Financial justification of nondestructive testing: cost of quality in manufacturing
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| Format: | Electronic eBook |
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| Language: | English |
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Boca Raton, FL
CRC/Taylor & Francis
2007
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| Subjects: | |
| Online Access: | Summary Inhaltsverzeichnis |
| Physical Description: | 1 Online-Ressource |
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| 245 | 1 | 0 | |a Financial justification of nondestructive testing |b cost of quality in manufacturing |c Emmanuel P. Papadakis |
| 264 | 1 | |a Boca Raton, FL |b CRC/Taylor & Francis |c 2007 | |
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| 650 | 4 | |a Nondestructive testing |x Cost effectiveness | |
| 700 | 1 | |a Papadakis, Emmanuel P. |e Sonstige |4 oth | |
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Record in the Search Index
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| adam_text | Contents
1 The Big Picture of Quality 1
1.1 What Quality Means to People 1
1.2 Trying To Manage Quality 3
1.3 ISO 9000 as the Management Standard for Quality
(Revised 2000) 4
1.3.1 Five Tiers of Quality Management per ISO 9000 5
2 How We Got to Where We Are 9
2.1 Early Philosophy of Manufacturing 9
2.2 Taylor Management Method and Mass Production:
Our Twin Nemesis 13
2.2.1 Taylor s System of Scientific Management 13
2.2.2 Ford s Extensions and Changes 21
2.2.3 Further Notes on Taylor and Ford 24
2.3 Quality Degradation under Taylor Management 29
2.4 The Inspector as the Methodology To Rectify Quality 30
2.5 Adversarial Confrontation: Inspector as Cop
and Laborer as Crook 32
2.6 Ineffectuality of Inspector To Improve Quality 32
2.7 The Perfect Inspector: Automated 100%
Inspection by Electronics 33
2.8 Fallacies of Early Implementation of 100% Inspection 34
2.9 The Root Problem: Out of Control Processes 36
3 Out of Control, Under Control, and Achieving
Control for Processes 37
3.1 Out of Control as a Question of Information 37
3.2 Statistical Process Control (SPC) To Get Information 39
3.3 A Review of Statistical Process Control 40
3.4 Automated Run Rules with Computers 45
3.5 Statistical Process Control Results as Statistics 46
3.6 Out of Control Quarantining Vs. Just in Time Inventory 47
4 Total Quality Management with Statistical
Process Control and Inspection 49
4.1 Total Quality Management and Deming s Fourteen Points 49
4.2 Deming s Fourteen Points Taken Sequentially 51
4.2.1 Point 1 Key Words: Decision: Improvement 51
4.2.2 Point 2 Key Words: Decision: Enforcement 53
4.2.3 Point 3 Key Words: Inspection: Taboo 53
4.2.4 Point 4 Key Words: Suppliers: Good, Not Cheap 56
4.2.5 Point 5 Key Words: Improvements: Pinpointing 61
4.2.6 Point 6 Key Words: Training: Modern 62
4.2.7 Point 7 Key Words: Supervision: Modern 66
4.2.8 Point 8 Key Words: Fear: Taboo 68
4.2.9 Point 9 Key Words: Teams, Not Barriers 69
4.2.10 Point 10 Key Words: Slogans: Counterproductive 73
4.2.11 Point 11 Key Words: Quotas: Taboo 74
4.2.12 Point 12 Key Words: Workmanship: Pride
(Remove Barriers That Hinder the Hourly Worker) 75
4.2.13 Point 13 Key Words: Education and Training 76
4.2.14 Point 14 Key Words: Implementation: Staffing 77
4.3 Summary 78
5 ISO 9000 with Statistics and Inspection 79
5.1 Background 79
5.2 ISO 9000: Keeping a Company under Control 81
5.3 Statistical Process Control and Statistics within
ISO Philosophy in the 1990 Version 81
5.4 Inspection in ISO 9000 1990 82
5.5 Changes in Emphasis in the ISO 9000 2000 Version 85
5.5.1 Philosophy 85
5.5.2 Reorganization 86
5.5.3 Additions 86
5.5.4 Applied to Organizations 87
5.6 Overview of Sections 4 through 8 88
5.6.1 Section 4: Quality Management System 88
5.6.2 Section 5: Management Responsibility 88
5.6.3 Section 6: Resource Management 88
5.6.4 Section 7: Product Realization 88
5.6.5 Section 8: Measurement, Analysis, and
Improvement 89
5.7 Failure Modes and Effects Analysis 89
5.7.1 Potential Risk Avoidance Planning 89
5.8 How Does NDT Fit into ISO 9000 2000? 90
5.9 Summary 92
6 Statistical Process Control as a Prerequisite
to Calculating the Need for Inspection 95
6.1 Recapitulation of Statistical Process Control 95
6.2 Necessary Data 96
6.2.1 Rate of Production of Nonconforming Parts 96
6.2.2 Detrimental Costs of Nonconformities 96
6.2.3 Costs of Inspection 98
6.2.4 Time until Improvement Lowers Nonconformities 99
6.3 The Costs of Inspection and the Detrimental Costs
of Not Inspecting 100
6.4 Summary 101
7 Three Financial Calculations Justifying 100%
Nondestructive Testing 103
7.1 Introduction 103
7.1.1 The Deming Inspection Criterion (DIC) Method 103
7.1.2 The Time Adjusted Rate of Return (TARR)
or the Internal Rate of Return (IRR) Method 104
7.1.3 The Productivity, Profitability, and Revenue Method 104
7.2 DIC: Low Investment 105
7.3 TARR or IRR: High Investment and Long Term Usage 106
7.4 Productivity, Profitability, and Revenue Method:
Nano Economics 107
8 High Tech Inspection Methods Ill
8.1 General Ill
8.1.1 Documentation and Methods Ill
8.1.2 Definition and Outlook 116
8.2 Various Classes of Methods: NDT and Others 118
8.2.1 Ultrasound 118
8.2.1.1 General View of Ultrasound in NDT 118
8.2.1.2 Production and Reception of Ultrasound 118
8.2.1.3 Integrated Instruments and Display Modes 121
8.2.1.4 Specialized Instruments and Applications 125
8.2.2 Acoustic Emission (AE) 140
8.2.2.1 General View of AE in NDT 140
8.2.2.2 Production and Reception of Acoustic Emission 141
8.2.2.3 Integrated Instruments and Display Modes 141
8.2.2.4 Specialized Instruments and Applications 141
8.2.3 Eddy Currents 144
8.2.3.1 General View of Eddy Currents in NDT 144
8.2.3.2 Production and Reception of Eddy Currents 145
8.2.3.3 Integrated Instruments and Display Modes 147
8.2.3.4 Specialized Instruments and Applications 147
8.2.4 X Rays and Fluoroscopy 154
8.2.4.1 General View of X Rays 154
8.2.4.2 X Ray Fluoroscopy on Connecting Rods 154
8.2.5 Sonic Resonance 155
8.2.5.1 General View of Sonic Resonance 155
8.2.5.2 Sonic Resonance for Automotive Crankshafts 157
8.2.6 Infrared Radiation (IR) 164
8.2.6.1 General View of Infrared 164
8.2.6.2 Infrared Assurance of Friction Welds 164
8.2.6.3 Other Examples of IR 166
8.2.7 Evanescent Sound Transmission 167
8.3 Correlations and Functions Relating Measurements
and Parameters 168
8.3.1 The Nature of Functions 168
8.3.2 The Nature of Correlations 168
8.3.2.1 Is There a Relationship? 168
8.3.2.2 The Need for Relationship 169
8.3.2.3 Extending the Relationship 170
8.3.3 Theory of Correlations 170
8.3.3.1 The Underlying Function 170
8.3.3.2 Origin of Perturbations to the
Underlying Function 173
8.3.4 Experiments with Correlations 175
8.3.5 Generic Curve for Reject Limits 176
8.3.6 Summary of the Correlation Approach 178
8.3.7 Philosophy of the Scientist and the Engineer 178
8.3.8 Conclusions Concerning Correlations 180
9 Real Manufacturing Examples of the Three Financial
Methods of Calculation and of Real Decisions Made
on the Basis of Those Calculations 183
9.1 General 183
9.2 Examples of the Deming Inspection Criterion (DIC) Method 184
9.2.1 A Process with Each Part Unique: Instant
Nodular Iron 184
9.2.2 Adhesively Bonded Truck Hoods: Sheet Molding
Compound Type FRP 187
9.2.3 A Safety Related Part: Front Wheel Spindle Support 192
9.2.4 Several Identical Parts in One Subassembly:
Connecting Rods 193
9.2.5 Intermediate Inspection of a Machined Part:
Engine Block 194
9.3 Examples of TARR and IRR Methods 195
9.3.1 Didactic Example: Hypothetical Data 196
9.3.2 Intermediate Inspection of a Machined Part 197
9.3.3 Aircraft Engine Discs 199
9.4 Examples of the Productivity, Profitability, and Revenue
Method 204
9.4.1 New Metal for Automotive Connecting Rods 204
9.4.1.1 The Baseline Calculation 205
9.4.1.2 The Real Situation with No Inspection 206
9.4.1.3 The Real Situation with Inspection 207
9.4.2 Aircraft Engine Discs 209
9.5 Summary 211
10 Nondestructive Inspection Technology and
Metrology in the Context of Manufacturing
Technology as Explained in This Book 213
10.1 Emphasis 213
10.2 Chronological Progression 213
10.3 A Final Anecdote 214
References 217
Related Titles 223
Index 225
|
| adam_txt |
Contents
1 The Big Picture of Quality 1
1.1 What Quality Means to People 1
1.2 Trying To Manage Quality 3
1.3 ISO 9000 as the Management Standard for Quality
(Revised 2000) 4
1.3.1 Five Tiers of Quality Management per ISO 9000 5
2 How We Got to Where We Are 9
2.1 Early Philosophy of Manufacturing 9
2.2 Taylor Management Method and Mass Production:
Our Twin Nemesis 13
2.2.1 Taylor's System of Scientific Management 13
2.2.2 Ford's Extensions and Changes 21
2.2.3 Further Notes on Taylor and Ford 24
2.3 Quality Degradation under Taylor Management 29
2.4 The Inspector as the Methodology To Rectify Quality 30
2.5 Adversarial Confrontation: Inspector as Cop
and Laborer as Crook 32
2.6 Ineffectuality of Inspector To Improve Quality 32
2.7 The "Perfect" Inspector: Automated 100%
Inspection by Electronics 33
2.8 Fallacies of Early Implementation of 100% Inspection 34
2.9 The Root Problem: Out of Control Processes 36
3 Out of Control, Under Control, and Achieving
Control for Processes 37
3.1 Out of Control as a Question of Information 37
3.2 Statistical Process Control (SPC) To Get Information 39
3.3 A Review of Statistical Process Control 40
3.4 Automated Run Rules with Computers 45
3.5 Statistical Process Control Results as Statistics 46
3.6 Out of Control Quarantining Vs. Just in Time Inventory 47
4 Total Quality Management with Statistical
Process Control and Inspection 49
4.1 Total Quality Management and Deming's Fourteen Points 49
4.2 Deming's Fourteen Points Taken Sequentially 51
4.2.1 Point 1 Key Words: Decision: Improvement 51
4.2.2 Point 2 Key Words: Decision: Enforcement 53
4.2.3 Point 3 Key Words: Inspection: Taboo 53
4.2.4 Point 4 Key Words: Suppliers: Good, Not Cheap 56
4.2.5 Point 5 Key Words: Improvements: Pinpointing 61
4.2.6 Point 6 Key Words: Training: Modern 62
4.2.7 Point 7 Key Words: Supervision: Modern 66
4.2.8 Point 8 Key Words: Fear: Taboo 68
4.2.9 Point 9 Key Words: Teams, Not Barriers 69
4.2.10 Point 10 Key Words: Slogans: Counterproductive 73
4.2.11 Point 11 Key Words: Quotas: Taboo 74
4.2.12 Point 12 Key Words: Workmanship: Pride
(Remove Barriers That Hinder the Hourly Worker) 75
4.2.13 Point 13 Key Words: Education and Training 76
4.2.14 Point 14 Key Words: Implementation: Staffing 77
4.3 Summary 78
5 ISO 9000 with Statistics and Inspection 79
5.1 Background 79
5.2 ISO 9000: Keeping a Company under Control 81
5.3 Statistical Process Control and Statistics within
ISO Philosophy in the 1990 Version 81
5.4 Inspection in ISO 9000 1990 82
5.5 Changes in Emphasis in the ISO 9000 2000 Version 85
5.5.1 Philosophy 85
5.5.2 Reorganization 86
5.5.3 Additions 86
5.5.4 Applied to Organizations 87
5.6 Overview of Sections 4 through 8 88
5.6.1 Section 4: Quality Management System 88
5.6.2 Section 5: Management Responsibility 88
5.6.3 Section 6: Resource Management 88
5.6.4 Section 7: Product Realization 88
5.6.5 Section 8: Measurement, Analysis, and
Improvement 89
5.7 Failure Modes and Effects Analysis 89
5.7.1 Potential Risk Avoidance Planning 89
5.8 How Does NDT Fit into ISO 9000 2000? 90
5.9 Summary 92
6 Statistical Process Control as a Prerequisite
to Calculating the Need for Inspection 95
6.1 Recapitulation of Statistical Process Control 95
6.2 Necessary Data 96
6.2.1 Rate of Production of Nonconforming Parts 96
6.2.2 Detrimental Costs of Nonconformities 96
6.2.3 Costs of Inspection 98
6.2.4 Time until Improvement Lowers Nonconformities 99
6.3 The Costs of Inspection and the Detrimental Costs
of Not Inspecting 100
6.4 Summary 101
7 Three Financial Calculations Justifying 100%
Nondestructive Testing 103
7.1 Introduction 103
7.1.1 The Deming Inspection Criterion (DIC) Method 103
7.1.2 The Time Adjusted Rate of Return (TARR)
or the Internal Rate of Return (IRR) Method 104
7.1.3 The Productivity, Profitability, and Revenue Method 104
7.2 DIC: Low Investment 105
7.3 TARR or IRR: High Investment and Long Term Usage 106
7.4 Productivity, Profitability, and Revenue Method:
Nano Economics 107
8 High Tech Inspection Methods Ill
8.1 General Ill
8.1.1 Documentation and Methods Ill
8.1.2 Definition and Outlook 116
8.2 Various Classes of Methods: NDT and Others 118
8.2.1 Ultrasound 118
8.2.1.1 General View of Ultrasound in NDT 118
8.2.1.2 Production and Reception of Ultrasound 118
8.2.1.3 Integrated Instruments and Display Modes 121
8.2.1.4 Specialized Instruments and Applications 125
8.2.2 Acoustic Emission (AE) 140
8.2.2.1 General View of AE in NDT 140
8.2.2.2 Production and Reception of Acoustic Emission 141
8.2.2.3 Integrated Instruments and Display Modes 141
8.2.2.4 Specialized Instruments and Applications 141
8.2.3 Eddy Currents 144
8.2.3.1 General View of Eddy Currents in NDT 144
8.2.3.2 Production and Reception of Eddy Currents 145
8.2.3.3 Integrated Instruments and Display Modes 147
8.2.3.4 Specialized Instruments and Applications 147
8.2.4 X Rays and Fluoroscopy 154
8.2.4.1 General View of X Rays 154
8.2.4.2 X Ray Fluoroscopy on Connecting Rods 154
8.2.5 Sonic Resonance 155
8.2.5.1 General View of Sonic Resonance 155
8.2.5.2 Sonic Resonance for Automotive Crankshafts 157
8.2.6 Infrared Radiation (IR) 164
8.2.6.1 General View of Infrared 164
8.2.6.2 Infrared Assurance of Friction Welds 164
8.2.6.3 Other Examples of IR 166
8.2.7 Evanescent Sound Transmission 167
8.3 Correlations and Functions Relating Measurements
and Parameters 168
8.3.1 The Nature of Functions 168
8.3.2 The Nature of Correlations 168
8.3.2.1 Is There a Relationship? 168
8.3.2.2 The Need for Relationship 169
8.3.2.3 Extending the Relationship 170
8.3.3 Theory of Correlations 170
8.3.3.1 The Underlying Function 170
8.3.3.2 Origin of Perturbations to the
Underlying Function 173
8.3.4 Experiments with Correlations 175
8.3.5 Generic Curve for Reject Limits 176
8.3.6 Summary of the Correlation Approach 178
8.3.7 Philosophy of the Scientist and the Engineer 178
8.3.8 Conclusions Concerning Correlations 180
9 Real Manufacturing Examples of the Three Financial
Methods of Calculation and of Real Decisions Made
on the Basis of Those Calculations 183
9.1 General 183
9.2 Examples of the Deming Inspection Criterion (DIC) Method 184
9.2.1 A Process with Each Part Unique: Instant
Nodular Iron 184
9.2.2 Adhesively Bonded Truck Hoods: Sheet Molding
Compound Type FRP 187
9.2.3 A Safety Related Part: Front Wheel Spindle Support 192
9.2.4 Several Identical Parts in One Subassembly:
Connecting Rods 193
9.2.5 Intermediate Inspection of a Machined Part:
Engine Block 194
9.3 Examples of TARR and IRR Methods 195
9.3.1 Didactic Example: Hypothetical Data 196
9.3.2 Intermediate Inspection of a Machined Part 197
9.3.3 Aircraft Engine Discs 199
9.4 Examples of the Productivity, Profitability, and Revenue
Method 204
9.4.1 New Metal for Automotive Connecting Rods 204
9.4.1.1 The Baseline Calculation 205
9.4.1.2 The Real Situation with No Inspection 206
9.4.1.3 The Real Situation with Inspection 207
9.4.2 Aircraft Engine Discs 209
9.5 Summary 211
10 Nondestructive Inspection Technology and
Metrology in the Context of Manufacturing
Technology as Explained in This Book 213
10.1 Emphasis 213
10.2 Chronological Progression 213
10.3 A Final Anecdote 214
References 217
Related Titles 223
Index 225 |
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| callnumber-subject | TA - General and Civil Engineering |
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| spelling | Financial justification of nondestructive testing cost of quality in manufacturing Emmanuel P. Papadakis Boca Raton, FL CRC/Taylor & Francis 2007 1 Online-Ressource txt rdacontent c rdamedia cr rdacarrier Nondestructive testing Cost effectiveness Papadakis, Emmanuel P. Sonstige oth http://www.engnetbase.com/ejournals/books/book_summary/summary.asp?id=5103> Summary HBZ Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=015463903&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Financial justification of nondestructive testing cost of quality in manufacturing Nondestructive testing Cost effectiveness |
| title | Financial justification of nondestructive testing cost of quality in manufacturing |
| title_auth | Financial justification of nondestructive testing cost of quality in manufacturing |
| title_exact_search | Financial justification of nondestructive testing cost of quality in manufacturing |
| title_exact_search_txtP | Financial justification of nondestructive testing cost of quality in manufacturing |
| title_full | Financial justification of nondestructive testing cost of quality in manufacturing Emmanuel P. Papadakis |
| title_fullStr | Financial justification of nondestructive testing cost of quality in manufacturing Emmanuel P. Papadakis |
| title_full_unstemmed | Financial justification of nondestructive testing cost of quality in manufacturing Emmanuel P. Papadakis |
| title_short | Financial justification of nondestructive testing |
| title_sort | financial justification of nondestructive testing cost of quality in manufacturing |
| title_sub | cost of quality in manufacturing |
| topic | Nondestructive testing Cost effectiveness |
| topic_facet | Nondestructive testing Cost effectiveness |
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