations. And it is absolutely not enough to simply control the quality of the product, deal with the consequences of deviations, and, therefore, put up with the risks of getting a low-quality product, high costs, etc.
Another important aspect is the culture of continuous improvement: there are no ideal processes; having reached a certain level, we set new heights. Many companies have realized this in one way or another, but only a few have decided to make it their business philosophy."
"On Cherepovets Metallurgical Plant , included in the division "Severstal Russian Steel" , economic effect of use statistical methods for product quality control at the end of 2009 amounted to over 27 million rubles,” said the technical director and chief engineer of the enterprise Andrey Lutsenko.”
"The main high-tech solution implemented within the project was the development of an information and analytical system (IAS) based on the use of statistical methods of analysis data on the movement of mechanisms. This approach has opened up great opportunities for analyzing the reasons for the decline in productivity due to losses during filling, as well as for identifying technical faults at the first sign of their appearance. In other words, the application statistical process control methods bottling allows you to answer the question of why it was not possible to fill the oven within the allotted time, record all the time lost in each operation, and also get hints on what you should pay attention to in order to eliminate these losses.”
"An integrated approach to production process management, focused on modern consumer requirements for product quality, is currently being implemented at Novolipetsk Iron and Steel Works (JSC NLMK) , Based teachings of W. Deming , "lean manufacturing" concepts, "six sigma" , taking into account the specifics of metallurgical production, the company has developed a mechanism for creating conditions for the continuous search for the root causes of any inconsistencies (in technology, equipment operation, quality of raw materials) and developing measures to prevent them. Moreover, the quality management system is structured so that the process of creating quality products is managed at increasingly earlier stages of production.
The implementation of the assigned tasks is facilitated by the use of statistical methods . They do not require large expenses, and the results obtained with their help provide objective information about the state of the processes under study, predict and regulate problems at all stages of the product life cycle, and based on this, develop optimal management decisions.
An important component of the approach being implemented is a unified information system, which allows almost real-time assessment process stability , optimize the collection of information about the causes of process violations, equipment failures, and also use the obtained data to develop preventive measures aimed at preventing inconsistencies and maintaining the continuous nature of improvement cycles. Another advantage of the system is the ability to conduct a retrospective analysis of negative situations.
One of the key statistical methods are quality control cards (Shewhart cards) . This tool was chosen to stabilize technological processes and reduce the variation in the quality characteristics of the products. Control card represents the analyzed characteristic in dynamics with the imposition of control limits on it. If a parameter goes beyond the control limits, it serves as a signal to production personnel to determine the cause of process instability and prompt adjustment."
"Crystal metallization technology is an urgent problem in the manufacture of microelectronic products. The development of crystal metallization technology consists of a series of experiments on the selection of metallization modes (beam current, vacuum level, temperature in the vacuum chamber) and the necessary equipment (free metal mask). A metallized crystal is a crystal made of LiNbO3 (lithium niobate) of a cylindrical shape, with submicron layers of vanadium and nickel deposited on one side through a free metal mask. Metallization modes affect the thickness and molecular composition of the coating, as well as the behavior of deposited atoms on the surface of the crystal. The topology of the metallization depends on the equipment configuration. Equipment and metallization modes are selected individually for each type of crystal and must ensure the manufacture of products that meet the requirements of the design documentation. It is also necessary that the equipment and metallization modes ensure a stable and reproducible process of metallization of crystals. To assess process stability, statistical methods are used, in particular Shewhart control charts (SCCH). Application of KKSh allows not only to assess the stability of the process, but also to detect and eliminate special reasons for changes in the properties of the product, leading to the production of a product that does not meet design requirements. This allows not only to select the optimal parameters of the equipment, but also to identify the dependence of the influence of the geometric dimensions of the equipment on the dimensions of the elements of the metallization topology. Identification of such a dependence provides the possibility of transition from process control to its management, i.e. to create a closed automated cycle of product development and obtaining the appropriate topology."
The professional standard "Specialist in technical quality control of products" in the description of labor functions contains 6 (six) references SPC and 33 (thirty-three) mentions statistical methods for quality control .
“Names of development organizations:
LLC "SoyuzMash of Russia"
, Moscow city
JSC "Angstrem"
, Moscow city
JSC "Installation and technological management "Altair"
, Moscow city
JSC "UEC"
, Moscow city
JSC "UEC-Perm Motors"
, Perm city
JSC "PO "Sevmash"
, Severodvinsk city, Arkhangelsk region
JSC "PO "Strela"
, Orenburg
JSC "Russian Space Systems"
, Moscow city
JSC "RSK "MiG"
, Moscow city
JSC "RT-Tekhpriemka"
, Moscow city
JSC "Tambov plant "Komsomolets" named after N.S. Artemov"
, Tambov city
Association "League for Assistance to Defense Enterprises"
, Moscow city
PJSC "Kirov Plant "Mayak"
, Kirov city
PJSC "ODK-Saturn"
, Rybinsk city, Yaroslavl region
PJSC "Tupolev"
, Moscow city
Union of enterprises and organizations ensuring the rational use of natural resources and environmental protection "Ecosphere"
, Moscow city
FSBEI HE "MSTU "STANKIN"
, Moscow city
Federal State Budgetary Educational Institution of Higher Education "Moscow State Technical University named after N.E. Bauman (National Research University)"
, Moscow city
FSBI "All-Russian Research Institute of Labor" Ministry of Labor of Russia
, Moscow city
FSUE NPO Tekhnomash
, Moscow city".
"Labor function - Organization of control over compliance with technological discipline in workshops and departments of a shipbuilding organization. Required knowledge:
- Methods
analysis of measurement processes
.
- Methods
statistical process control
and their applicability for increasing the efficiency of technological processes in shipbuilding and ship repair."
Names of development organizations:
JSC "United Shipbuilding Corporation"
, Moscow city
Federal State Budgetary Institution "All-Russian Research Institute of Labor" Ministry of Labor of Russia, Moscow
"The QMS, built in accordance with the requirements of the EN 9110:2016 standard, helps organize enterprise management through process management, measuring their effectiveness through a set of indicators that allow identifying and eliminating weaknesses in the organization. The main indicators are indicators of service safety, compliance of services with standards quality, delivery of services on time and customer satisfaction,” commented Oleg Golomolzin, Quality Director S 7 ENGINEERING LLC ".
"An effectively functioning QMS, built in accordance with standard requirements and best global practices, already allows S7 Technics Holding organize production processes in an optimal way, eliminate duplication, non-productive losses of resources, have personnel sufficient in quantity and quality, ensure a world-class level of services provided,” noted Evgeny Shipilov, certification director of Bureau Veritas Certification Rus JSC. — Of course, order and transparency in processes provides the necessary basis that simplifies the implementation of modern production technologies and the concept of lean production in S7 Technics Holding . Moreover, most lean manufacturing tools are based on statistical methods of quality management and the principles of the concept of Total Quality Management, on the philosophy of which all management system standards are based."
"In October 2021 EVRAZ United West Siberian Metallurgical Plant (EVRAZ ZSMK) awarded a contract to Primetals Technologies for an integrated quality control system for its steel and rolling mill in Novokuznetsk, Russia.
Integrated quality control system. All quality-related data along the entire production line of the steel and rolling mill is collected and stored in a structured manner in the "Process Quality Control (TPQC)" system, which is part of the TPO. The result is a detailed product genealogy containing comprehensive information about each stage of production. The TPO solution supports systematic data analysis, from which improvement measures are derived to continually improve the quality of production processes and end products. Among other features, the implemented TPO system will include statistical process control (SPC) and digital assistance functions to identify improvement measures.”
"One of the areas ensuring the implementation of the policy OJSC MMK in the field of quality, is the certification of the enterprise’s products in accordance with the requirements of the standard ISO/TU 16949:2002 “Quality management systems. Special requirements for the use of ISO 9001:2000 in the automotive industry and organizations producing related spare parts." To certify products according to this standard, it is necessary to bring production processes into a statistically controlled state. IN OJSC MMK Constant monitoring of the level of mechanical properties of manufactured products is carried out. The technological process must provide product quality indicators that meet all consumer conditions, therefore it must be stable and have a small natural variation in indicators. To assess the stability of production processes and their management at the enterprise, the methodology is used statistical process control (SPC) . In accordance with the methodology SPC for product quality indicators conduct statistical analysis, including the construction of Shewhart control charts ".
"Company's mission NPO "RIVS" consists of the design, construction, reconstruction of turnkey mining and processing plants with the development and implementation of new mineral processing technologies, with the development, manufacture and supply of technological equipment, automation tools and systems.
An important and relevant, from the authors’ point of view, modern direction in the development of complex automation at mining and processing enterprises can be the widespread use of the basic principles of the theory statistical control based on various Shewhart control charts (CHC) [4] . The development of this area is facilitated by standardization in Russia (GOST R 50779.42-99) statistical methods of process control based on CCS , as well as a certain universality of these methods, which allows not only to identify the moment when the controlled process exits the state of statistical controllability (norm), but also to establish (with a certain probability) the possible reasons for this exit, at least at the level of expert assessment."
"The article presents the results of development and implementation in the First - Fourth Mining Departments OJSC "Belaruskali" systems statistical methods for final control and assessment of the quality of shipped products . The system consists of electronic packages of modified acceptance control cards shipped contract lots according to all standardized indicators. The cards are intended for use by quality control specialists, factory technologists, service and management of OJSC Belaruskali.
Products OJSC "Belaruskali" , which has 10 main types (brands) of potash fertilizers, is exported to more than 60 countries around the world. In connection with the increasing competition in the global fertilizer market, issues of quality of shipped products, which are checked by the quality control department before loading, are of particular importance. For each type of product, from 3 to 12 quality indicators are monitored.
Wholesale supplies of products are the subject of legal relations between suppliers and consumers. Poor quality batches should not be supplied to customers. If this condition is violated and the consumer discovers a discrepancy, they may be re-evaluated or even returned entirely to the supplier. Levels of discrepancy in group quality indicators are determined using statistical methods. They set criteria for the quality of product batches, which make it possible to build clear relationships between the parties during wholesale supplies and objectively resolve any disagreements that arise.
The main tool for statistical methods of quality control and assessment are various acceptance control charts (ACC) [3, 4]. Acceptance control chart based on Shewhart control chart , serves to determine the position of the indicator level in the tolerance zone (Fig. 1) and timely send a signal that the indicator has left the state of statistical stability (stability)."
" Shewhart control charts – an effective lean manufacturing tool for optimizing production business processes. This is a visualized analysis of statistical data in real time, on the basis of which you can promptly respond to deviations in the process and make adjustments. The charts look like a constantly updated graph, where upper and lower control limits are set for indicators. Going beyond these boundaries is precisely deviation. .
IN Unipro control cards first began to be used on power unit No. 2 of Surgutskaya GRES-2 , and their effectiveness could be judged already last year. The tool helps employees choose the most optimal way to produce electricity with minimal fuel consumption. Continuous monitoring is carried out over four parameters that affect technical and economic indicators: live steam temperature, live steam pressure, reheat steam temperature, oxygen content in flue gases. Deviations beyond the control limits are automatically recorded using IT tools and become a reason for adjusting the operating mode or making other decisions.
Denis Vasiliev, leading process engineer
CTC of Surgutskaya GRES-2
:
“Today we are able to control parameters more effectively. By using
Shewhart charts
you can quickly understand when a deviation has occurred. But the data needs to be analyzed and its reasons identified. The first stage of analysis is carried out hourly by operational personnel. I conduct assessments on a daily basis. Also, analytics based on the results of the week are carried out by representatives of the operational efficiency unit and the deputy chief operating engineer. We make decisions based on the analysis. For example, there were cases when the temperature of live steam exceeded control limits. We quickly discovered this and found out the reason. It turned out to be associated not with the maintenance of the regime, but with a defect in the fittings of the injection regulators. And they urgently initiated measures to eliminate the problem.
The effectiveness of the innovation has been proven by real figures. 70% of the company’s costs are fuel, and its savings entail an undeniable economic effect. Coming soon
Shewhart control charts
will be replicated to other power units of the stations
Unipro
.
Shewhart control charts
at power unit No. 2 of Surgutskaya GRES-2
– the number of attacks beyond control limits has decreased by more than 20 times:
2929 attacks in 2019;
100 lunges in 2021."
"Relevance. The problem of studying the quality of products during their production has always been acute for manufacturers. Carrying out only quality control of finished products does not allow quickly detecting deviations in technological production processes, while the use statistical control methods makes it possible not only to identify violations, but also to maintain the process in a stable state and, thus, ensure the repeatability of its results.
Using statistical process control tools , can be monitored in a timely manner the appearance of significant variations and thus minimize the likelihood of their occurrence, which will ultimately lead to a reduction in the level of defects and errors. One of these tools is indispensable for in-line quality monitoring control charts (or Shewhart control charts) , visualizing the statistical characteristics of the production process under study [2].
In enterprise pharmacopoeial monographs for solid dosage forms (tablets), one of the important quality indicators is the average weight of the tablet. Using the example of the production of the drug “Diazolin tablets 200 mg”, a control chart of moving ranges was constructed for 18 product series..."
"When assessing the quality of samples of alcoholic products, organoleptic control is carried out: the completeness of pouring, color and transparency, taste and aroma are assessed. The strength of the drink and alkalinity are controlled by physical and chemical methods. The concentration of fractions is determined - methyl, ethyl alcohol, water, higher alcohols included in the composition fusel oils. The content of toxic microimpurities must be checked.
When carrying out intra-laboratory control, they are used statistical methods. For example, Shewhart cards are used to control the stability of analysis results ".
"The positive response from the business could not but please the boss PTU (Volga Customs Administration) Vyacheslav Goloskokov , who in turn noted that work is often built on the principle “it’s always been done this way,” but modern conditions dictate the need for constant improvement. Volga Customs Department for its part, makes every effort to simplify customs formalities and tries to make controls adequate. This project is intended to serve as one of the measures contributing to this. Vyacheslav Ivanovich also noted that customs authorities of the Volga region today they act on the basis statistical process control using Deming's theory and Shewhart control charts . “We are trying to understand the variability of processes during customs control,” he concluded. - Let’s move on to checking the declaration as a production operation, which should result in a high-quality result: the state receives money and compliance with prohibitions and restrictions, and the foreign trade participant minimizes its costs. And minimizing the costs of a participant in foreign economic activity (received the goods on time and its production processes were not affected in any way) will ultimately lead to our ultimate goal: the growth of our economy, the growth of the country’s well-being and the transformation of Russia into a competitive power.”