Jose Maria Chavez Celaya

EFFORT REDUCTION BY OPERATOR DURING BEARING ASSEMBLIES IN ROLLER SYSTEMS

INTRODUCTION
Quality is, generally speaking and according to the Online Oxford Dictionaries
(https://www.merriam-webster.com/dictionary/quality), the standard of something as
measured against other things of a similar kind; the degree of excellence of something.
The influence that good quality has on any system is of great impact. It is what maintains
everything in order and working correctly. Effective process and quality control is usually
based on different methods that regulate any companys actions and strategies according
to implemented statistical analyses that draw limits and specifications of what should be
expected in the process and basically keeps things in place. Standards; ideas or things used
as a measure, norm, or model in comparative evaluations; are introduced into the process.
This is required because of the competition in the market and the need to fulfill/satisfy
customer demands. Everybody expects quality. The advancement of technology only
hastens the evolution of systems. Management and maintenance of successful systems that
meet customer demands and required functionality is one of the main purposes of a
systems or industrial engineer.

It is important to take into consideration that quality refers to the ability of

a product or service to consistently meet or exceed customer requirements or
expectations. Different customers will have different expectations, so a working definition
of quality is customer-dependent. This is why one must focus resources into quality
inspection, preparation and reviews. It is important to ensure good quality to avoid hidden
costs. This allows a company to come up with different solutions or options and select the
one that is expected to have a better outcome on a cost/benefit basis. In other words, it
can provide an organization with a clear competitive advantage since the correct
application of systems principles and practices will have substantial benefits as a result.

The process and quality controls in the workplace are measured and analyzed by
implementing different statistical methods and by keeping efficient logistics. Quality is an
experience of the customer. Product quality perception comes from your design
specifications and the manufacture standards achieved. Service quality perception comes
from your service process design and the customer contact impressions
(http://www.lifetime-reliability.com/cms/free-articles/work-quality-assurance/what-is-
quality/). The process is driven by specifications that are set to be met. If the requirements
are being accomplished, then the process is stable and the limits are being respected.
Quality is partly measured by observing the percent of outputs passing customer
acceptance and by the number of rejects from customers. There are many ways to
represent quality in a company, depending on the situation at hand.
 Jose Maria Chavez Celaya

THEORETICAL FRAMEWORK

The seven basic quality tools:

1. Cause-and-effect diagram (also called Ishikawa or fishbone chart): Identifies many possible
causes for an effect or problem and sorts ideas into useful categories.
2. Check sheet: A structured, prepared form for collecting and analyzing data; a generic tool
that can be adapted for a wide variety of purposes.
3. Control charts: Graphs used to study how a process changes over time.
4. Histogram: The most commonly used graph for showing frequency distributions, or how
often each different value in a set of data occurs.
5. Pareto chart: Shows on a bar graph which factors are more significant.
6. Scatter diagram: Graphs pairs of numerical data, one variable on each axis, to look for a
relationship.
7. Stratification: A technique that separates data gathered from a variety of sources so that
patterns can be seen (some lists replace stratification with flowchart or run chart).

(Tague, 2005)

Process capability:

Refers to the capability of a process to consistently make a product that meets a

customer- specified range (tolerance). Capability indexes are used to predict the
performance of a process by comparing the width of process variation to the width of the
specified tolerance.

(http://isoconsultantpune.com/, 2017)

Verification Sheet:

It is a special format to collect data easily, where all articles or factors are previously
established so it can be better captured at the moment it is required.

(Rother and Mike, 2009)

PDCA (Demings cycle):

Plan
Establish the objectives and processes necessary to deliver results in accordance with the
expected output (the target or goals). By establishing output expectations, the
Jose Maria Chavez Celaya

completeness and accuracy of the specification is also a part of the targeted improvement.
When possible start on a small scale to test possible effects.

Do
Implement the plan, execute the process, and make the product. Collect data for charting
and analysis in the following "check" and "act" steps.
Check
Study the actual results (measured and collected in "do" above) and compare against the
expected results (targets or goals from the "plan") to ascertain any differences. Look for
deviation in implementation from the plan and also look for the appropriateness and
completeness of the plan to enable the execution, i.e., "do". Charting data can make this
much easier to see trends over several PDCA cycles and in order to convert the collected
data into information. Information is what you need for the next step "act".

Act
If the check shows that the plan that was implemented in do is an improvement to the prior
standard (baseline), then that becomes the new standard (baseline) for how the
organization should act going forward (new standards are enacted). If the check shows that
the plan that was implemented in do is not an improvement, then the existing standard
(baseline) will remain in place. In either case, if the check showed something different than
expected (whether better or worse), then there is some more learning to be done... and
that will suggest potential future PDCA cycles.

(Mehta, 2012)

Bill of materials:

A bill of materials or product structure (sometimes bill of

material, BOM or associated list) is a list of the raw materials, sub-assemblies, intermediate
assemblies, sub-components, parts and the quantities of each needed to manufacture
an end product. A BOM may be used for communication between manufacturing partners,
or confined to a single manufacturing plant. A bill of materials is often tied to a production
order whose issuance may generate reservations for components in the bill of materials
that are in stock and requisitions for components that are not in stock.

(http://www.businessdictionary.com/, 2017)

Arc Welding:
Jose Maria Chavez Celaya

Arc welding uses an electrical arc to melt the work materials as well as filler
material (sometimes called the welding rod) for welding joints. Arc welding involves
attaching a grounding wire to the welding material or other metal surface. Another wire
known as an electrode lead is placed on the material to be welded. Once that lead is pulled
away from the material, an electric arc is generated. It's a little like the sparks you see when
pulling jumper cables off a car battery. The arc then melts the work pieces along with the
filler material that helps to join the pieces.

Feeding the filler into the welding joint takes steady hands and an eye for detail. As the rod
melts, the welder must continuously feed the filler into the joint using small, steady, back-
and-forth motions. These motions are what gives welds their distinctive appearance.

(Atteberry, 2009)

Attribute Data:

Attribute data is also known as "count" data. Typically, we will count the number of
times we observe some condition (usually something we do not like, such as an error) in a
given sample from the process. This attribute data definition is different from measurement
data in its resolution. Attribute data has less resolution, since we only count if something
occurs, rather than taking a measurement to see how close we are to the condition. For
example, Attributes data for a health care process might include the number of patients
with a fever, whereas Variables data for the same process might be the measurement of
the patient temperature.

Thus, Attributes data generally provides us with less information than measurement
(variables) data would for the same process. Thus, for attributes data, we will generally not
be able to predict if the process is trending towards an undesirable state, since it is already
in this condition.

(http://support.minitab.com/, 2017)

Defects:

A defect is any item or service that exhibits a departure from specifications. A defect
does not necessarily mean that the product or service cannot be used. A defect indicates
only that the product result is not entirely as intended.
Jose Maria Chavez Celaya

Suppose service in a restaurant is being evaluated. If a waiter greets his table after 5
minutes, the customer can still order and enjoy a meal even though the promptness of the
greeting did not meet expectations. Therefore, this could be considered a defect (late
greeting) in the service.

(http://support.minitab.com/, 2017)

Defectives:

A defective is an item or service that is considered completely unacceptable for use.

Each item or service experience is either considered defective or notthere are only two
choices.

Before final shipment, a quality inspector evaluates auto supply parts and rates each item
as pass or fail to ensure that the company does not ship any parts that will be unusable.

(http://support.minitab.com/, 2017)

Process Flow Diagram:

Also called: process flowchart, process flow diagram. A flowchart is a picture of the
separate steps of a process in sequential order.

Elements that may be included are: sequence of actions, materials or services entering or
leaving the process (inputs and outputs), decisions that must be made, people who become
involved, time involved at each step and/or process measurements.

The process described can be anything: a manufacturing process, an administrative or

service process, a project plan. This is a generic tool that can be adapted for a wide variety
of purposes.

(http://asq.org/, 2017)

Diagram of Relationships:

The relations diagram shows causeandeffect relationships. Just as importantly,

the process of creating a relations diagram helps a group analyze the natural links between
different aspects of a complex situation.
Jose Maria Chavez Celaya

(http://asq.org/, 2017)

Matrix Diagram:

A matrix diagram is a tool that illustrates the critical relationships between or among
two or more groups. It can be enhanced to show things like the strength of the relationship
or the different aspects of the relationship.

(http://www.sixsigmadaily.com/, 2017)

How-How Diagram:

How to use it

The How-How diagram uses cards that can be Post-it Notes, Index cards or boxes on a
computer application such as Powerpoint. When working with a group, you will need wall
area on which to stick up notes with a large sheet of paper or a whiteboard on which to
draw.

State problem

State your problem clearly and write it on one card. Make sure that the problem is written
as a 'need', so the 'how' question will work. Put the card in the middle of the left of the work
area. When working with a group of people, make sure they all are very clear about the
meaning.

Ask 'How can this be done?'

Asking this question should result in several possible solutions, which you can write on cards
(one per card) and stick up to the right of the problem card.

Note that there can be boolean relationships between these - that is, some may be
alternatives and some may need to happen as well as other solution cards. Show these
either by using different colors of cards or by writing 'and' or 'or' as in the example below.

You can draw in connecting lines at this stage, but if you need to shift the cards to make
space, then these will be out of place. It is often better to leave line-drawing until later.

Repeat and conclude

Jose Maria Chavez Celaya

Repeat the process of asking 'how' for each card, building up a hierarchy as below.

(http://creatingminds.org/, 2017)

Solution Selection Matrix:

A solution-selection matrix is a powerful selection tool used to choose between

multiple solution alternatives during a problem-solving or continuous improvement project.
A solution-selection matrix may also be used as an alternative to a Pugh matrix for choosing
the best design concept for a new process, product, or service.

A solution-selection matrix may be used when:

The current process has problems, issues, errors, or defects

The current process, product, or service requires improvement
Choosing the best solution among several potential solutions
The current solution is not meeting customer requirements or performing as
required

Benefits of a solution-selection matrix include:

Reduce emotion and bias from the decision-making process

Provide a consistent approach for selecting the best solution among several options
Save cost and time by efficiently and effectively selecting the best solution
Provide a collaborative team environment

(https://www.bing.com, 2017)

Tree Diagram:

Tree diagrams allow us to see all the possible outcomes of an event and calculate
their probability. Each branch in a tree diagram represents a possible outcome.
Jose Maria Chavez Celaya

If two events are independent, the outcome of one has no effect on the outcome of the
other. For example, if we toss two coins, getting heads with the first coin will not affect the
probability of getting heads with the second.

(Tague, 2005)

Affinity Diagram:
The affinity diagram organizes a large number of ideas into their natural
relationships. This method taps a teams creativity and intuition. It was created in the 1960s
by Japanese anthropologist Jiro Kawakita.
(http://asq.org/, 2017)

Why- Why Diagram:

The purpose of the Why-Why Diagram is to enable individuals and teams to
creatively explore and consider numerous causes of a problem. It helps individuals achieve
divergent thinking.
(http://sustainableimprovement.weebly.com/, 2017)

5WH1 Diagram:

There are many skills and techniques for better cause and effect analysis. For
instance, the 6M method (Manpower, Machinery, Materials, Methods, Measurements,
Mother-nature and Manpower) is effective in finding out and categorizing major reasons.
Another useful way is brainstorming, through which more causes can be figured out.The
simple 5W1H method can also be adopted to ease the analysis process.

The first W is what. What should be improved? What is the purpose of improvement? Is
there anything else to do? What should be done?

The second W is where. Is the worker's orientation or method correct when changing the
workplace? Why operate in that location? Which is the best location to achieve highest
efficiency?

The third W is when. Change the time, period or sequence of the operation. Why perform
at that time? Will it be better to execute at other time?
Jose Maria Chavez Celaya

The forth W is who. Manpower, collaboration or task assignment. Check and discuss this
issue again. Why designate someone as the person in charge? Is there a better candidate?

Then it is about how. Change the method or procedure so that less manpower is needed.
Apply the method that requires less degree of proficiency and expense. Why to do it? Is
there a better method to replace the current one?

The last W is why. Doubt everything again. Think over and discuss the above 5 questions by
asking more why and then find out the best solution for improvement.

(https://www.edrawsoft.com/, 2017)

Tempering Process:

Process of toughening a material (such as glass), metal (such as cast iron), or an alloy
(such as steel) to make it more resistant to stress by (1) heating it to a particular
temperature, (2) maintaining it at that temperature for a particular duration, and (3) cooling
it rapidly to normal temperature at a particular rate. Opposite of annealing. Not to be
confused with tampering.

(http://www.businessdictionary.com/, 2017)

Project Scheduling:

The project schedule is the tool that communicates what work needs to be
performed, which resources of the organization will perform the work and the timeframes
in which that work needs to be performed. The project schedule should reflect all of the
work associated with delivering the project on time. Without a full and complete schedule,
the project manager will be unable to communicate the complete effort, in terms of cost
and resources, necessary to deliver the project.

(http://www.projectinsight.net/, 2017)

Boring Tool:

A boring bit with its supporting boring bar and arbor, used to enlarge and accurately
finish a large bore previously formed by casting or otherwise.

(http://www.thefreedictionary.com/, 2017)
Jose Maria Chavez Celaya

Vernier Tool:

A small movable graduated scale for obtaining fractional parts of subdivisions on a

fixed main scale of a barometer, sextant, or other measuring instrument.

(http://www.thefreedictionary.com/vernier, 2017)

Solidworks 2017 Premium:

SOLIDWORKS Premium is a comprehensive 3D design solution that adds powerful

simulation and design validation to the capabilities of SOLIDWORKS Professional, as well as
ECAD/MCAD collaboration, reverse engineering, and advanced wire and pipe routing
functionality.
(http://www.solidworks.com/, 2017)

Newtons.

In order to calculate the force made by the press, we look at the manual of the press,
which is the DAKE Ratchet lever arbor press 1-1/2B, which has the capacity of 3 tons, by
using conversion tables we found that:
Press capacity 3 tons
Conversion of tons to newton
Force Tons (tf) = 1000 (kgf or kp) kilonewtons (kN) 9.80665
3*9.80665= 29.41995 kN or 29,419 N
(http://www.100autoguias.com/, 2017)