Riassunto analitico
Despite motorsport has always been a market that didn’t focus on cost as a driving metric, the changes in regulations such as budget caps, and the various economic crisis of the last 20 years, lead to making cost an important voice of interest in competitions too. Maintaining a high quality along the processes is the best way for reducing waste and control costs. Different approaches exist for the reduction of nonconformities, but most companies lack a systematic approach in this field. The most common practice is to apply SPC and quality tools without a retrospective analysis.
This thesis aims to develop a methodology for the reduction of non-compliances by the implementation of a systematic approach. This approach connects and orders different best practices to create a standard that could be applied to any product.
The methodology allows having a better sharing of continuous information between the quality control office, manufacturing & engineering. The practical benefits obtainable are the reduction of defective pieces and the requests for any dimensional derogation.
The right approach starts with a design verification of the functional features of the element to be manufactured. The idea is to determine the right set of datums for the identification of the main functional features. On such features, tolerance feasibility is assessed. The best case is to have the same drawing with the same references for both engineering, manufacturing and metrological testing. In such a way, any possible effect of wrong placement of stack-up tolerances can be reduced. Once this is performed, the metrological measurement is the last activity that a part must undergo.
The last part of a robust process requires post-processing by the analysis and the correlation of data collected during the flow of the part in the plant. This could be implemented by combining IoT devices, machine logs, a traceability feature, and a database. Therefore, the best solutions for traceability are described and the best one is identified. But this is only the last part of a systematic approach.
For the purpose of validating the methodology, a case study is developed on a racing application part: a motorsport oil pump body. This method was developed together with HPE COXA, one of MUNER’s founding partners, whose business focuses on engineering projects, manufacturing of high added value components and additive manufacturing.
The main outputs of the dissertation are discussed in the final section of the thesis, focusing on the effects of the new approach introduced both in terms of pure quality and of economic impact, from the productivity point of view and from the scrap reduction one. The possible future outcomes of this methodology could set the basis for developing a machine learning pattern for early detection of possible defectivity causes based on the data produced in the plant, from manufacturing to the final measurement.
|
Abstract
Despite motorsport has always been a market that didn’t focus on cost as a driving metric, the changes in regulations such as budget caps, and the various economic crisis of the last 20 years, lead to making cost an important voice of interest in competitions too. Maintaining a high quality along the processes is the best way for reducing waste and control costs. Different approaches exist for the reduction of nonconformities, but most companies lack a systematic approach in this field. The most common practice is to apply SPC and quality tools without a retrospective analysis.
This thesis aims to develop a methodology for the reduction of non-compliances by the implementation of a systematic approach. This approach connects and orders different best practices to create a standard that could be applied to any product.
The methodology allows having a better sharing of continuous information between the quality control office, manufacturing & engineering. The practical benefits obtainable are the reduction of defective pieces and the requests for any dimensional derogation.
The right approach starts with a design verification of the functional features of the element to be manufactured. The idea is to determine the right set of datums for the identification of the main functional features. On such features, tolerance feasibility is assessed. The best case is to have the same drawing with the same references for both engineering, manufacturing and metrological testing. In such a way, any possible effect of wrong placement of stack-up tolerances can be reduced. Once this is performed, the metrological measurement is the last activity that a part must undergo.
The last part of a robust process requires post-processing by the analysis and the correlation of data collected during the flow of the part in the plant. This could be implemented by combining IoT devices, machine logs, a traceability feature, and a database. Therefore, the best solutions for traceability are described and the best one is identified. But this is only the last part of a systematic approach.
For the purpose of validating the methodology, a case study is developed on a racing application part: a motorsport oil pump body. This method was developed together with HPE COXA, one of MUNER’s founding partners, whose business focuses on engineering projects, manufacturing of high added value components and additive manufacturing.
The main outputs of the dissertation are discussed in the final section of the thesis, focusing on the effects of the new approach introduced both in terms of pure quality and of economic impact, from the productivity point of view and from the scrap reduction one. The possible future outcomes of this methodology could set the basis for developing a machine learning pattern for early detection of possible defectivity causes based on the data produced in the plant, from manufacturing to the final measurement.
|
