scholarly journals A Factory Analysis on the Proportion of Defects Reduction in The Animal Feed Pellet Production Process using Design of Experiment Analysis

2019 ◽  
Vol 3 (2) ◽  
pp. 26-33
Author(s):  
Keyword(s):  
Production Process ◽  
Failure Modes ◽  
Animal Feed ◽  
Fractional Factorial ◽  
Pareto Chart ◽  
Manufacturing Defects ◽  
Root Cause ◽  
Pellet Production ◽  
Feed Pellet

The aim of this research is to reduce a number of defects during a feed pellet production process to improve customer satisfaction. A factory case study produces the feed pellets for several species such as food for pigs, chickens, and ducks. Production data from January to June 2017 manufacturing found that the manufacturing defects rate were about 3.32%. The data showed that the overall defects originated from different problems; 1) cracked or broken food; 2) high humidity; 3) distorted of product color; and 4) an ingredient error, respectively. Statistical methods, design analysis, and cause analysis techniques e.g. the Ishikawa diagram, Pareto chart, and FMEA (Failure Mode and Effects Analysis) were applied to help the factory to identify the main root cause of the defects and the potential failure modes of the factory case study. Due to an increasing number of complaints, this study only concentrated on the duck feed pellet production process. The study was divided into two parts: finding the root cause of the defects, which are the most critical factors for further analysis, and applying an experimental statistical design to decrease the number of defects during the duck pellet production process. The problem with cracked or broken pellets (dust) was found as the main factor affecting the production defects. Results showed that the main factors contributing to the amount of dusk in the duck feed productions came from three factors as follow: the thickness of die, distance between compression rollers and die, and time and temperature of mill machine needed during compressing the duck feed pellet production. Both the fractional factorial experimental design, 2k and 3k, were used to evaluate the influence of each factor on the duck feed production defects. The results by using the factorial 2K experimental show that the most important variable in duck pellets production were thickness of the die, distance between compression rollers and die, and temperature of mill machine needed during compressing the duck feed pellet production while time was not an interaction effect in this problem. The 3k factorial design was used to determine the interaction effects for the duck pellets production process. The experiment was ran and tested for 3 months. The final outcomes showed a significant reduction of defects from 2.51% to 1.09% (P<0.01). The results indicated that thickness -20 mm. of the die, 0.05 mm of distance between compression rollers and die, and 95 degree Celsius of temperature of mill machine needed during compressing the duck feed pellet production would be the most appropriate set of pelleting machine for the duck production process case study.

Case Study and Fault Modeling for Wrong Redundancy Evaluation on DRAM Devices

2007 ◽  
Author(s):  
Martin Versen ◽  
Dorina Diaconescu ◽  
Jerome Touzel
Keyword(s):  
Failure Mode ◽  
Failure Modes ◽  
Fault Modeling ◽  
Mode Analysis ◽  
Root Cause ◽  
Failure Mode Analysis

Abstract The characterization of failure modes of DRAM is often straight forward if array related hard failures with specific addresses for localization are concerned. The paper presents a case study of a bitline oriented failure mode connected to a redundancy evaluation in the DRAM periphery. The failure mode analysis and fault modeling focus both on the root-cause and on the test aspects of the problem.

Applying Advanced FMEA Methods to Vehicle Fire Cause Determinations

2011 ◽  
Author(s):  
Kerry D. Parrott ◽  
Pat J. Mattes ◽  
Douglas R. Stahl
Keyword(s):  
Automotive Industry ◽  
Failure Modes ◽  
Illustrative Case ◽  
Analysis Tool ◽  
Fire Investigation ◽  
Root Cause ◽  
Product And Process ◽  
Illustrative Case Study ◽  
Fire Cause

This paper proposes that the advanced Failure Modes and Effects Analysis (FMEA) techniques and methodology currently used by the automotive industry for product and process design can be reversed and used as an effective failure/root cause analysis tool. This paper will review FMEA methodologies, explain the newest advanced FMEA methodologies that are now being used in the automotive industry, and will then explain how this methodology can be effectively reversed and used as a failure analysis and fire cause determination tool referred to as a “reverse FMEA” (rFMEA). This paper will address the application of these techniques and methodology to vehicle fire cause determination. This methodology is particularly suited to situations where multiple potential fire causes are contained within an established area of origin. NFPA 921 Guide for Fire & Explosion Investigations [1] and NFPA 1033 Standard for Professional Qualifications for Fire Investigator [2], often referenced by the fire investigation community, prescribe following a systematic approach utilizing the scientific method for fire origin and cause determinations. The rFMEA methodology is proposed as a fire investigation tool that assists in that process. This “reverse FMEA” methodology will then be applied to a hypothetical, illustrative case study to demonstrate its application.

An integrated TRIZ approach for technological process and product innovation

2015 ◽  
Vol 231 (6) ◽  
pp. 1062-1077 ◽  
Author(s):  
Miao Li ◽  
Xinguo Ming ◽  
Maokuan Zheng ◽  
Lina He ◽  
Zhitao Xu
Keyword(s):  
Problem Solving ◽  
Technological Process ◽  
Manufacturing Process ◽  
Product Innovation ◽  
Interaction Matrix ◽  
Function Model ◽  
Manufacturing Defects ◽  
Root Cause ◽  
Innovative Solution

Process trimming (also can be called as trimming for process) helps to trim and eliminate process operations by redistributing their functions among other operations. It offers one way to eliminate key disadvantages in product and manufacturing process that other methods do not see. However, few methods have been disclosed in a structured way for process trimming effectively. Therefore, this article proposes an integrated process focused on technological process and product innovation to solve the key problems with process trimming-based TRIZ (theory of inventive problem-solving) approach. This method helps to identify and inventively solve the key problems and maximize use resource of system and supersystem. First, process trimming candidates are identified based on component function model, component trimming rules, process function model analysis, component–process interaction matrix, and root cause analysis. Then, three types of process trimming strategies are presented. Algorithm of process trimming is developed to identify key problems in technological process. TRIZ problem-solving tools are used to solve these key problems. Finally, a case study of refrigerator door foam innovative design and manufacturing process is investigated to test the efficiency of the approach. The innovative solution significantly decreases manufacturing defects and service cost.

Fault root cause tracing of complicated equipment based on fault graph

2012 ◽  
Vol 227 (1) ◽  
pp. 17-32 ◽  
Author(s):  
Xinlin Huang ◽  
Jianmin Gao ◽  
Hongquan Jiang ◽  
Zhiyong Gao ◽  
Fumin Chen
Keyword(s):  
Failure Modes ◽  
Complex Structure ◽  
Special Kind ◽  
Multiple Root ◽  
Propagation Mode ◽  
Mathematical Tool ◽  
Fault Propagation ◽  
Root Cause ◽  
Graph Reachability

Fault root causes tracing of complicated equipment in modern process industry is very important for accident and economic loss prevention. Due to the structure complexity of complicated equipment, failures happen from small parts and propagate through complex pathways often leading to serious system faults. These kind of faults caused by non-critical parts account for a large part of all the faults of complicated equipment and often cannot get enough attention in fault diagnosis. In order to trace the root causes of this kind of fault, the failure dependent relationship and fault propagation mode must be modeled accurately and effectively. Fault graph proposed by H. P. Alesso is a useful tool to represent complex structure and fault propagation pathway of complicated equipment with a special kind of fault-oriented directed graph expanded from fault tree. Fault graph takes advantage of graph rather than tree to describe complex relation between failure modes of components, and uses logic connectives to connect failure modes with logical relationship. Based on the basic concept of fault graph introduced by H. P. Alesso, this article focuses on the issues of fault graph constructing and fault graph fault root causes deducing. A fault graph constructing method was firstly discussed which uses the results of failure mode and effects analysis and the mathematical tool of polychromatic matrix and can be easily performed with the least manual work. Then the fault root causes deducing method of fault graph was investigated which focuses on fault graph reachability calculation and fault propagation pathway searching. The fault graph reachability calculation is put forward from doubletons to multiple root causes so that the reachabiltiy of any steps of fault graph pathway can be calculated. The fault propagation pathway searching method can be performed to reveal the detailed fault propagation pathway. A case study of fault graph modeling and fault root causes analysis based on fault graph of a certain type of centrifugal compressor which has complex internal structure is introduced. The case study shows that the proposed method is effective for fault root cause tracing of complicated equipment.

scholarly journals Breakdown Cause and Effect Analysis. Case Study

2018 ◽  
Vol 26 (2) ◽  
pp. 83-87 ◽  
Author(s):  
Witold Biały ◽  
Juraj Ružbarský
Keyword(s):  
Production Process ◽  
Management Tools ◽  
Effect Analysis ◽  
Pareto Chart ◽  
Cause And Effect ◽  
Ishikawa Diagram ◽  
Machine Operators ◽  
Additional Costs ◽  
Cause And Effect Analysis

Abstract Every company must ensure that the production process proceeds without interferences. Within this article, the author uses the term “interferences” in reference to unplanned stoppages caused by breakdowns. Unfortunately, usually due to machine operators’ mistakes, machines break, which causes stoppages thus generating additional costs for the company. This article shows a cause and effect analysis of a breakdown in a production process. The FMEA as well as quality management tools: the Ishikawa diagram and Pareto chart were used for the analysis. Correction measures were presented which allowed for a significant reduction in the number of stoppages caused by breakdowns.

scholarly journals Root Cause Analysis of a Printed Circuit Board (PCB) Failure in a Public Transport Communication System

2022 ◽  
Vol 12 (2) ◽  
pp. 640
Author(s):  
Cher-Ming Tan ◽  
Hsiao-Hi Chen ◽  
Jing-Ping Wu ◽  
Vivek Sangwan ◽  
Kun-Yen Tsai ◽  
...  
Keyword(s):  
Printed Circuit Board ◽  
Failure Modes ◽  
Essential Element ◽  
Circuit Board ◽  
Cause Analysis ◽  
Printed Circuit ◽  
Root Cause ◽  
Burn Out ◽  
Root Cause Identification

A printed circuit board (PCB) is an essential element for practical circuit applications and its failure can inflict large financial costs and even safety concerns, especially if the PCB failure occurs prematurely and unexpectedly. Understanding the failure modes and even the failure mechanisms of a PCB failure are not sufficient to ensure the same failure will not occur again in subsequent operations with different batches of PCBs. The identification of the root cause is crucial to prevent the reoccurrence of the same failure. In this work, a step-by-step approach from customer returned and inventory reproduced boards to the root cause identification is described for an actual industry case where the failure is a PCB burn-out. The failure mechanism is found to be a conductive anodic filament (CAF) even though the PCB is CAF-resistant. The root cause is due to PCB de-penalization. A reliability verification to assure the effectiveness of the corrective action according to the identified root cause is shown to complete the case study. This work shows that a CAF-resistant PCB does not necessarily guarantee no CAF and PCB processes can render its CAF resistance ineffective.

Root-Cause Investigations of Stitch Bond – Shearing by Means of 3D-X-ray Computer Tomography (XCT), Metallographic Polishing and FIB

2010 ◽  
Author(s):  
Peter Jacob ◽  
Iwan Jerjen ◽  
Giovanni Nicoletti
Keyword(s):  
Failure Modes ◽  
Typical Case ◽  
Bending Properties ◽  
Thermomechanical Stress ◽  
X Ray ◽  
Root Cause ◽  
Electrical Connections ◽  
Non Destructive ◽  
Non Destructive Characterization

Abstract Since new packaging technologies came up, sensitive failure modes, which were difficult to prove, increased. In many cases, an interaction of bending properties, thermomechanical stress and the material compounds used, cause intermittent failures related to electrical connections. Since any decapsulation might falsify analysis results, non-destructive characterization approaches are of utmost importance for future failure analysis. By means of a typical case study, the capabilities and limitations of a highly developed X-ray tool in such application has been outlined as well as the complexity of root cause findings.

Pengaruh Kecepatan Putar Terhadap Hasil Coran pada Metode Pengecoran Sentrifugal dalam Pembuatan Produk Pisau Pakan Ternak dengan Material Ni-Hard1

2019 ◽  
Vol 11 (01) ◽  
pp. 1-7
Author(s):  
Roni Kusnowo ◽  
Kus Hanaldi
Keyword(s):  
Animal Feed ◽  
Centrifugal Casting ◽  
Impact Resistance ◽  
Literature Study ◽  
Gravity Casting ◽  
Friction Resistance ◽  
Optimal Speed ◽  
Mold Making

Animal feed knife is a tool that serves to cut and chop animal feed consisting of grass as the main ingredient with additives such as bran, herbs, centrate, cassava, tofu pulp and others. Therefore, as a cutting tool must have the properties of friction resistance, impact resistance, and have good sharpness, so that the material chosen is Ni-Hard 1. The use of centrifugal casting method was chosen because it has the advantage of being able to make castings with relatively thin thickness this is due to the influence of the centrifugal force on the distribution of metal liquids throughout the cavity in the mold. Case study in this study is the use of centrifugal casting methods as an alternative to gravity casting methods to overcome defects of misruns. This research was conducted to investigate the effect of speed on the formation of castings products. The method that was carried out began with a literature study on centrifugal casting, and continued by determining the material, the temperature of the cast is in the range 1250ºC - 1300ºC, and the type of mold. The next step is to do work drawings, pattern making, mold making, casting processes, fettling processes, and analysis. With variations in speed of 200 rpm, 300 rpm and 400 rpm, it can be seen the optimal speed for making this product. The results of this study obtained optimal speed at a speed of 300 rpm to make good quality of animal feed knife products.

Case Study of ESD-induced Pin Leakage Failure Solved Using Novel Powered TIVA Technique

2018 ◽  
Author(s):  
Sneta Mishra ◽  
Daniel R. Bockelman
Keyword(s):  
Root Cause ◽  
Leakage Failure

Abstract A case study is presented of a core CPU product where FA/FI debug is performed for an ESD-related pin leakage issue on an IO family to root cause and qualify the product. A Powered TIVA technique is used to localize the damage to the termination resistor circuitry of the affected IO block when the pin is tristated using a device tester. Failure characterization shows a gate to drain short on the transistor, with nanoprobing confirming a solid short on gate to drain and TEM finding a short at the location indicated by the TIVA hits.

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