ANALYSIS OF QUALITY OF METAL AND COMPLICATED TECHNOLOGY OF PRODUCTION- PRODUCTS

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1 ANALYSIS OF QUALITY OF METAL AND COMPLICATED TECHNOLOGY OF PRODUCTION- PRODUCTS a) Andrzej Kempa b) Prof. dr hab. Eng. Stanisław Borkowski a) Telekomunikacja Polska S.A. b) Technical University of Częstochowa, of Management, Division of Production Engineering, Częstochowa, Armii Krajowej St. 19 B, tel/fax , , Abstract In article it passed quantitative estimation of level of quality of products serf to etching, to pulling, to expression, to dry-cleaning, to superficial tooling. Products are intended on American market, what forces to warnings of technological parameters and of precise control. It ascertained, that main areas of disagreements' occurrence are: final material, dimensions of product, protective coat 1. IDENTIFICATION OF INVESTIGATIVE OBJECT Recognition of object- metallurgical firm producing metal - parts, covered igneous with zinc, for buildings, was passed basing on rules of Pareto-Lorenz's diagram [1]. Characterization ascertained non-conformances in period of term (general level of lacks in this period 6, 2 %) was introduced in table 1. From graphic dependences (Fig.1) results, that reasons: lack of cover and roughness (in sum 54 %) are connected with process of zincing. Articles in one place was covered layer of zinc with excessive thicknesses, in other places this cover wasn't, what shows on lack of removing defatting the fat of surface before intervention [2]. Table 1 Non-conformances in period of term No Name of nonconformances Proportional participation Accumulated value P1 lack of cover P2 badly flattened P3 Rough P4 not straight P5 badly cut off 6 88 P6 Thin 5 93 P7 Fat 4 97 P8 too short 2 99 P9 too long 1 Source: own elaboration

2 Structure of non-conformances P1 P2 P3 P4 P5 P6 P7 P8 P9 Kind of non-conformances Fig. 1. Pareto-Lorenz's Diagram for investigative term. Source: Own elaboration In half-yearly period (Table 2 and Fig. 2) as main reasons of defects stepped out: too short and thin articles, what shows, that devices (drawing die and scissors) are not qualitatively efficient (general level of lacks in this period 4, 8 %). Table 2 Non-conformances in half-yearly period No Name of non-conformances Proportional participation Accumulated value P8 too short P6 thin P7 fat P9 too long P5 badly cut off 8 90 P4 not straight 4 94 P1 lack of cover 3 97 P3 rough 2 99 P2 badly flattened 1 Source: Own elaboration % udział niezgodności w całości wyrobów Structure of non-conformances niezgodnych rodzaj niezgodnoś ci P8 P6 P7 P9 P5 P4 P1 P3 P2 Kind of non-conformances Fig. 2. Pareto-Lorenz's Diagram Pareto for investigative half-year. Source: Own elaboration

3 Period of one year's investigations (Table 3 and Fig. 3) shows, that main reason defects of articles is lineal dimension, articles similarly as in half-yearly period are too short. This together articles are too fat, what can point on waste of drawing die (general level of lacks in this period 4, 2 %) [ 3 ]. Table 3 Non-conformances in period of year No Name of non-conformances Proportional Accumulated value participation P8 too short 45,7 45,7 P7 fat 21,0 66,7 P9 too long 12,4 79,0 P6 thin 6,7 85,7 P5 badly cut off 4,8 90,5 P3 rough 3,8 94,3 P4 not straight 2,9 97,1 P1 lack of cover 1,9 99,0 P2 badly flattened 1,0,0 Source: Own elaboration structure of non-conformances P8 P7 P9 P6 P5 P3 P4 P1 P2 kind of nonconformances Fig. 3. Pareto-Lorenz's Diagram for investigative year. Source: Own elaboration 2. H. MREŁA DIAGNOSTIC TEST Simplified diagnostic test with reference to organizational-technical structure (according to H. Mreła) founds, that if 1 / 3 answers is affirmative, exist odds, that one can reach advantages from preprojection of organization. At 2 / 3 answers,, yes'' economies obtained from projecting of new organization are almost certain, what presents table4.

4 Table 4 Results of Mreła Diagnostic Test A. Machines Yes No Machines stand idly. Large quantity of damage. Obsolete machine - park. Gadgetry cause excessive noise, twitches, dirt and smells fumes. Equipment not adapted / with height, length, width and balance / to place In which is situated. Difficult access to machines and devices. B. People Yes No Dangerous conditionses of work Or high coefficient of events. Area not adapted to requirements and rules of safety and hygienes and against fire. Complaints and inconvenient conditionses of work. High level of fluctuation Workers stand idly or lose a lot of time on going. Lack agreement between operators and staff of service divisions. Qualified workers spend much time on service - works. C. Dislocation - transportation Yes No Two-sided Movement or crossing of flow. Qualified operators work at translocating. Large percentage of time operators sacrifice on loading and unloading of materials. Frequent lifting or manual transportation. Translocating and exacting lifting of excessive effort. Expectation operators on transport-staff or forwarding equipment. Operators forced to synchronization of work with equipment to translocating. Translocating on long distances. Too frequent translocating Equipment or workers of transportation not used. Conflicts on forwarding ways. Renewed translocating and delivering among positions. D. Materials Yes No High percentage of lacks. High percentage of materials quantity worn out in productive operations. Large, heavy or expensive materials moving on large distances, and little, light and cheap on smaller distances. Too free flow among departments. Materials die during of production or lose signatures. Cycle productive too long in relation to topical time of tooling. Source: Own elaboration How it results from above - test 50 % of answer is affirmative thus exist large possibilities of improvement of work organization and enlargement its effectivities. In the first part of test relating machines step out only 2 affirmative answers on 6 questions. It is connected with obsolete machine - park, which this influences on large quantity of damages, standstills and excessive noise and twitches, and on exactitude of dimension - articles, what one ascertained during investigations. Exchange of machines on new, more effective and better silenced is not possible from financial regards and this, that

5 grew less application on articles that department. From here it would also take part to strike over organizational changes and certain with little technical improvement in existing machine - park. 3. ANALYSIS OF WORKING TECHNICAL SERVICE Technical services and maintenances of movement are organized in metallurgical firm in multistage manner and are subject to officially different members of management (Fig. 4). Technical Manager Mechanic Energetics Technologists Division of Mechanic Division of Energetics Technical Support Tooling Electric Energetistic Division of Technologists and quality control Divisi on of SHW Boiler Room Fig. 4. Modernized organizational structure connected with Technical Manager Fig. 4 shows, that for lowering of level of lacks it was decided to connect problems of technology and quality in one organizational division. 4. RECAPITULATION In work it was used Pareto-Lorenz's diagram to identification and estimation of nonconformances structure of metal-articles for buildings. Investigations this parts pointed on organizational shortcomings and lack of efficiency of machines. These data confirmed

6 diagnostic test according to H. Mreła. Firm on the ground of obtained results executed organizational changes, uniting e.g. technology with quality. LITERATURE: [1] Bank J.: Zarządzanie przez jakość. Wydawnictwo Getheberg i S-ka, Warszawa [2] Fosforowanie walcówki i półfabrykatów w trawelni. Materiały własne [3] Kolman R. Inżynieria jakości. PWE, Warszawa 1992.

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