Global Assembly Quality Methodology

Supplying high-quality products to markets is an
essential mission of manufacturers. The recent
globalization of mass production has led to lower
prices for consumers and potentially higher profit
for manufacturers. However, inadequate quality
management severely increases quality costs as well
as negatively impacting on a company s brand image.
Traditional statistical quality control has not
provided any definite guidelines for dealing with
sporadically-occurring assembly defects. This book
introduces newly developed metrics for assembly
complexity. A process-based complexity factor is
derived from a time standard defined for a set of
assembly tasks, and shows satisfactory correlation
with defect rates for each assembly step. A design-
based complexity factor is derived from the DFA
method for rating ease-of-assembly to augment
factors not captured by the process-based complexity
factor. Integrating these complexity factors not
only alerts product designers of deficiencies in the
original design concept, but also enables
manufacturing engineers to take proactive measures
for potential highly error-prone assembly processes.

Autorentext

Hirokazu Shibata, Ph.D.: Studied Design for Manufacturability at Stanford University. Manager at TV Business Group of Sony Corporation, Tokyo.

Klappentext

Supplying high-quality products to markets is an essential mission of manufacturers. The recent globalization of mass production has led to lower prices for consumers and potentially higher profit for manufacturers. However, inadequate quality management severely increases quality costs as well as negatively impacting on a company's brand image. Traditional statistical quality control has not provided any definite guidelines for dealing with sporadically-occurring assembly defects. This book introduces newly developed metrics for assembly complexity. A process-based complexity factor is derived from a time standard defined for a set of assembly tasks, and shows satisfactory correlation with defect rates for each assembly step. A design-based complexity factor is derived from the DFA method for rating ease-of-assembly to augment factors not captured by the process-based complexity factor. Integrating these complexity factors not only alerts product designers of deficiencies in the original design concept, but also enables manufacturing engineers to take proactive measures for potential highly error-prone assembly processes.