STATISTICAL PROCESS

Manufacturing processes have been improved by use of on-line computer control and statistical process control leading to more uniform final products. Production methods now include inverse (water-in-oil) suspension polymerization, inverse emulsion polymerization, and continuous aqueous solution polymerization on moving belts. Conventional azo, peroxy, redox, and gamma-ray initiators are used in batch and continuous processes. Recent patents describe processes for preparing transparent and stable microlatexes by inverse microemulsion polymerization. New methods have also been described for reducing residual acrylamide monomer in finished products. 

A molten metal alloy would normally be expected to crystallize into one or several phases. To form an amorphous, ie, glassy metal alloy from the Hquid state means that the crystallization step must be avoided during solidification. This can be understood by considering a time—temperature—transformation (TTT) diagram (Eig. 2). Nucleating phases require an iacubation time to assemble atoms through a statistical process iato the correct crystal stmcture... 

QA = quahty assurance QC = quaUty control SQC = statistical quaUty control SPC = statistical process control CIM = computer-integrated manufacturing. 

Quality in Japan. Japanese economic prowess has been attributed variously to such quahty improvement activities as quahty circles, statistical process control (SPG), just-in-time dehvery (JIT), and zero defects (ZD). However, the real key to success hes in the apphcation of numerous quahty improvement tools as part of a management philosophy called Kaizen, which means continuous improvement (10). 

Statistical Process Control. A properly miming production process is characterized by the random variation of the process parameters for a series of lots or measurements. The SPG approach is a statistical technique used to monitor variation in a process. If the variation is not random, action is taken to locate and eliminate the cause of the lack of randomness, returning the process or measurement to a state of statistical control, ie, of exhibiting only random variation. 

Statistical Control. Statistical quahty control (SQC) is the apphcation of statistical techniques to analytical data. Statistical process control (SPC) is the real-time apphcation of statistics to process or equipment performance. Apphed to QC lab instmmentation or methods, SPC can demonstrate the stabihty and precision of the measurement technique. The SQC of lot data can be used to show the stabihty of the production process. Without such evidence of statistical control, the quahty of the lab data is unknown and can result in production challenging adverse test results. Also, without control, measurement bias cannot be determined and the results derived from different labs cannot be compared (27). 

While the single-loop PID controller is satisfactoiy in many process apphcations, it does not perform well for processes with slow dynamics, time delays, frequent disturbances, or multivariable interactions. We discuss several advanced control methods hereafter that can be implemented via computer control, namely feedforward control, cascade control, time-delay compensation, selective and override control, adaptive control, fuzzy logic control, and statistical process control. 

Statistical Process Control Statistical process control (SPG), also called statistical quahty control (SQC), involves the apphcation of statistical concepts to determine whether a process is operating satisfactorily The ideas involved in statistical quahty control are over fifty years old, but only recently with the growing worldwide focus on increased productivity have applications of SPG become widespread. If a process is operating satisfactorily (or in control ), then the variation of product quahty tails within acceptable bounds, usually the minimum and maximum values of a specified composition or property (product specification). 

There are important economic consequences of a process being out of control for example, product waste and customer dissatisfaction. Hence, statistical process control does provide a way to continuously monitor process performance and improve product quahty. A typic process may go out of control due to several reasons, including... 

More details on statistical process control are available in several textbooks (Grant and Leavenworth, Statistical Quality Control, McGraw-HiU, New York, 1980 Montgomery, Introduction to Statistical Quality Control, Wiley, New York, 1985). 

Historical DataBase Subsystem We have discussed the use of on-hne databases. An historical database is built similar to an on-line database. Unlike their on-line counterparts, the information stored in a historical database is not normally accessed directly by other subsystems for process control and monitoring. Periodic reports and longterm trends are generated based on the archived data. The reports are often used for long-term planning and system performance evaluations such as statistical process (quality) control. The trends may be used to detect process drifts or to compare process variations at different times. 

Statistical Process Control (SPC) The use of statistical techniques (such as control charts) to analyze a process and take appropriate action to maintain statistical control and improve process capability. 

Figure 2.27 Statistical process data for dimension A of the cover support leg...

Fig. 4.12. Statistical process control chart for TXRF measurement systems. The sensitivity of the system can be controlled by daily calibration with an...

Failure modes analysis Statistical process control Measurement systems analysis Employee motivation On-the-job training Efficiency will increase through common application of requirements for Continuous improvement in cost Continuous improvement in productivity Employee motivation On-the-job training... 

Several methods have evolved to achieve, sustain, and improve quality, they are quality control, quality improvement, and quality assurance, which collectively are known as quality management. This trilogy is illustrated in Figure 2.1. Techniques such as quality planning, quality costs, Just-in-time , and statistical process control are all elements of... 

You should review the contract and the detail specifications to identify whether your existing controls will regulate quality within the limits required. You may need to change the limits, the standards, the techniques, the methods, the environment, and the instruments used to measure quality characteristics. One technique may be to introduce Just-in-time as a means of overcoming storage problems and eliminating receipt inspection. Another technique may be Statistical Process Control as a means of increasing the process yield. The introduction of these techniques needs to be planned and carefully implemented. 

The action taken during process monitoring (see Part 2 Chapter 9) can be considered preventive action when corrections are made to the process ahead of occurring nonconformities. Hence Statistical Process Control is a technique which serves nonconformity prevention as well as detection. 

Fundamental statistical process control reference manual (GM, Ford, Chrysler)... 

Guidelines to Statistical process control Parts 1 2 (SMMT)... 

It should be noted that, even with optimal PIFs, errors are still possible. There are two reasons for this. Even in the optimal case, some random variability in performance will remain. These random variations correspond to the "common causes" of process variability considered in statistical process control. Variations in PIFs correspond to the "special causes" of variability considered within the same framework. 

The alternative is hexane, which because of the explosion hazard requires a more expensive type of extractor construction. After the extraction the product is dull gray. The continuos sheet is slit to the final width according to customer requirements, searched by fully automatic detectors for any pinholes, wound into rolls of about 1 m diameter (corresponding to a length of 900-1000 m), and packed for shipping. Such a continuous production process is excellently suited for supervision by modern quality assurance systems, such as statistical process control (SPC). Figures 7-9 give a schematic picture of the production process for microporous polyethylene separators. 

Ionic transport in solid electrolytes and electrodes may also be treated by the statistical process of successive jumps between the various accessible sites of the lattice. For random motion in a three-dimensional isotropic crystal, the diffusivity is related to the jump distance r and the jump frequency v by [3] ... 

Statistical process control (SPC) is an important on-line method in real time by which a production process can be monitored and control plans can be initiated to keep quality standards within acceptable limits. Statistical quality control (SQC) provides off-line analysis of the big picture such as what was the impact of previous improvements. It is important to understand how SPC and SQC operate. 

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