Controlling Quality Through Process Control In Metal Fabrication

Perpetuating quality in products is necessary to any company.  Taking a broader stance, maintaining product quality can be achieved via controlling the quality of the methods that it takes to fabricate that product.  An example of controlling of a process would be to take calculations of something when it is operating optimally so that the measurements can be compared to calculations in the future, to ensure that optimum quality functions are still operational.  For instance, strain on the frames of machines can be measured via a strain monitor to rate quality.  The machine’s frame strain must have been measured when it was operating optimally and producing quality parts so that calculations from that assessment can be employed as a control to measure against when the machine starts operating in a way that is not best.  This can help measure the whole production process.  Monitoring processes for differences is a revolutionary new way of looking at quality assurance rather than looking for flaws in parts.  If a process manufactures quality parts and is able to be reiterated, this is an ideal scenario for a manufacturing environment.  

Process Valuation Monitoring

The characteristics of process variation monitoring include overseeing all of the production but not having to add any extra procedures in the process.  Also, if a piece is discovered to be defective, processing is ceased so that there is no squandering of time in producing defective parts and the defective parts do not cause squandered materials.  When process variation monitoring is put in place, maintenance employees do not need to insist that machines are turned off at irregular times so that they can perform their maintenance duties or worry about not doing their maintenance frequently enough, and the machines don’t perform.  In this environment, the maintenance occurs only when it is necessary.  Maintenance prices will therefore be reduced and efficiency in machine activity and operation as a whole will grow.  

Tooling will only be swapped on an as-needed basis in this environment so money will be saved because the tooling will not be replaced too soon or too late.  The final characteristic is that all workers in the company will concentrate on process rather than the actual parts being produced so growth will be found in several areas including the quality of the end product.

For process control to be useful in any environment, it must have a goal that is focused and understandable. There needs to also be a system of measurement in place so that it can be found if the aim is within reach or at what point it will have been attained.  There should also be a set of methods with responses that are expected to operate, so that performance can be assessed.

Process Control: Case Study

At Maloya, they put in place process control in their manufacturing setting.  They used it as part of their regular maintenance of machinery which included regular calibration of the machines.  Their laser machines were equipped with test components and these would be measured and the results recorded to ensure that the machine was reporting accurate results within the original equipment manufacturer (OEM) specifications.   This afforded Maloya with a proven process capability to ensure that their methods are working optimally which then transforms to their quality levels and standards. This process can also be replicated in regions such as machining and welding, additionally as in forming work centers.

By instituting process controls, you will find it a productive way of continuing quality management in a metal production setting.  Rather than focus on the parts, concentrate on the processes and everything will fall into place if performed correctly.

Roger Hug is the Vice President of Sales Engineering of Maloya Laser, leaders in <A href=”http://www.MaloyaLaser.com”>contract manufacturing</a> and <A href=”http://www.maloyalaser.com/turnkey_products.php”>turnkey manufacturing</a> servicing aerospace, medical, machinery, scientific and transportation needs with Laser Cutting systems.