Effect of Synthesis Procedure on Particle Dispersion and Hardness of Al- Sic Functionally Graded Metal Matrix Composite

Fabrication of Functionally Graded Metal Matrix Composites (FGMMC) especially with high ceramic reinforcement's volume fraction is highly challenging. Depending on the processing technique and process parameters various defects may arise. This research aims to find the best procedure to make FGMMCs with the highest quality and minimum cost. A new method is proposed that incorporates lost-foam and melt infiltration with semicentrifugal casting to produce FGMMC. Experiments were performed to in-situ fabricate 6061-Aluminum alloy reinforced with gradient distributed Silicon carbide particles (Al/SiC FGMMC). Effect of SiC %, Al pouring temperature and rotational speed on the fabricated specimens hardness and reinforcement gradient were investigated using design of experiments and regression analysis. Results reveal the optimum procedure and process settings based on desired properties/gradient required. Mathematical model formulated captures the effect of these process parameters on process cost, and cost of poor quality. Improper selection of those parameters may lead to extensive losses due cost of poor quality which is 12 times higher than the material cost. The proposed manufacturing process proved satisfactory in ensuring proper dispersion. A desirability function can by used to determine the process parameters and volume fraction that minimizes the defects and gives superior properties for a specific application.

Relationship Between Cost of Poor Quality and Continuous Improvement

Quality is a vital factor for every organization that seeks to sustain its competitive advantage. As such, organizations, especially those operating in the manufacturing industry, have enhanced their level of awareness on matters that align with quality, especially because of ever-advancing technology. In this regard, the cost of poor quality (COPQ) has been identified as a major component that is negatively impacting the profit maximization of many organizations. COPQ causes significant losses of revenue and businesses, as it takes the form of external and internal product failures. Nevertheless, there is a relationship between COPQ and continuous improvement; COPQ acts as a driver for continuous improvement initiatives that the organization adopts to enhance its quality. Thus, COPQ and continuous improvement are related because after an organization experiences the losses associated with COPQ, then it will strategize on ways to achieve continuous improvement.

Analysis on Product Quality of Semi Refined Carrageenan using Six Sigma and Cost of Poor Quality

The study aimed to minimize defective products to improve the production process quality of PT BI by identifying the most types of defects, calculating Defect per Million Opportunities (DPMO) value, suggesting the quality improvement of the Semi Refined Carrageenan (SRC) production process, and calculating Cost of Poor Quality (COPQ) value. The methods used in this research were Six Sigma and the COPQ. The priority improvement based on the Pareto chart was moisture defects with the percentage of damage of 36.9%. The Sigma level of the production process of PT BI was 3.42 with a defect rate of 27,429 DPMO. The analysis on the cause and effect diagram showed that factors affected the occurrence of defective products were error in reading on moisture content, diverse raw material, the wrong method of mixing raw materials prior to production process, and the lack of inspectors of production process. The most influential-dominant factor was the obsolete machine which causes error in reading on moisture content. The company can take preventive and corrective actions to suppress defective products and improve product quality. Based on the calculation of the COPQ, the costs that must be incurred by the company due to defective products was IDR 1,007,690,694.

How Cost of Poor Quality Factors Into Continuous Improvement Models

This article aims to investigate the patterns of the relationship between the cost of poor quality (COPQ) and the process of continuous improvement. Methods of qualitative research are used to conduct the detailed inquiry between both variables from every critical angle. Comprehensive secondary analysis, which is comprised of a structured and unstructured literature review, is performed for this purpose. The findings of the study reveal that the cost of poor quality directly relates to the process of incremental improvement. Each business is faced with certain redundancies and other issues that cause the actual cost of a process to exceed the optimally reduced cost. The management of each organization should focus on a system that consistently identifies any loopholes, which would be followed by a method to eliminate or minimize them. These cost reductions incrementally result in the improvement of company processes. In the end, the evidence proves the research hypothesis.