Management Systems
in
Production Engineering
, No , pp -A stra t:
The a i le p ese ts the esults of studies o du ted i a o pa a ufa tu i g alu i iu fo gi gs fo the auto oi e i dust . The ai of the esea h as to ide if the defe ts hi h fo du i g the p odu io p o ess as ell as the lo aio s a d auses of thei o u e e. “ele ted ualit a age e t tools e e used i the p o ess. Based o the FMEA a d the osts ge e ated the ide iied defe ts, a hie a h of the as eated fo the o pa alo g ith a p oposal of i p o e e ts i ase of the ost sig ii a t o es i o de to edu e thei u e a d i ease the dete -io ei ie .
DEVELOPMENT OF AN INTEGRATED APPROACH
OF QUALITY MANAGEMENT IN DIFFICULT TECHNICAL PROCESSES
INTRODUCTION
I ode o ld o o e ould eapp aisal e essit of aki g elia le ode of o t ol a d ualit a age e t of dife e t te h ologi al p o esses o ate of it’s
desi-aio , e ause a ious dispa iies i a te h ologi al p o ess i g o ple of te h i al, i a ial a d e ologi al isks. That is h su h app oa h as o ked out a d i -luded th ee o se ui e odes of isk a age e t [ , ,
].
P ese ted o p ehe si e app oa h is ased o the se ue ial use of th ee ethods: FTA – fault t ee a al sis, HA)OP – Haza d a d Ope a ilit stud a d FMEA – a al sis [ , , ].
COMPLEX OF QUALITY MANAGEMENT METHODS
Deepl st u tu i g esea h of te h i al de i es o p o-ess ake the i st step i the appli aio of this app oa h. As a esult, it is e essa to eate hie a hi al t ee, des i i g the p i ipal of o k of ou te h i al de i e fu -io i g o ou failu e p o esses [ ].
As a esult of usi g this ope ato s a d a iied t ee of e e ts goi g do step step, e ha e to ea h the asi e e ts ha ges of hi h a e esi ated i it ua it , the a agi g of the dete i es the state of the te h i al de i e o the te h ologi al p o ess [ ]. Du i g the o -st u io of this t ee, o e should o side a fe asi pos-tulates. Fi stl , it is i po ta t to espe t hie a h of p e-edi g e e ts du i g thei o st u io ; o e "la e " e e ts should e ou ted i o e s ale.
“e o dl , i the ou se of o st u i g FTA t ee it is i po ta t to use t o ope ato s – "AND" a d "OR". These ope ato s allo ou to g oup the p e edi g e e ts. If ou failu e depe ds of the fu the se e al failu es e use AND ope ato . If the o u e e of a failu e de a ds
failu e i a si gle e e t, use the ope ato "OR".
Be ause of usage of these ope ato s a d a hed e e ts t ee, o i g le el le el do it is e essa to ea h the asi ele e ts e e ts , ha ges i hi h akes ua if i g i e isi g u it possi le. Fi all , at this stage of the esea h, ele e ts, hi h o t ol pa a ete s a d de-te i e the status of the de-te h i al de i e o p o ess th oughout a e o tai ed [ ].
Ne t step ill e use the HA)OP ethod fo ou fa ilit . Usi g spe ial o t ol, o ds a d s ste s fo a al ze of asi lo ks dis o e ed ith FTA ill p o ide ha a te is-i fo su p o esses a d his-ighlis-ight ollis-isis-io s is-i the . HA)OP is ased o " o t ol o d" e pe ise, hi h is a sea h fo de iaio s f o goals of the p o ess.
A o g dife e t o t ol o ds those a e the ost o -o l used: "NO" – o plete a se e of the ele e t o a se e of it's fu io s fo e a ple, if ele t i al i uit is
do , the the la p is do too ; "MORE" – ele e t has a
alue of o e tha it's li ited too high te pe atu e,
ig-ge di e sio s of the ite ; "LOWER" – ele e t has a
al-ue of less tha it's e pe ted to e p o essi g i e is lo e tha e pe ted, size of ele e t is lo e tha it should e .
As a esult of usi g t o ethod sho a o e Fig. a
full - o e ged FTA t ee e e a ui ed, hi h ep ese ts
all of the ele e ts hi h afe t o state of te h i al de i e a d o the lo of the p o ess. A HA)OP pi ot ta le e e also a ui ed, hi h ep ese ts elaio ship et ee
ele-e ts of difele-e ele-e t lele-e ele-el, thele-ei opele-e ai g opio s i asele-e of appl i g dife e t o t ol o ds.
I ge e al, a ep ese taio eated ith those t o ethods sho s us a detailed lo of a fails a d e o s i side the p o ess o te h i al de i e. Ho e e , to t a s-fo this ep ese taio to a ualit a age e t tool e
also eed to use the thi d ethod – FMEA a al sis.
Victo NORDIN
Kali i g ad State Tech ical U ive sity Pavel SHCHERBAN
Balic Fede al U ive sity of I. Ka t
Ke o ds: ethods of uality co t ol, tech ical p ocesses, tech ical isk assess e t uali et ic
Ma age e t “ ste s i P odu io E gi ee i g / V. NORDIN, P. “HCHERBAN - De elop e t of a i teg ated app oa h of ualit a age e t i dii ult te h i al p o esses
B g oupi g ele e ts of FTA t ee ased o su p o ess-es, e ill appl failu e ode a d efe ts a al sis ethod
FMEA . Fi st step i usi g this ethod is illi g Ta le . O this step g oup of e pe ts aluates the follo i g pa a
e-te s ased o a -le el s ale: “ – se e it , O – p o a ilit
of o u i g of failu e, D – p o a ilit of diag osi g the failu e. All of these pa a ete s e should i lude i ta le
[ ]. Based o the follo i g pa a ete s e ill al ulate
RPN of a p io it isk u e :
RPN = SOD
I ase if du i g a al sis RPN is highe tha e pe ted, the a al zed su p o ess eeded to e i p o ed, usi g usi g ualit o t ol tools. It is e essa to e io , that this i p o ed it is possi le to lo e ate of o t ol a d i ease ate of diag osi g ii al failu e i a su p o ess
Fig. .
Ho e e , se iousl ele t o a se e it of a failu e is al ost i possi le. O e of the ost i po ta t thi gs i FMEA is o pa i g li ited isk u e ith a fa tual isk u e . Results of this o pa i g allo s to ake a a -age e t de isio o p o idi g o e i e o k a d also esta lish o de hi h ill e used to i o pe fe t te
h-ologi al p o esses o ele e ts of a te h i al de i e Ta le .
Be ause fo dife e t te h ologi al p o esses a d de i -es it is i possi le to fo a u iied li ited isk u e , it's
e essa fo ea h ase al ulate isk u e ased o data f o staisi s a d est p a i e. Opi al a is to elate li ited isk u e ith a p o a ilit of failu e o -u e e i s-u p o ess o ele e t of the s ste [ ].
Fig. E a ple of FTA – t ee fo p o ess of a ual a eldi g of su sea pipeli e:
A – The gap of eld of su sea oil pipeli e; B – U a epta le eld defe ts; C – ii al efe ts of e te al o diio s; D – a a o ali-t of fu io s of ali-the pipeli e s sali-te ; E – The eaio of eld defe ali-ts due ali-to isalig e t of pipes; e – isalig e t of elded pipes; e – Violaio of the shell side of the gap; e – Geo et iolaio of the ui g edges; e – Violaio of the i aio igidit ; F – The o u e e of defe ts i the i st pass; J – The o u e e of defe ts du i g su se ue t passes of eldi g; f , j – Violaio of eld-i g ode; f , j – Veld-iolaeld-io of e eld-i o e tal o diio s; f , j – Violaio of ualit of eldi g o su a les; f , j – Lo ualii aio of pe so el; H – The o u e e of defe ts du i g heat t eat e t; h – te pe atu e of the heat t eat e t of the eld; h – The i e of heat t eat e t; h – A ea of heat t eat e t; I – The e e ge e of defe ts du i g h d otest; i – Ti e of h d otest; i – p essu e i the pipeli e.
Fig. Result of a ki g su eldi g p o esses FMEA a al sis:
– Ope aio of do ki g a d e te i g of pipeli e lashes i to the sea, – Weldi g of the oot pass at the sea, – Ta k a d eldi g of the eld oot o la d, – Fo aio of po es du i g eldi g at the sea, – Alig e t e o s du i g eldi g o la d, – I ple e taio of the i al ualit o t ol, – Fo
Ma age e t “ ste s i P odu io E gi ee i g / V. NORDIN, P. “HCHERBAN - De elop e t of a i teg ated app oa h of ualit a age e t i dii ult te h i al p o esses
Ta le Ta le fo FMEA a al sis
Let’s de ote this g oup of odes as FHF FTA-HA)OP
-FMEA . Due to the usage of su h o of odes of te h o-logi al p o ess e ould e eal ai su u s he e so e dispa iies ould e ade. I addiio , this o of odes helps us to ide if i st auses of dispa iies a d dei e isk le el i ea h p o ess. All of these ake se ious ase fo
e t doted usi g of ualit a age e t i st u e ts. Ne e theless this app oa h ha e se ious d a a k e-ause of HA)OP ode. At i st, this HA)OP ode akes o siste t esi aio ea h of ase e e ts i luded i te h-ologi al p o ess. It akes this usi g of ite aio a d appli aio to ea h e e t all di e sit of a agi g o ds. “u h a akes ple t of lo i fo ai e a d dou li g data. “e o dl , these data ostl ha e e aluai e t pe a d the should e o ked up e t usi g of e pe t ode
this step i ludes e t stage of FHF o . Thi dl usi g of
a agi g o ds f o HA)OP o a ula ould ’t e a e so e ou da o diio s. Let’s o pa e the list of a -age o ds a d dife e t o diio s of asi e e t. At igu e
e a see, that HA)OP ode ould ’t sho eithe o e o a othe ele e t pa a ete s he it is situated i ou da o diio . That is h usi g e uisiio s of I“O : it is e essa to i lude i this FHF o ode su h ethod hi h a di e tl i a d des i e ea h pa a ete of su u if it has so e ou da o diio .
MODERNIZATION OF AN INTEGRATED APPROACH OF QUALITY MANAGEMENT IN DIFFICULT TECHNICAL PRO-CESSES
Most opi al step i this ase ould e a ete e t of this o app oa h i ludi g of uali et ode – QM. “u h o i aio of QM a d HA)OP odes ill help to ite ize p o le of aki g dispa iies a d ou da o di- io s i ea h asi e e t. A te h ologi al su u o sist
of dife e t asi e e ts o . “o e of the ould ha e al ulated ha a te isi ut the othe s ould ’t. The ha e o l ualit i fo aio .
Ate o st u io of FTA-t ee ea h of it’s su u a h ha e to e sepa ate i to t o t pes of asi e e ts g oup of o putaio al pa a ete s a d g oup of ualit pa a ete s , as a esult of su h sepa aio a d e t e -pa ded app oa h esea he ould get u h detailed data a out s ste o diio . I this ase, ost efe i e ould e usi g of HA)OP ode fo su h e e ts, hi h e ould-’t esea h, QM ode Fig. .
QM ode is ased o ua it dete io et ee fa t pa a ete data a d asi pa a ete data. O l t o a i-a ts of tole i-a e zo e i-a e ist fo ei-a h pi-a i-a ete – ili-at- ilat-e al o as et i [ ].
Let’s sho t o a ia ts of a e pa a et i dete io fo ula, depe di g of tole a e zo e.
Dete io of pa a ete i ilate al tole a e zo e.
he e:
Pi – i- ea h si gle pa a ete asi e e t of esea hi g su u ,
Pбi – o i al sig ii a e of ea h i- si gle pa a ete,
Ti – tole a e zo e fo ea h i- si gle pa a ete hi h is e ual to dife e e et ee up a d do le els of tole -a e zo e [ ].
Fo pa a ete ith as et i tole a e zo e, e ill ha e follo i g fo ula:
Du i g the p o essi g of QM data ould e ete to dei e po de a ilit of pa a ete s a d thei dele io s e ha e a al zed p e iousl usi g e pe t ode [ ]. At the sa e i e su h elaio s should e a ied out:
Also, e ha e to o elate di e sio of dele io s of ea h pa a ete ith o ai e do u e ts, egulai g
di-e sio s of thdi-esdi-e difdi-e di-e di-es.
The g oup of e pe ts is to o k out data fo ea h su u s hi h ha e ee e ei ed QM a d HA)OP odes a d i all i di e sio s “, O, D fo FMEA – ode. That is h e ha e to g oup a d use o espo di gl QM a d HA)OP odes i ases he it is e essa a d thus to i p o e FHF app oa h Fig. .
P o ess
T pe of the pote ial defe t Co se ue es of pote ial defe t The se e it a d atu e of the o se ue es “ The possi le auses of e e ge e of dis epa ies
E e ge e O E isi g ea su es of dete io
Dete ta ilit D RPN
Fig. Co pa iso of a a ge o diio s of a asi e e t ith the ai a agi g o ds ethod HAZOP
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CONCLUSION
Follo i g the esults of appli aio of oth ethods, the e pe t g oup hi h is a i g out a assess e t of the “, O, D pa a ete s fo the su se ue t FMEA – the a al sis, ill possess o e a u ate a d st u tu ed data that ill allo to dei e o e p e isel , oth ou da o diio s, a d ou da isk u e . Thus ad a ed i teg ated ap-p oa h o ualit a age e t of ap-p o ess of a o st u io of dii ult te h i al o je ts ill e o e o e po e ful tool p o idi g the detailed su p o ess a d pa a et i al a al sis. Dei i g of e a t alues of de iaio s ith QM a al ses ill help us to ake p e ise o e io of dife e t pa a ete s of ou te h ologi al p o ess.
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