As a result, the controllable inputs (that the operator can actually modify) are adjusted according to the previous results without considering that other uncontrollable input variables may vary unpredictably. In fact, the majority of control systems currently adopted in the automotive industry, and specifically in metal part production plants, are based only on feed-back behavior. This way, the results are as consistent as possible (keeping the process within capability requirements).īut, if on one hand, robustness analyses are easily performed in the virtual world, on the other, continuously tuning the process generally requires a huge investment of time and resources. In other words, the engineering team should aim to design a robust manufacturing process (stable and within tolerance) and the press operator should “tune” the process for every change to the input parameters (e.g., change of material batch). As Franke stated in an article previously published on this blog, “Even the most experienced press operators often cannot avoid producing scrap.” This is because “randomness” is intrinsic in all processes and must therefore be taken into account - firstly during the engineering phase by the simulation engineer, and later during the production phase by the press operator. ![]() On the other hand, adopting the goal of zero defects could mean striving for a level of perfection that cannot realistically be met. Achieving a zero (or low) defect level results in consistent waste reduction when manufacturing products according to customer specifications - this means higher customer satisfaction and loyalty, which ultimately translates to improved sales and profits. This high quality forms the basis for reaching increasingly stringent requirements in terms of safety and cost reduction. In recent years, the automotive industry has embraced a path of constant evolution with accompanying enhancements in product quality. Coverage of a Research Paper Published by Politecnico Di Bari Italy
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