Manufacturing Technology and innovation

 SMED is stand for Single Minute Exchange of Die. SMED is used in place where is frequent change over of tools or there is any frequent job change over on machine or production line.  As name suggested single minute exchange of Die, tool is not change in one minute but change over time is in single digit i.e. less than 10 minutes.  Exchange of die or tool in less than 10 mins, mean there should be only done through only one changeover on the machine during continue production. The SMED is a principle of Lean Manufacturing , which tell us to eliminate waste in the manufacturing process which help us to increase production & profitability of the organization. Similarly SMED also reduce changeover time from the process and increase available time for manufacturing, which in turn increases the production of the company. The changeover time reduce the production in the process, i.e uneven flow of production which is one of the waste out of three waste of Lean Manufacturing, this one is

  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