INTRODUCTION AND OBJECTIVES:

As part of understanding process variability, control charts will be utilized in this assignment to evaluate and improve upon the quality aspects of the process.  Virtual TQM will illustrate the variability within a hypothetical process and will take the necessary measures for correcting them.  Reduction in process variability is an important aspect within a manufacturing environment and needs special attention.  Minimizing variability will reduce costs associated with process downtime and manufacturing defects.  Complete understanding and utilization of these tools will ensure product reproducibility, ultimately ensuring that the customer receives a quality product.

APPLIED METHODOLOGIES:

Control Charts in the form of X-bar and R charts will be used.  Corrected control charts will show how a process can be corrected by analyzing data feedback.  The utilization of such charts will lead to a controlled process that will result in a mistake free product.  They can be utilized to monitor the processes and generate real time data that can be used to make necessary corrections.   By identifying components of the process that are resulting in process malfunctions or defective product, corrections can be made to avoid future mishaps.  The potential for reworked materials will ensure that waste is minimized.  Similar manufacturing concepts and equipment will also minimize line changeover and cost.  This will result in lower production costs while maintaining a quality operation and product.  The performance of the process will be monitored for a variety of control variables at various inspection stations.  Virtual TQM in collaboration will the other four companies will use similar processes for production and packaging purposes. By analyzing the data generated during process operation Virtual TQM will ultimately provide more efficient processing.  The analysis will incorporate the GE Fanuc automated software system to monitor the process and identify defects while manufacturing each of the products of the three companies. 

For the purposes of this assignment and to illustrate the benefits of process monitoring the graphics displayed on the packaged product will be visually inspected for orientation and flaws.

MAIN BODY OF THE PROJECT:

The manufacturing process for each of the products requires that it be packaged in an attractive box with graphics that are appealing to the consumer.  An attractive package should be able to convey a message to the consumer that the contents inside is fun and exciting.  Each company prides itself on quality and needs to display not only the brand name but to entice the consumer to by their product.  The packaged product will be examined for defects and will be monitored using control charts.   Orientation of text and images will be focused upon.  By utilizing the programmable software each of the respective products packaging can be visually inspected for flaws.  The packaging materials can be inspected and rejected if they do not meet the acceptance criteria.  Contents within the package can be repacked if necessary, assuming that the defect is isolated to the packaging carton.  Periodic inspection of the processing line will be the area of focus.  The data contained herein will illustrate the non-conformances on a continuous operation of a packing line for over a span of an eight hour shift.  The inspection is performed on five samples every twenty minutes for a total of one hundred and twenty samples inspected.  The inspection will consist of centering of the company logo from the edge of the packaging.  The control variable is 6 inches from the edge of the box.