Crc Financial Justification Of Nondestructive Testing Cost Of Quality In Manufacturing

Finance is not, in general, a part of the curriculum for scientists, engineers, and even nondestructive testing (NDT) specialists. Therefore, justifying proposals for new methods and equipment that may seemingly add a modicum of cost to the production process can be problematic. Financial Justification of Nondestructive Testing not only explains how 100% inspection by high-tech methods can save money for a manufacturing organization, but also explains how to justify this cost to upper management. Placing NDT in the historical context of quality and inspection, the author demonstrates three methods of calculation for proving the validity of NDT. He includes a forum of arguments, for and against, on the use of NDT; covers how NDT relates to quality standards like ISO-9000; and provides new examples of successful NDT. The book draws on examples from real life, demonstrating use of 100% NDT in factory situations when proven justified by financial calculations. It also describes high-tech inspection technology in the context of modern ISO Quality Standards, Total Quality Management theory, and Statistical Process Control. Inspection by means of NDT is a process that has a definite place in the big picture of quality and cost-effective manufacturing. Obtaining finance is key to the implementation of NDT, yet financial calculations are often the stumbling block to getting the needed approvals. Demonstrating how to apply financial formulas to prove or disprove the utility of 100% NDT, Financial Justification of Nondestructive Testing helps you build the financial case for your NDT projects. Financial Justification of Nondestructive Testing: Cost of Quality in Manufacturing......Page 1 Preface......Page 3 Introduction......Page 4 Notes on How To Use This Book......Page 9 Author......Page 11 Acknowledgments......Page 12 Contents......Page 14 Related Titles......Page 19 Contents......Page 0 1.1 What Quality Means to People......Page 20 1.2 Trying To Manage Quality......Page 22 1.3 ISO-9000 as the Management Standard for Quality (Revised 2000)......Page 23 1.3.1 Five Tiers of Quality Management per ISO-9000......Page 24 2.1 Early Philosophy of Manufacturing......Page 27 2.2.1 TaylorÌs System of Scientific Management......Page 31 2.2.2 Ford's Extensions and Changes......Page 39 2.2.3 Further Notes on Taylor and Ford......Page 42 2.3 Quality Degradation under Taylor Management......Page 47 2.4 The Inspector as the Methodology To Rectify Quality......Page 48 2.6 Ineffectuality of Inspector To Improve Quality......Page 50 2.7 The "Perfect" Inspector: Automated 100% Inspection by Electronics......Page 51 2.8 Fallacies of Early Implementation of 100% Inspection......Page 52 2.9 The Root Problem: Out- of- Control Processes......Page 54 3.1 Out of Control as a Question of Information......Page 55 3.2 Statistical Process Control ( SPC) To Get Information......Page 57 3.3 A Review of Statistical Process Control......Page 58 3.4 Automated Run Rules with Computers......Page 63 3.5 Statistical Process Control Results as Statistics......Page 64 3.6 Out- of- Control Quarantining vs. Just- in- Time Inventory......Page 65 4.1 Total Quality Management and DemingÌs Fourteen Points......Page 66 4.2.1 Point 1 Key Words: Decision: Improvement......Page 68 4.2.3 Point 3 Key Words: Inspection: Taboo......Page 70 4.2.4 Point 4 Key Words: Suppliers: Good, Not Cheap......Page 73 4.2.5 Point 5 Key Words: Improvements: Pinpointing......Page 78 4.2.6 Point 6 Key Words: Training: Modern......Page 79 4.2.7 Point 7 Key Words: Supervision: Modern......Page 83 4.2.8 Point 8 Key Words: Fear: Taboo......Page 85 4.2.9 Point 9 Key Words: Teams, Not Barriers......Page 86 4.2.10 Point 10 Key Words: Slogans: Counterproductive......Page 90 4.2.11 Point 11 Key Words: Quotas: Taboo......Page 91 4.2.12 Point 12 Key Words: Workmanship: Pride ( Remove Barriers That Hinder the Hourly Worker)......Page 92 4.2.13 Point 13 Key Words: Education and Training......Page 93 4.2.14 Point 14 Key Words: Implementation: Staffing......Page 94 4.3 Summary......Page 95 5.1 Background......Page 96 5.3 Statistical Process Control and Statistics within ISO Philosophy in the 1990 Version......Page 98 5.4 Inspection in ISO- 9000 Ò 1990......Page 99 5.5.1 Philosophy......Page 102 5.5.3 Additions......Page 103 5.5.4 Applied to Organizations......Page 104 5.6.4 Section 7: Product Realization......Page 105 5.7.1 Potential Risk- Avoidance Planning......Page 106 5.8 How Does NDT Fit into ISO- 9000 Ò 2000?......Page 107 5.9 Summary......Page 109 6.1 Recapitulation of Statistical Process Control......Page 111 6.2.2 Detrimental Costs of Nonconformities......Page 112 6.2.3 Costs of Inspection......Page 114 6.2.4 Time until Improvement Lowers Nonconformities......Page 115 6.3 The Costs of Inspection and the Detrimental Costs of Not Inspecting......Page 116 6.4 Summary......Page 117 7.1.1 The Deming Inspection Criterion ( DIC) Method......Page 118 7.1.3 The Productivity, Profitability, and Revenue Method......Page 119 7.2 DIC: Low Investment......Page 120 7.3 TARR or IRR: High Investment and Long- Term Usage......Page 121 7.4 Productivity, Profitability, and Revenue Method: Nano- Economics......Page 122 8.1.1 Documentation and Methods......Page 125 8.1.2 Definition and Outlook......Page 130 8.2.1.2 Production and Reception of Ultrasound......Page 132 8.2.1.3.1 The Generic Ultrasonic Instrument......Page 135 8.2.1.3.3 The Commercial Instrument......Page 136 8.2.1.4.1.1 The System......Page 139 8.2.1.4.1.2 Probability of Detection......Page 140 8.2.1.4.2.1 Strength and Graphite Shape......Page 142 8.2.1.4.2.2 Generic Velocity Tank Diagram......Page 143 8.2.1.4.2.3 Strength vs. Velocity......Page 144 8.2.1.4.2.4 Reject Limit and Equivalent POD......Page 145 8.2.1.4.2.5 Large Practical Tank......Page 146 8.2.1.4.2.6 The Electronics for the Tank......Page 147 8.2.1.4.3.1 Flaw Detection Instrument......Page 148 8.2.1.4.3.2 Spot Welds......Page 149 8.2.1.4.3.3 Spot Weld Transducer......Page 150 8.2.1.4.4.1 The Forward Extrusion Process......Page 151 8.2.1.4.4.3 Ultrasonic Test for Chevrons......Page 153 8.2.2.1 General View of AE in NDT......Page 154 8.2.2.4.1 Instruments......Page 155 8.2.2.4.2 An Experiment......Page 156 8.2.3.1 General View of Eddy Currents in NDT......Page 158 8.2.3.2 Production and Reception of Eddy Currents......Page 159 8.2.3.4.1 Gray Iron Hardness......Page 161 8.2.3.4.2 Case Depth of Steel Axles......Page 165 8.2.4.2 X- Ray Fluoroscopy on Connecting Rods......Page 168 8.2.5.1 General View of Sonic Resonance......Page 169 8.2.5.2 Sonic Resonance for Automotive Crankshafts......Page 171 8.2.6.2 Infrared Assurance of Friction Welds......Page 178 8.2.6.3 Other Examples of IR......Page 180 8.2.7 Evanescent Sound Transmission......Page 181 8.3.2.1 Is There a Relationship?......Page 182 8.3.2.2 The Need for Relationship......Page 183 8.3.3.1 The Underlying Function......Page 184 8.3.3.2 Origin of Perturbations to the Underlying Function......Page 187 8.3.4 Experiments with Correlations......Page 189 8.3.5 Generic Curve for Reject Limits......Page 190 8.3.7 Philosophy of the Scientist and the Engineer......Page 192 8.3.8 Conclusions Concerning Correlations......Page 194 9.1 General......Page 196 9.2.1 A Process with Each Part Unique: Instant Nodular Iron......Page 197 9.2.2 Adhesively Bonded Truck Hoods: Sheet Molding Compound-Type Fiber-Reinforced Plastic (FRP)......Page 200 9.2.3 A Safety-Related Part: Front Wheel Spindle Support......Page 205 9.2.4 Several Identical Parts in One Subassembly: Connecting Rods......Page 206 9.2.5 Intermediate Inspection of a Machined Part: Engine Block......Page 207 9.3 Examples of TARR and IRR Methods......Page 208 9.3.1 Didactic Example: Hypothetical Data......Page 209 9.3.2 Intermediate Inspection of a Machined Part......Page 210 9.3.3 Aircraft Engine Discs......Page 212 9.4.1 New Metal for Automotive Connecting Rods......Page 217 9.4.1.1 The Baseline Calculation......Page 218 9.4.1.2 The Real Situation with No Inspection......Page 219 9.4.1.3 The Real Situation with Inspection......Page 220 9.4.2 Aircraft Engine Discs......Page 222 9.5 Summary......Page 224 10.2 Chronological Progression......Page 226 10.3 A Final Anecdote......Page 227 Demonstrating how to apply financial formulas to prove or disprove the utility of 100% Nondesctructive testing (NDT), this book helps readers build the financial case for their NDT projects. It not only explains how 100% inspection by high-tech methods can save money for a manufacturing organization, but also how to justify this cost. Providing examples of successful NDT implementation drawn from factory situations, the author describes high-tech inspection technology in the context of modern ISO Quality Standards, TQM theory, and Statistical Process Control. Placing NDT in the historical context of quality and inspection, the book provides three methods of calculation for proving its validity. Explains how 100 per cent inspection by high-tech methods can save money for a manufacturing organization, and also how to justify this cost to upper management. Placing Nondesctructive testing (NDT) in the historical context of quality and inspection, the author demonstrates three methods of calculation for proving the validity of NDT.