Rekayasa Kualitas

Materi ke – 2
Dasar Rekayasa Kualitas
Contents
 Basics of Quality by Design
 Quality
 Quality Loss Function
 Quality and Process Capability
 Process capability
Basics of Quality by Design
Quality by
design is one
of such
engineering
methodology
Basics of Quality by Design
 Product is designed to meet customer needs and performance
requirements
 Process is designed to consistently meet product quality
attributes
 Impact of starting raw materials and process parameters on
product quality is understood
 Critical sources of process variability are identified and
controlled
 The process is continually monitored and updated to allow for
consistent quality over time
Basics of Quality by Design
 A large amount engineering
manufacture products in conducting in
experiments
 Customer’s perception of quality
( Sony television case in Japan and USA )
Basics of Quality by Design
 Consider the popular story of Sony and two of their
television production facilities, one in the USA, the
other in Japan.
 The color density of the televisions manufactured by
Sony-USA were uniformly distributed and fell
within the tolerance limits, m ± 5 ( where m is the
target for color density).
 While the televisions from Sony-Japan followed a
normal distribution, more televisions were on
target but about 0.3% fell outside of the tolerance
limits.
Basics of Quality by Design
Colour density
distribution of
Sony America
and Japan

(April, 1979)
Basics of Quality by Design
 The differences in customer perceptions of quality
resulted from Sony-USA paying attention only to
meeting the tolerances whereas in Sony-Japan, the
focus was on meeting the target and minimizing
the variance around that target.
 Overall, a much larger portion of Sony-Japan's
televisions receive higher grades then those made
by Sony-USA
 Hence, the customer’s preferred the televisions sets
produced by Sony-Japan over those produced by
Sony-USA.
Basics of Quality by Design
 Taguchi’s definition of quality
“ the quality of a products is the ( minimum )
loss imparted by the product to society from
the time the products is shipped “
 What is loss – and who pays for it
 Loss as additional manufacturing cost
 Loss be paid by society
Basics of Quality by Design
 Interpretation of loss
 Quality loss function (QLF) is quantitative
evaluation of quality loss due to functional
variation

m = target
y = hasil pengukuran
Δo = toleransi
Ao = jumlah kerugian
Basics of Quality by Design
Basics of Quality by Design
 Interpretation of loss
 A quality characteristics is the object of interest
of a product or process
 Three types quality characteristics
• Nominal the best ( NTB )

• Smaller the better ( STB )

• Larger the better ( LTB )

QLF - Nominal the best ( NTB )
( One piece )
• A measurable characteristics with a specific user-
defined target value. ( Sony TV : 115 ± 20 volts )
• QLF for NTB
QLF - Nominal the best ( NTB )
QLF - Nominal the best ( NTB )
( Many pieces )
QLF – Smaller the better ( STB )
( One piece )
QLF - Smaller the better ( STB )
( One piece )
Example
QLF - Smaller the better ( STB )
( One piece )
QLF - Smaller the better ( STB )
( Many pieces )
QLF – Larger the better ( LTB )
( One piece )
QLF – Larger the better ( LTB )
( One piece )
Example
QLF – Larger the better ( LTB )
( Many pieces )

n  1 

1  
L ( y )  k x
n  y 2 
i 1  i 
QLF – Asymmetric
Quality and Process Capability
Capability process
Quality and Process Capability
Capability process
Quality and Process Capability
 Spec limit : fixed engineering limit for the product
dimmensions
 Cp index

 Cpk index
 Cpk is an important measure
 Cpk as a measure of quality
Quality and Process Capability
Quality and Process Capability
Quality and Process Capability
Cpk as a measure of quality
 The conventional methods
Loss-by-defect = numbers of defect x cost of product
= proportion out of spec x total number x cost
of product

 The quality loss function methods

Loss-by-dispersion =
2

A0 2
  ( y m) 2
 x numbers of
product
Quality and Process Capability
Cpk as a measure of quality
Example ( Sample 100.000 unit )
Quality and Process Capability
Cpk as a measure of quality
Quality and Process Capability
Cpk as a measure of quality
Quality and Process Capability
Cpk as a measure of quality
Case Study ( Tugas – 2 )
A spring is used in the operation of a camera shutter. The
manufacturing process suffers from a degree of variability, in
terms of the spring constant (measured in oz/in), which
significantly effects the accuracy of the shutter times. The
functional limits for this spring constant are m±0.3oz/in
(m=0.5oz/in), and the average cost for repairing or replacing a
camera with a defective spring is $20.
What is the loss function? Hence, what is the loss associated with
producing a spring of constant 0.25oz/in versus the loss
associated with one at 0.435oz/in.
Next Week
 The Design Process
 Principle of robust design in the
production process
 Robust design process
 Parameter design