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Verification
Introduction
In the IDOV methodology this step comes after the Optimization step where thefirst level of design verification, through design axioms, design guidelines,FEA/FEM analysis, DFX analysis, Design and Process FMEA and conceptverification through testing is already done and the design proved for itsintended function and reliability through accelerated tests- as a subsystem or astwo related subsystems.
Operation definition
Verification in this V step of IDOV is the first part of Verification and Validation.This step is to verify the following process in the prototype:
1. The design process in integrating all subsystems verifies the DFMEA2. Initial manufacturing process for the prototype verifies the PFMEA3. The assembly process4. The fit between customer requirements and the test protocols.
Verification parameters
Where do we start: Customer requirements as per the eight dimension ofQUALITY
Description Measure-Impact to
customer
Function test Tools to validate
Performance
Acceptable outputin absolute termsand
Loss study-the sixbig losses
*OEE in %age(OverallEquipmentEffectiveness ) further defined asthe multiplicationof AxPxQ
Check sheet,Pareto chart incase of deviationsand SEDAC toolsfor any problemsolving andHypothesis testsfor performancemeasures thatare enhanced.
Multivary studyand DOE
Availability % Equipmentefficiency orbreakdownsSet up andadjustmentbetween batches
Performance % Reduced speedIdling and minorstoppages
Quality % Start up and shutdown losses
Yield losses-
process defects
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Description Measure-Impact tocustomer
Function test Toolsto
validateFeatures Improvement in
qualityparameters
Specify theimprovement overthe previousmachine and thecustomerrequirementimpact
Hypothesis testafter the testprotocol
FeaturesImprovement inflexibility
What is inbuiltlevel of **visualmanagementsystems
Specify theimprovement overthe previousmachine and thecustomerrequirementimpact
Specify theimprovement overthe previousmachine and thecustomerrequirementimpact
Compliance
Sound level-dBA Specs versus
actual
Xbar chart
Air quality-dustparticles/cm3
Dust levels(/cubic mtr)
Check sheet
Vibration level-m/sec
Specs versusactual
Check sheet
Safety needs-accident points
Functions andhazard level
Check sheet andjob hazard scorecard
Reliability No equipmentfailures-MTBF
Protocol testing ofsubsystems andthe entire system
MTBF confidenceintervals
No loss inperformance-process capabilityindex
Quality andOutput levels forthe verificationrunning hours
Process Capability-xbar r charts ,standarddeviation-bellcurve
Maintainabilityand serviceability
Ease ofmaintenance,AutonomousMaintenancescores for COT,MTTR, -link toequipment failure,
MMTS for criticalsubsystems
What is theimprovement fromthe previousmachine-what arethe values
Check list andtimes
Durability Plannedmaintenance-frequency and lifecycle costs
What is theimprovement fromthe previousmachine-what arethe durable partsand wear and tearparts
Check list andtimes and costcomparison
Aesthetics Ergonomics foroperationColor impact interms of appealAny questionnaire
What is theimprovement fromthe previousmachine..what arethe aesthetic parts
Scores as possible
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Description Measure-Impact tocustomer
Function test Toolsto
validatebase index or form
Customerperception
Look goodFeel GoodUse goodAbuse/abnormalconditions ofusage
What is theimprovement fromthe previousmachine-keyattributes
Scores throughsurvey
*OEE definitions
Overall Equipment Effectiveness defined by the multiplication ofAvailability % x Performance % x Quality %
Availability = Planned run time breakdown time-set up and adjustments time X100
Planned timePlanned time = 24 hrs x 60 minutes any cleaning time &/or planned
downtime
Performance = actual output on available time x100
Standard output (based on rated speed) on available time
Quality = (Total output waste) i.e acceptable output x 100Total output
OEE Calculation example
Calendar time: 24 hrs x 30 days
Operating time: 24hrs x 27 days ( 3 days equivalent for planned down time etc)
Therefore A. Availability = (24*27/24*30)*100= 90%
Standard Production rate: 1000t/day
Actual Production Volume:
1. (500t/day*1 day) + (1000t/day*6 days)+(800t/day*5 days)+(400t/day*1day)=10900t
2. (500t/day*1 day) + (1000t/day*12 days) + (500t/day*1 day) =13000t
Total: 10900+13000= 23900t
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Therefore Actual production rate =23900/27=885t/day
B: Performance rate = (885/1000) * 100=88.5%
If 100t of rejectable product is produced (i.e. yield loss or waste)
C. Quality rate :( 23800/23900)*100=99.6%
D. Overall Equipment Effectiveness= (A)* (B) *(C) * 100
= (0.9)*(0.885)*(0.966)*100 = 79.3%
** Visual Management Systems
Poka Yoke
Jidoka
ANDON
Standardisation
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Salient Features linked to the 8 dimensions of Quality
Notes Descriptor &impactlocation
Verification tool Pl mentionthe designprocessbeingverified
Higherproduction
Upto 1000kg/hr Performance Processcapabilitystudies CpK
Modified anglegrids for better
cleaning(gravityextraction)
Link to qualityless loss of
good fibre
Yieldimprovement
-a feature
Quantity of yield over
previousmachine andverify throughactual resultsand hypothesistests
Less number ofmoving parts infeeding anddedusting
Earlier andcurrent partcountreduction andassembly time
reduction
DFM index-costreductionthrough partcount
reduction,assemblytimereductionMaintainabilityindex i.ereduction in# of parts tobemaintained
Designefficiency, DFAformat
Auto grid beater setting
Set up timereduction-
machineavailability
Performanceenhancemen
t. how much?
Simulation withexisting
machine andverify the
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Notes Descriptor &impactlocation
Verification tool
Pl mentionthe designprocessbeingverified
improvement improvementas yes and if sohow much.
Feed roller trio-for bettercompacting
Presentationenhancementfor sliverformation?
Improvingperformance- Yield orqualitymeasure and
Verify functionswith existingparts
Machine can beinstalled asstand alone
with in builtpanelarrangement
What are thedrawbacks withexisting
machine? Isthis adelighter?
Flexibility feature-timeto install is
reduced andvertical startup is apossibility
Earlier to New -time measure
# oftouches/stepsmeasure?(reduction)
CanaccommodateCUBICSACN asoptional
Not possiblenow
Compatibilityand spacereduction?
Space in sq mrduction..
Continuoussuction system
Currentsystem?
U kgreduction
maintainability
How much andhypothesis testand cleanlinessindex
Single platformfor coarse andfine cleaningposition
Feature? Ormaintainability
Reduction ofstrain? Betterergonomicstime saving?
Replaceablenose typebeatingelements forcoarse beater(optional)
Why thisfeature? Adelighter
Feature Cost benefitanalysis andefficacy
Specification-dimensions
NewMachine
Earliermachine
Benefit and will be eliminate anydissatisfier, enhance satisfactionand enable delight?
Working width 1600 mmBeater diameter 585 mmFeed rollersdiameter
100 & 120mm
Beater type Pinned/Sawtooth/Optional coarse
Beater speed 400750
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NewMachine
Earliermachine
Benefit and will beeliminate anydissatisfier, enhance satisfactionand enable delight?
rpmPower (approx) 10.2 kw
Overall dimensions 1400x2600x3500(LxWxH)
Applicable for alltype of cottons andMMF upto 60 mmSL
Yes No
Performance as in output consistency, safety and vertical start up after plannedmaintenance-Electrical Parameters
Measure forverification
Earlier New Benefit/improvement
Normalfunctioning ofopening rollermotor, feedroller motorand flap motor
Amperes
Speedvariation of
the openingroller throughdisplay
rpm vs timegraph
consistencyand displayreadability?
What is thevariation?
Reduction? Repeatability
Speedvariation ofthe feed rollerthroughdisplay
rpm vs timegraphconsistencyand displayreadability?
What is thevariation?
Reduction? Repeatability
Gridmovementcontrolthrough
display
Repeatability?
Material flowbased on thefeed truckphoto cells
Start and stop-test protocol
Notprovided?
Providedand reliable
Option forfeeding 1 lineand feeding 2lines
Feature forflexibility
Notprovided
Providedand reliable
Functioning offeed rollersafety limitswitch
What is thefragility andweakness?
What is theimprovement androbustness?
Functioning of
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Measure forverification
Earlier New
Benefit/improvement
beater locksafety limitswitch
Check verticalstart up andsimulationunder stressand abusecondition-define theseconditions..theconditions tocreate failures
Functioning ofdoor safetyand cabinetsafety limitswitchesFunctioning ofregulatingsafety limitswitchFunctioning of
beaterproximitysafety limitswitchFunctioning ofsafety actuatorat wastecollection sideFeed rollerreverseoperationthroughdisplay
rpm vs timegraphconsistencyand displayreadability?
What is thevariation?
Reduction? Repeatability
Shift report,fault report inthe display tobe checked
What is thevalue add andhow isdiagnosticsfacilitated?
Notavailable
available
Test protocolKey Machine Specification and preparation for test
Sl
No.
Information for check Measure How to check
1 Is equipped with pinnedbeater
Yes/no Visual check list
2 Total # of pins 22135 Count?3 PPSI 5 Count?4 Pin projection 7.5 ? Vernier if in mm5 Pin angle 20 Protractor?6 Staring suction pressure 200 pascal Gauge-visual7 Microdust suction control Only bleeding air? ?8 WCS suction 1000 pascal Gauge visual
Verification Parameters
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SlNo.
Information forverification
Measure How toverify and charts
1 Production and quantitydetails
@ 400, 600, 800 and1000 kg/hr
Xbar-r charts and CpKindex .Hypo thesistest in comparisonwith earlier Card
1.1 Effect of grid setting (1-3mm)
On a check sheet andDOE
As 1 above
1.2 Suitability of 1 or 3mmgrid
Hypothesis testbetween 1 and 3 gridon the measures ofoutput and quality
2 Performance of gravitygrid over normal grid
Output? And DOE Hypothesis test onmean and standarddeviation
3 Functioning of automatic
grid setting
Reliability# of
continuous runninghours before failure?
MTBF?
4 Functioning of flaps in thefeed duct and effect ofnot using it
DOE andperformance?
Hypothesis testbetween flap and noflap grid on themeasures of outputand quality?
5 Pressure at outlet atvarious production rates
Correlationcoefficient
Repeatable resultsCpK?
6 Pressure at feedingchamber at variousproduction rates
Correlationcoefficient
Repeatable resultsCpK?
7 Pressure at microdustextraction at variousproduction rates
Correlationcoefficient
Repeatable resultsCpK?
8 Functioning of safetyswitch in the back swingcover
Reliability# ofcontinuous safeoperations?
# of repeatedoperations-Histogram
9 Functioning of beater lock Reliability# ofcontinuous safeoperations?
# of repeatedoperations-Histogram
10 Quality with self lockingsaw tooth beater
Quality parameters CpKresults..hypothesis
tests with and w/o thefeature
Accessibility feature- maintainability
SlNo.
Information forverification
Measure How to verify andcharts
1 To grids via swing covercomp
Efforts in kgs, orvisual
Operator feedback?
2 To photo sensors andlimit switches
One touch, one look,one motion?
Time and motionstudy?
3 To other machineelements Without bending, ateye level, within Ergonomic factors?Tome to set and time
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elbow reach etc to removeandreassemble serviceability index?
Validation
After the verification phase is over for the prototype, the design ifnecessitated is revised based on inputs from manufacturing and assemblyprocess and results from testing at pilot mill. The prototype is not to bebuilt somehow, but more of what will the mass production represent.
Operation definition
Validation in this V step of IDOV is the second part of Verification and Validation.This step is to validate the following process in the building of pilot batch (say 10and testing:
1. Any design change based on verification2. Vendor supply consistency quality and quantity3. Manufacturing process validation for mass production4. Assembly process validation for mass assembly- confirmation of PFMEA andcontrol plans5. The relationship between key process input variables and key process outputvariables in meeting customer requirements.
6. The serviceability aspects
Validation protocol
Product requirement validation design
1.1 The protocol will be similar to the verification protocol for machines with therelated upstream and down stream machines for one year or one cycle ofseasons.
The statistical tools will be Xbar- r charts, standard deviation, multi vary analysisand of needed DOE and hypothesis tests. It has to be investigated whetherresponse surface modeling will help in maximizing yield.
1.2 Adherence to target cost
Vendor supplies
2.1 Capability of vendor to supply consistent quality, in time and target cost
Manufacturing Process-suitability for mass production
3.1 Confirmation of manufacturing PFMEA and control plans-CpK index and
adherence to optimized manufacturing process3.2 Capability to manufacture to design
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3.3 Manufacturing time and cost (throughput)
Assembly Process suitability for mechanized assembly &/or withinstandard assembly times
4.1. Confirmation of assembly PFMEA and control plans-adherence to time andmotion study based assembly times4.2 Capability to assemble right first time
4.3 Assembly time and cost (throughput)
After the validation phase
1. The knowledge data bank on the design process and guidelines evolved has tobe updated2. Time line achieved through concurrent engineering
3. Standard operating procedure for manufacturing and assembly andprocurement items3. Things gone right and things gone wrong and key learnings to reduce designerrors, time to market along with emerged themes and avenues for ideation.
After the validation the product can be released for commercialization.