SNEHA GIRISH PUROHIT

IE 673 Fall 2014

12/10/2014
eLearning Pack ID: - IE673-FALL-2014-63-18

Process Improvement and Process Control Analysis

Authorship:
This assignment has been completely solely by Sneha
Purohit , I based the content of this assignment on the
study material provided in the e-Book for this class and
some additional research done on the web. I have
included all the references and credits below.
Contents:
(1) Introduction and Objectives
(2) Methodologies applied
(3) Body of the project
- Process Control Charts and Limitations
- Analysis of Results
(4) Collaboration

(5) Summary
(6) Further work needed/proposed
(7) References and Bibliography
(1) Introduction and Objectives:
"SGP
area of my company. Statistical process control will
help Corp. is a positive manufacturing company that
designs, manufactures and provide service to ecofriendly pumps. As more people are seeking to have
green and eco-friendly lifestyle, we serve our
customers to meet such requirements by providing
them versatile range for the use of pharmaceutical, oil
and gas, military purpose.
While working in such a large scale and in an
expanded horizon, quality at each step needs to be
properly monitored which can be best done by using
appropriate methods. The objective of this project is to
decide on the measurable and statistically controllable
area of my company i.e. '' Pumps and Equipments
Corp.'' that needs to be improved by employing
Process control methods. This project will help us in
improving and controlling the quality of a significant us
in identifying the area which start getting out of control,
help us deciding how to fix and eliminate the problem
and thereby will also help in bringing the process back
to control. While this project serves on improving a
specific area it actually underpins the quality of entire
process because it avoids out-of-control processes by

means of timely statistical trend analysis and eliminate

the chances that could lead to huge process failures
and monetary losses.
The objective of this project is to understand,
implement and maintain continuous process
improvement in the manufacturing of pumps by using
the means of statistical process control, lean
manufacturing and engineering technology. We use
TQM process improvement, process control analysis
and also a quantitative computational solution by Dr.
Paul G Ranky. As part of this project we will develop
and analyze statistical process control (SPC) charts, of
which one will be for variable and two charts for
attributes (or factors) by using templates from
Ranky_stat_library linked to the e-book developed by
Dr. Paul G Ranky.
2)Methodologies applied
Statistical Control Charts are used to develop the
green, sustainable, and bio-friendly processes which
are toxic free, and safer for the newer generation.
Once these areas are identified we will develop several
process control charts; one for Variables and two for
Attributes, to measure the factors .The process requires
developing measurable processes to identify limits of
tolerance for the operations. The process then needs
the data to be entered into the forms supplied which
plots the center line, upper limit, lower limit and the
process. Now the charts are analyzed where we
understand if the process is in limits. If not then the
process has to be examined, corrected to bring the

process line with in limits. We will than analyze the

process control charts and identify the main process
limitations and document a TQM improvement solution.
In conclusion we will discuss how the new TQM
improvement solution will integrate within the SGP
Company collaborative companies.
(3) The main body of project:
At SGPCorp.'' a very essential critical to quality
is the time taken to transfer certain amounts of liquid.
This is used as a key performance indicator as
manufacturing of pumps.
One of the main aspect to have a better
quality depends on the amount of liquid transferred
during the quality control process, the time required to
transfer the liquid is tested. For the qualitative analysis,
sample of 3 pumps are tested for a period of 24 weeks.
We tested for the time required to transfer the liquid at
various stages like we've turned on the pump till the full
container was drained out or till half the container was
drained etc. The results of the analysis are presented in
the graph below:

When we analyze the R-chart which shows

that there are three points which are crossing the
control limit line (R). This also shows that the R-chart is
out of control.
After the analysis of the R-Chart, it is seen from
the X-Chart, that there are seven consecutive points
below the central line (X-bar)which make the process
out-of control. Based on the above analysis, we can
conclude, that the X-chart process is out of control.

Production Machining:
This company mainly deals with our CNC
and VMC machines' based production and periodic
maintenance, parts and accessories. What we need to
is basically R & D work and quality assurance of the
pumps and equipments. Hence, they are put to
extreme regression testing and spend amount of time in

the A2 (Design Engineering) phase mentioned above.

Meta:
This company would take care of our office and
other stationary and file storage in the company. This
company is as important as other company which
are collaborated because with the help of this
company all of the company records will stay safe and
organized for a long period of time and that can be
useful in future to improve the conditions.
This company is also important because it will
help us in proper inventory management. It will also
help us for vertical installations of parts and accessories
and it will be useful in cyclic process while machining.
Canon:
Canon will be useful in quality assurance of the
machined parts, accessories and also its high definition
cameras will be useful to recognize the defects in high
tolerance parts. So, Canon plays an important role in
the company's annual sales and quality.
Summary
In this Assignment we have used some of TQM
Graphical Methods which involve a statistical analysis
approach that can be put forth in allowing a
controlled manufacturing process to be implemented
in the factories.If the process is controlled, monitored
and examined timely then it will be easier for the
Process Manager to check if the process is going in line
with the expectations or not. With the help of
statistically analyzing the process control charts like the
control variable and control attribute charts we can
examine the data and calculate the need of the
process, which is the best way to avoid out of control

processes.
Further work needed / proposed
We need to identifymore materials of different
composition that the four companies use and new
techniques should be invented to recycle these
materials in such a way that it supports sustainability.
References and Bibliography
TQM 3D ebook by Paul G. Ranky, PhD. Professor, NJIT
and editor, ADAM with IT, USA
http://www.techniwaterjet.com/documents/ESP.pdf
http://en.wikipedia.org/wiki/C-chart
http://en.wikipedia.org/wiki/P-chart
http://en.wikipedia.org/wiki/Xbar_and_R_chart
http://physics.info/electric-resistance/
Google images
Grade our Assignment
This assignment was a highly informative one and I
have learnt a lot from this assignment. I have read the
chapters10, 11 and 12 and that has helped me a lot
towards the completion of my assignment. If I were to
grade my assignment I would give myself a 100% with
your approval as I believe that I have worked to the
best of my ability and reviewed all the questions asked
and answer them in line with your expectations. I have
also done a lot of study on how I can further improve
my work related to my company and its betterment
and tried finding new techniques which will help me
make my companies products more eco-friendly and
non-toxic. I am submitting late but I worked hard , but
im doing it before final deadline .