Manufacturing Technology and innovation

 APQP is stand for Advance product Quality planning. APQP is a process that is used satisfy product quantity as per customer requirements. APQP is not just a process but it is set of process or framework of process that are used while developing new product or new process. By APQP we ensure that new product or process should well established before product reach to the customer. APQP (Advance Product Quality Planning) is one of the five basic core tool of IATF 16959 . Other four core tools of IATF16949 are: PPAP : Production Part Approval Proces FMEA: Failure Mode and Effects Analysis SPC : Statistical Process Control MSA: Measurement Systems Analysis  Soon we will be writing about these four core tools. In this article we will concentrate on APQP only. There two aims of APQP   Firstly , To increase communication between different departments of the company specially R&D, production, logistics, sales, etc. Most of the work what R&D is doing, is not aware to other departments,

Six Sigma (6σ) is a systematic and data based approach to solve problem. The objective of Six Sigma  is to remove variation and reduce defect from process. Six Sigma is a process improvement tool. Bill Smith American engineer introduced 6 sigma in 1986 while working in Motorola. Six sigma (6σ) process is one in which 99.99966% of process is defect free. i.e. there is very less chance to have a defect in the process. Six sigma is profit making tool for business, i.e. 6σ tool is used to increase quality in process or increase production of process or make delivery of product faster or remove any non value added process, etc. Six Sigma is data based approach and root cause is analysed after statical analysis. Philosophy of 6 sigma is based on DMAIC theroy. Where D is stand for Define, M is stand for Measure, A is stand for Analysis, I is stand for Improvement, C is stand for Control. Any 6 sigma project is solved in Five different phase. Five different phases of 6 Sigma project: 1. Defin

 It is very important to have a good working environment in company so that employees give their best. The iteration rate of employee will also reduce if company has good and healthy environment. Profitability or production of company increase. If a company has good and safe working environment, give opportunities to employees to take their decisions and work to achieve objective of the company. It is important that employees should come  with a smile to company and with the aim that he has to do something good for the company and whenever he goes back to his home he should not have any stress related to company in evening when he is spending time with his family, such an environment in a company is called a good and healthy environment or a great place to work. There are many ways to make firm a great place to work, here we discuss few points that makes good and healthy environment of company. 10 Ways to make your company a great place to work:- Treat your employees as your custom

Before to know how to increase production, it is important to know what production is and why it is necessary to increase production in any manufacturing industries. English meaning of Production is?  The action of making or manufacturing from components or raw materials, or the process of being so manufactured. Production is a process of making finished goods by processing single raw material or combination of more than one single raw material, it may include single process or combination of process. Some finish products for one company can be finish product for next company. Production is also defined as manufacture finish goods in high volume. Apart from raw material there are other inputs in production such as manpower, electricity, machinery, Chemicals, system, money, etc. There are two ways to produce products: Batch production  Continuous production In batch production finish product is manufactured in batches, for say one batch is of 100 Pcs and another of 200 Pcs. This type o

 What is centerless Grinding Machine? Centerless Grinding is machine that is used to do grinding of outer surface of cylindrical shape, like outer diameter of bearing races, camshaft, pistons, rollers using Grinding Wheel, Regulating wheel &work rest blade. As name suggests centerless machine not required job to hold in center to grind. Before invention of centerless grinding machine job is hold in center position and cutting/grinding is done center edge of job, like we do on Lathe machine. Centerless grinding machine give high volume of output of the grind product. This machine is also helpful to get accurate product and in large volume, that is centerless grinding machine give high output with exactly the desired size. Centerless grinding machine is used for High production volume with greater precision in less cost, as set-up of machine is simple so it can also used for small volume of production.  Centerless machine is consist of Grinding Wheel, Regulating Wheel and Work rest b

 Before we start with internal audit we should understand, what is audit ? Audit is a process of examination or revalidation of the work done other than the core owner of the that area or work done by the person. Audit is basically done by external agencies or internal agency. External agencies are customers, government agencies or third party agencies. Customers do Audit to check how well their product is manufactured, and all compliance are followed during production of their product that are mutually agreed in the contract. Customers also do initial audit to check whether company is able to give them as per desired requirement in terms of quality and quality and some other special requirements. Government agencies do Audit to check is company is following legal compliance that are required to run the company. Tax, safety of employees, safety of women, control of environment are some examples of leagal requirements. Third party agencies are hired by the customers, government or even

 Lean manufacturing is a system to eliminate waste from manufacturing process to increase benifit. Lean manufacturing focus on removing unwanted process, inventory that is not useful in production and add cost in manufacturing product. Main motto of Lean Manufacturing is to reduce the cost of product, reduce delivery time and improve quality of product. Lean Manufacturing is first introduced in Toyota, Japan. Ohno Taiichi was a businessman and engineer is considered as father of Lean Manufacturing and he gave concept of removing of waste (this waste is term as Muda) from production system. He gave seven Muda that should be eliminate from production system. Lean manufacturing is also know as Lean management or just Lean. Initially Lean was used in only manufacturing industries only but after analysing the advantages of this system, it is now widely used in IT industries, medical industries and even financial institutions. This topic is also included in Management syallabus. Seven Muda

Intelligence is the ability to apply knowledge and experience to solve problems. Natural intelligence is used by human and animals to do daily task and other activities. If machines start doing work that can be done by humans then it is known as artificial intelligence. With the help of artificial intelligence anyone can make there work easy and need very less physical work. Machines with artificial intelligence help human beings specially in the area where it is hazardous to work for human beings. What is Artificial intelligence? Artificial intelligence (AI) is ability of machines or computer that take decision to solve the problem (as human does) with the help of huge data base and set of instructions given with the help of software. It is combination of software and hardware that make machines to work like human and animals and solve daily task.  Most common example of artificial intelligence is computer  playing Chess.

 IATF 16949 is a quality standard for automobile industries. This standard is used to maintain the quality of parts used in an automobile. To give your product to automobile industries your company should be certified with IATF16949. To supply product to automobile industries this certificate is compulsory. Exact meaning of automobile here is the vehicles that run on road or they are made to run on the roads, tractors, Earth movers and trains are not include in automobile. IATF is modified by group of OEMs and technical committee of ISO. It was developed to provide best quality product to the customer and also include specific requirements of the customer and focus on continuous improvement in all phase of manufacturing cycle even in supply chain management. Full form of IATF is International Automotive Task Force.  Task force is group of OEMs, that govern IATF. IATF members include the following vehicle manufacturers: BMW Group, Daimler AG, Ford Motor Company, Geely Group, Gen

 What is Audit? Audit is a process of examination or revalidation of the work done other than the core owner of the that area or work done by the person. For example if you gave your car for repairing work and service center have you back the car back and you check the work of service team, it is a type of audit. Person how did the repairing work and he himself check the quality then it is not an audit but his manager or delivery team check repair work before hand over to the customer then also this process is known as audit. Audit is on-site varification of the fulfillment of the compliance. Mostly Audit is done on-site but now a days some audit can be done online also. Some people or institute take audit as a burdon but it is process that improves the existing process or system and eliminate any loop holes in the system. Different type of Audit? As per ISO 19011 there are three different types of audit, this is on the basis of what is auditing. Process Audit System Audit Product Audi