Manufacturing Technology and innovation

  LPA is a stand for Layer Process Audit . LPA is Quality technique that focus on how well the process is working or following by the manufacturing Industry at the shop floor. LPA is not just an fault finding audit but it is a process improvement audit as it is audit where changes (Observation Closure) can be done during audit only. By LPA, rejection and other waste is reduced and  work towards continual improvement.  It is one of the important part of IATF16949 (Clause no. 9.2.2.3) and OEM customers (CSR) requirement.  LPA is not only confined with Quality department, rather it include all departments and all level of management and supervisor. Supervisor do LPA at their own function and frequency of doing may be weekly. Middle management do LPA at their function and other functions also but for them frequency of doing audit may be monthly. Senior management do LPA to any one function and frequency is quarterly.  LPA in one of the Audit where supervisor and operator learn about proce

SPC is stand for S tatistical Process Control.   SPC is a tool used for continuous improvement. SPC used to maintain quality by monitoring the process and well detect the possible occurrence of the error before it actually happened and we'll detective. It is one of the core tool of IATF16949 . Other core tool of IATF16949 are: APQP: Advance Product Quality Planning PPAP: Production Part Approval Planning MSA: Measurement System Analysis FMEA : Failure Mode and Effective Analysis   The SPC process is better than other quality tools because it is based on detection and prevention rather than the correction of problems after they have occurred, it means it help us to detect the fault or give indication before error actually occur, which means we can correct the process or the job size before any error occur in our job. It is real time process, so machine operator can easily identify the trend of the job and take corrective action before generation of any NG product. SPC is not only u

 FMEA is stand for Failure Mode and Effects Analysis. FMEA is a process analysis tool. FMEA is used to identify all the failures or potential failures that may occur in a process, before any physical error occur in the process and analysis consequences due to failures. It is one of the core tool of IATF16949 . Other core tool of IATF16949 are: APQP: Advance Product Quality Planning PPAP: Production Part Approval Planning MSA: Measurement System Analysis SPC : Statistical Process Control Type of FMEA: There are two type of FMEA: DFMEA (Design Failure Mode and Effects Analysis) PFMEA (Process Failure Mode and Effects Analysis) 1. DFMEA (Design Failure Mode and Effects Analysis): DFMEA is a methodology which is used to analyse the risk or failure during new product or process development, it also used during any change or modification in product or process. 2. PFMEA (Process Failure Mode and Effects Analysis) PFMEA is a methodology which is used to analyse risk or failure during manufact

 Full form of MSA is Measurement Systems Analysis. MSA is a process to validate the measurement system of an organisation. It indicates error in measurement system.  The main aim of MSA is to assure that measurement system delivers reliable results with repeatability and reproducibility (R&R). It is important to get the right data for the each part of the product, if there is an error gauge, then, we will not able to get correct data which in turn give wrong interpretation about the data and wrong size product will reach to the customer, so it is important to have each gauge R&R at regular frequency. MSA is define mathematically method of determining the amount of variation that exists within a measurement process. Variation in the measurement process can directly contribute to overall measurement system. MSA is used to certify the measurement system for use by evaluating the system’s accuracy, precision and stability. It is one of the core tool of IATF16949 . Other core tool o

  PPAP is stand for Production Part Approval Proces . PPAP is standard process in automotive and aerospace industries. It is basically written contact between supplier and customer about a product or process through which product will manufacture. It is output of APQP. Intresting thing about pronunciation of PPAP is that is not pronounced as P P A P, where as it is pronounce as P-PAP .   It is one of the core tool of IATF16949 . Other core tool of IATF16949 are: APQP: Advance Product Quality Planning FMEA: Failure Mode and Effects Analysis SPC : Statistical Process Control MSA : Measurement Systems Analysis You can read about above topic by clicking on them. PPAP is very important for supplier and manufacturer, to understand the requirement of customer and also helpful to the customer to know, that, how well product will produce through it's lifetime by manufacturer. PPAP is a risk identification and mitigation process used to provide evident to the customer that there is a relia

 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