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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



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?



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?



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



7 Pressure at microdustextraction at variousproduction rates



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.

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