Control of Manufacturing Processes. Spring 2004 Lecture #1 Introduction
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1 Control of Manufacturing Processes Subject Subject Spring 2004 Lecture #1 Introduction February 3, 2004
2 Background Pre-requisites requisites Your Background and Interests Relevant Experience Course Schedule 2/3/ /6303 Lecture #1 David E. Hardt 2
3 Expectations Assignments ~ Weekly 1 Lab in class 2 Quizzes in Class Textbook (for middle half of course) Montgomery, D.C., Introduction to Statistical Quality Control, 4 th Ed. Wiley, /3/ /6303 Lecture #1 David E. Hardt 3
4 Syllabus Details Instructors: MIT : David Hardt (Office Hours by appointment) Singapore: Dr. Lu Wen Feng NTU Prof. Chen I-Ming, NTU Class Support: Lisa Falco 2/3/ /6303 Lecture #1 David E. Hardt 4
5 Syllabus Details Prerequisites: Either or both : Classical control systems Probability and Statistics Text Required: Montgomery, D.C., Introduction to Statistical Quality Control, 4 th Ed. Wiley, 2001 Grading: Problem sets 50%; Quizzes 35% Class Participation 15% Assignments: All except Optimization Project are to be Individual efforts Course URL: (Certificate Required) 2/3/ /6303 Lecture #1 David E. Hardt 5
6 Part I - Origins of Variations Lecture # Tue, 03 Feb 1 8:00-9:30AM Thurs, 05 2 Feb Tues, 10 3 Feb Date Lecture Topic Assignment Introduction Process Modeling for Control Sources of Variation 4 Thur, 12 Feb Laboratory 5 Thur, 19 Feb The Nature of Variation: Lab Interpretation #1 Process Overview Ź #1 Due, #2 Lab and Data Reduction Raw Data in Spreadsheet due ASAP after lab # 2 Due, # 3Process Modeling 2/3/ /6303 Lecture #1 David E. Hardt 6
7 Part II Statistical Description Lecture # Date Lecture Topic Assignment 6 Tue, 24 Feb Describing Variation: Probability and Random Variables Ź 7 Thur, 26 Shewhart Model of Manufacturing # 3 Due, Feb and ŅChartingÓ #4 Normal Statistics 8 Tue, 02 Mar SPC Charting and Process Capability Ź 9 Thur, 04 # 4 Due, #5 SPC and SPC Methods and Process Capability Mar Cpk 10 Tue, 9 Mar Advanced SPC: Moving Average Approaches Ź 11 Thur, 11 Introduction to Empirical Process # 5 Due Mar Modeling and Optimization Ź Tue, 16 Mar Quiz #1 (Covers through Lecture 10) Ź 2/3/ /6303 Lecture #1 David E. Hardt 7
8 Part III Process Optimization Lecture # Date Lecture Topic Assignment Thur, 18 Mar Tue, 30 Mar Thur, 01 Apr Tue, 06 Apr Thur, 08 Apr Designed Experiments: the 2-k problem Model Building and Testing Analysis of Variance and Model Testing # 6 DOE and Process Models Ź # 6 Due #7 ANOVA model tests Optimization using Empirical Models Ź # 7 Due #8 Process Fractional Factorial Models Optimization Project 2/3/ /6303 Lecture #1 David E. Hardt 8
9 Part IV Feedback Control Lecture # 17 Tue, 13 Apr Date Lecture Topic Assignment Thur, 15 Apr Thur, 22 Apr Tue, 27 Apr 21 Thur 29 Apr Tue, 04 May Thur, 06 May Feedback Control for Process Improvement: Introduction: Basic Servo Problem Basic Loop Analysis Position Servo Analysis Cycle to Cycle Control: The Basics Discrete System Closed-Loop Dynamics Variation Reduction in Cycle to Cycle Control Application of Cycle to Cycle Control Ź#11 Due Ź # 8 Due #9 Machine Feedback control # 9 Due #10 Cycle to Cycle Control Ź # 10 Due, # 11 Summary Project Ź 2/3/ /6303 Lecture #1 David E. Hardt 9
10 Manufacturing Process Control Process Goals Cost Quality Rate Flexibility 2/3/ /6303 Lecture #1 David E. Hardt 10
11 Processes and Systems Successive Operations Serial Quality Dependence Parallel Operations Dependence at Assembly Μ1 Μ2 Μ1 Μ2 Μ3 Μ3 2/3/ /6303 Lecture #1 David E. Hardt 11
12 2.830 Focus Unit Operations (1) Maximizing Quality Conformance to Specifications (2) Improving Throughput (3) Improving Flexibility (4) Reducing Cost 2/3/ /6303 Lecture #1 David E. Hardt 12
13 2.830 Perspectives Process Operation Make the best with what we have Statistical Process Control Process Design Explore limits Process Optimization Re-design to change what we have Feedback Control 2/3/ /6303 Lecture #1 David E. Hardt 13
14 2.830 Methods Physical Origins of Process Variations Manufacturing as a Random Process Empirical Process Optimization Feedback Control of Random Processes 2/3/ /6303 Lecture #1 David E. Hardt 14
15 The General Case: It s always feedback control Part Spec. Controller Process Part e -Ts measurement delay T process ~hour ~days ~months In-Process Every Cycle sampled inspection customer returns warranty recall 2/3/ /6303 Lecture #1 David E. Hardt 15
16 Typical Process Control Problems Extrusions for an Airframe don t fit-up at assembly Electrical Connector bodies don t fit securely Circuit Board connector terminals don t line up with solder pads Semiconductor resist coating is non- uniform 2/3/ /6303 Lecture #1 David E. Hardt 16
17 Typical Process Control Problems Airframe skin needs trimming and bending to fit frame Web thickness of a machined panel is non-uniform Plastic throttle bodies for fuel injection are out of round Submarine hull welds need constant rework in production 2/3/ /6303 Lecture #1 David E. Hardt 17
18 Typical Process Control Problems Minimum feature size on a semiconductor chip has too much variability DNA Diagnostic Chip has uneven flow channels Toys never fit when assembled at home! Next generation high density electrical connector cannot be made reliably 2/3/ /6303 Lecture #1 David E. Hardt 18
19 Other Related Problems: Cost, Rate and Flexibility: 100% inspection with high scrap rates low throughput high costs 100% Inspection with frequent rework low throughput high costs High Variability at changeover Reluctance to changeover low flexibility
20 Manufacturing Processes How are they defined? How to they do their thing? How can they be categorized? Why don t they always get it right? 2/3/ /6303 Lecture #1 David E. Hardt 20
21 The Process Components Operator Equipment Workpiece Material Part Etch bath Injection Molder Lathe Draw Press... Coated Silicon Plastic Pellets Bar stock Sheet Metal... Semiconductor Connector Body Shaft Hood... 2/3/ /6303 Lecture #1 David E. Hardt 21
22 Process Definition A Manufacturing Process is a Change in the Workpiece Material A change in geometry A change in constitutive properties 2/3/ /6303 Lecture #1 David E. Hardt 22
23 What Causes the Change? A Directed Energy Exchange with the Equipment E(t ) Equipment Material Geometry & Properties E(t ) mechanical electrical thermal chemical 2/3/ /6303 Lecture #1 David E. Hardt 23
24 Modes of Geometry Change? Removal of Material Plastic Deformation of Material Addition of Material Formation of Material from a Gas or Liquid Any others??? 2/3/ /6303 Lecture #1 David E. Hardt 24
25 What Controls the Geometry Change? Location and Intensity of Energy Exchange Examples: location of max. shear stress in turning 2/3/ /6303 Lecture #1 David E. Hardt 25
26 What Controls the Geometry Change? Location and Intensity of Energy Exchange Examples: heat transfer at the mold surface in injection molding 2/3/ /6303 Lecture #1 David E. Hardt 26
27 Control of Geometry Change? Location and Intensity of Energy Exchange Examples: location of laser beam in laser cutting 2/3/ /6303 Lecture #1 David E. Hardt 27
28 Control of Geometry Change? Location and Intensity of Energy Exchange reaction rate - time product on substrate surface in LPCVD 2/3/ /6303 Lecture #1 David E. Hardt 28
29 Control of Geometry Change? Location and Intensity of Energy Exchange Location and Intensity of Energy Exchange displacement field in sheet forming : 2/3/ /6303 Lecture #1 David E. Hardt 29
30 Two Extremes of Interactions Concentrated, Lumped Energy Port Small Area Wrt Total Part Geometry Distributed Energy Port Area ~ Total Part Geometry 2/3/ /6303 Lecture #1 David E. Hardt 30
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