Rekayasa Kualitas

Materi ke 2
Dasar Rekayasa Kualitas
ekopujiyanto@ft.uns.ac.id

Contents

Basics of Quality by Design

Quality
Quality Loss Function

Quality and Process Capability

Process capability

Basics of Quality by Design

Quality by
design is one
of such
engineering
methodology

Basics of Quality by Design

Product is designed to meet customer needs and performance

requirements
Process is designed to consistently meet product quality
attributes
Impact of starting raw materials and process parameters on
product quality is understood
Critical sources of process variability are identified and
controlled
The process is continually monitored and updated to allow for
consistent quality over time

Basics of Quality by Design

A large amount engineering

manufacture products in conducting in
experiments
Customers perception of quality
( Sony television case in Japan and USA )

Basics of Quality by Design

Consider the popular story of Sony and two of their

television production facilities, one in the USA, the
other in Japan.
The color density of the televisions manufactured by
Sony-USA were uniformly distributed and fell
within the tolerance limits, m 5 ( where m is the
target for color density).
While the televisions from Sony-Japan followed a
normal distribution, more televisions were on
target but about 0.3% fell outside of the tolerance
limits.

Basics of Quality by Design

Colour density
distribution of
Sony America
and Japan
(April, 1979)

Basics of Quality by Design

The differences in customer perceptions of quality

resulted from Sony-USA paying attention only to
meeting the tolerances whereas in Sony-Japan, the
focus was on meeting the target and minimizing
the variance around that target.
Overall, a much larger portion of Sony-Japan's
televisions receive higher grades then those made
by Sony-USA
Hence, the customers preferred the televisions sets
produced by Sony-Japan over those produced by
Sony-USA.

Basics of Quality by Design

Taguchis definition of quality

the quality of a products is the ( minimum )
loss imparted by the product to society from
the time the products is shipped
What is loss and who pays for it

Loss as additional manufacturing cost

Loss be paid by society

Basics of Quality by Design

Interpretation of loss

Quality loss function (QLF) is quantitative

evaluation of quality loss due to functional
variation

m = target
y = hasil pengukuran
o = toleransi
Ao = jumlah kerugian

Basics of Quality by Design

Basics of Quality by Design

Interpretation of loss

A quality characteristics is the object of interest

of a product or process
Three types quality characteristics
Nominal the best ( NTB )
Smaller the better ( STB )
Larger the better ( LTB )

QLF - Nominal the best ( NTB )

( One piece )

A measurable characteristics with a specific userdefined target value. ( Sony TV : 115 20 volts )

QLF for NTB

QLF - Nominal the best ( NTB )

QLF - Nominal the best ( NTB )

( Many pieces )

QLF Smaller the better ( STB )

( One piece )

QLF - Smaller the better ( STB )

( One piece )
Example

QLF - Smaller the better ( STB )

( One piece )

QLF - Smaller the better ( STB )

( Many pieces )

QLF Larger the better ( LTB )

( One piece )

QLF Larger the better ( LTB )

( One piece )
Example

QLF Larger the better ( LTB )

( Many pieces )
1
L ( y ) k x
n

i1

y 2
i

QLF Asymmetric

Quality and Process Capability

Capability process

Quality and Process Capability

Capability process

Quality and Process Capability

Spec limit : fixed engineering limit for the product

dimmensions

Cp index

Cpk index
Cpk is an important measure
Cpk as a measure of quality

Quality and Process Capability

Quality and Process Capability

Quality and Process Capability

Cpk as a measure of quality

The conventional methods

Loss-by-defect = numbers of defect x cost of product
= proportion out of spec x total number x cost
of product

The quality loss function methods

Loss-by-dispersion =
product

A0 2
2

(
y

m
)
2

x numbers of

Quality and Process Capability

Cpk as a measure of quality
Example ( Sample 100.000 unit )

Quality and Process Capability

Cpk as a measure of quality

Quality and Process Capability

Cpk as a measure of quality

Quality and Process Capability

Cpk as a measure of quality

Case Study ( Tugas 2 )

A spring is used in the operation of a camera shutter. The
manufacturing process suffers from a degree of variability, in
terms of the spring constant (measured in oz/in), which
significantly effects the accuracy of the shutter times. The
functional limits for this spring constant are m0.3oz/in
(m=0.5oz/in), and the average cost for repairing or replacing a
camera with a defective spring is $20.
What is the loss function? Hence, what is the loss associated with
producing a spring of constant 0.25oz/in versus the loss
associated with one at 0.435oz/in.

Next Week

The Design Process

Principle of robust design in the
production process
Robust design process
Parameter design