Rekayasa Kualitas

Materi ke – 1Pendahuluan

ekopujiyanto@ft.uns.ac.id

Agenda Hari Ini

Tentang kuliah ini

Tentang saya

Pendahuluan

Tentang kuliah ini

Waktu kuliah :

Senin, 09.20 – 11.05

Waktu konsultasi :

Senin, 11.10 – 11.45

Homepage kuliah :

eko.staff.uns.ac.id/rekayasakualitas

Silabus, Penilaian and Referensi

Jadwal kuliah

Silabus, Penilaian and Referensi

Prasyarat :

Probabilitas dan Statistik Industri, PengendalianKualitas , Desain Eksperimen

Tujuan :

Membantu mahasiswa untuk memahami danmengaplikasi metoda Taguchi. Beberapa studikasus masalah industri diberikan untukmemahami aplikasi metoda Taguchi secarasistematik.

Silabus, Penilaian and Referensi

Isi Mata kuliah :

Pendahuluan : dasar-dasar rekayasa kualitas , kualitas dan kemampuan process

Proses Perancangan : proses perancangan , prinsip kekokohan

Orthogonal Array dan Mariks Eksperimen : matriks eksperimen , interaksi , seleksi karakteristik kualitas

Fungsi Tujuan Dalam Perancangan Kokoh : SN ratio untuk masalah statis , analisis kecacatan fraksi , aplikasi SN ratio

Silabus, Penilaian and Referensi

Isi Mata kuliah :Mengelola Eksperimen : proses menyelesaikan

masalah, eksperimen perancangan kokoh , eksperimen industri

Modifikasi Orthogonal Array : perancangan multi level, perancangan dummy level , perancangancombination factor , perancangan nested-factor , perancangan idle-column , interaksi distribusi

Strategi Perancangan KokohKonsep dan Aplikasi Rekayasa Kualitas Multi Respons

State of the art quality engineering

Silabus, Penilaian and Referensi

Syarat Penilaian

Kuis → Tingkat partisipasi lebih dari 75% dan tingkat kebenaran lebih dari 40 %

Tugas → Tingkat partisipasi lebih dari 75% dan tingkat kebenaran lebih dari 40 %

Kehadiran di kelas → Tingkat kehadiran lebih dari 75%

Silabus, Penilaian and Referensi

Unsur Penilaian

Ujian Tengah Semester = Nilai 100

Ujian Akhir Semester = Nilai 100

Nilai Akhir ( NA ) = 0.5 UTS + 0.5 UAS

Silabus, Penilaian and Referensi

Aturan Tambahan

Mahasiswa yang tidak mengikuti salah satu UTS atau UAS yang diadakan dengan ijin yang sah masih mungkin lulus dengan mengikuti Ujian Perbaikan dengan nilai maksimum B.

Mahasiswa yang nilai-nya E, D atau/dan C, WAJIBmengikuti Ujian Perbaikan dengan nilai maksimum B.

Silabus, Penilaian and Referensi

Unsur Penilaian KelompokPeer evaluation forms will be filled up by each student to

evaluate each team member in the following categories:

1. Participation

2. Team player, peace maker, consensus builder

3. Efforts in his/her assignment

4. Perceived expertise

5. Willingness to help others on the team with their needs

6. Amount of work accomplished

7. Overall evaluation team members performance for project

Silabus, Penilaian and Referensi

Angka dan HurufSesuai SK Rektor UNS No. 644/UN27/HK/2015 )

Referensi : Belavendram , N. , Quality by Design , Prentice Hall ,

London , 1995

Phadke , M.S., Quality Engineering Using Robust Design , Prentice Hall , 1989

Roy, R.K., Design of Experiments Using the Taguchi Approach : 16 Steps to Product and Process Improvement , John Wiley & Sons, 2001 .

Genichi Taguchi , Subir Chowdhury , Yuin Wu, Taguchi’s Quality Engineering Handbook , John Wiley & Sons, Inc., Hoboken, New Jersey, 2005

Rencana Kuliah

Tentang saya

Academics Background

1993 : Undergraduate, Mathematics ITB

1998 : Graduate , Industrial Engineering ITB

2012 : Doctoral , Mechanical Engineering, UGM

Research Interest : Biomaterial , Quality Engineering and Optimization

Status : Married , 4 boys

Hobbies : Iqro’ , Studying and Teaching

Posisi mata kuliah ini

Statistik IStatistik I

Statistik IIStatistik II

Pengendalian Kualitas

Pengendalian Kualitas

Perancangan EksperimenPerancangan Eksperimen

Rekayasa Kualitas

Rekayasa Kualitas

OR I-IIOR I-II

Matriks dan Vektor

Matriks dan Vektor

Definition of Quality

Quality means different things to different people ( Juran, Deming, Crosby, Garvin and Feigenbaum )

Taguchi

“We measure the quality of a product in terms of the total loss to society due to functional variation and harmful side effects”

Definition Quality Engineering

Quality Engineering is defined as "the branch of engineering which deals with the principles and practice of product and service quality assurance and quality control ".

A Quality Engineer would therefore responsible for the implementation of a Quality Management System in the company as well as for the maintenance of the QMS. Changes in Processes and Products should be consulted by the Quality Engineer.

Quality EngineeringCourse dan Research

Quality EngineeringCourse dan Research

The Research Group of Quality Engineering has no disciplinary boundaries: its methodologies are applicable to every branch of engineering and business.

The focus of the Group is on the analytical aspect, making heavy use of applied probability and statistical tools for data collection, analysis, interpretation, and decision making.

http://www.ise.nus.edu.sg/research_groups/quaeng/

Quality EngineeringCourse dan Research

In particular, the systems perspective employed will often lend broad views and provide sharpened insights to industrial leaders and managers in their pursuit of quality excellence and business viability.

Research conducted includes statistical process control, robust design, design of experiments, engineering reliability, and software reliability.

http://www.ise.nus.edu.sg/research_groups/quaeng/

Quality EngineeringCourse dan Research

Pengetahuan dan ketrampilan untuk meningkatkan kualitas produk dan jasa melalui pemahaman terhadap standar, quality control , quality assurance , berbagai alat statistik untuk keperluan pengendalian dan peningkatan kualitas, serta implementasi konsep Total Quality Management, Six Sigma, dan perbaikan berkelanjutan.

S2 - ITS

Batasan Rekayasa Kualitas Dalam Kuliah Ini

Membantu mahasiswa untuk memahami danmengaplikasi metoda Taguchi.

Beberapa studi kasus masalah industri diberikanuntuk memahami aplikasi metoda Taguchi secara sistematik.

What is the Design of Experiment technique?

It all began with R. A. Fisher in England back in 1920’s.

Fisher wanted to find out how much rain, sunshine, fertilizer, and water produce the best crop.

Design Of Experiments(DOE):

statistical technique

study the effect of multiple variables simultaneously

Who is Taguchi?

Born in Japan, 1924

Electrical Engineer

Worked during 1950’s to improve Japan’s post-WWII telephone communication system

Father of the “Taguchi Method” and “Robust Engineering”

He devoted much of his quality improvement effort on simplifying and standardizing the application of the DOE technique.

Who is Taguchi?

Source : www.qualitydigest.com

What is The Taguchi Approach ?

Design of Experiments (DOE) using Taguchi Approach is a standardized form of experimental design technique (referred as classical DOE) introduced by R. A. Fisher in England in the early 1920’s.

What is The Taguchi Approach ?

Although Dr. Taguchi successfully applied the technique in many companies throughout the world, it was introduced to USA and other western countries only in the early 1980’s.

Design of Experiment using the Taguchi Approach is just one of the many tools.

WHAT’S NEW? Philosophy !

Traditionally, quality activities took place only at the production end.

Dr. Genichi Taguchi proposed that a better way to assure quality is to build it in the product by designing quality into the product

WHAT’S NEW? Philosophy !

DO IT UP-FRONT:

He emphasized that the return on investment is much more when quality was addressed in engineering stages before production

The best way is to build quality into the design

DO IT IN DESIGN. DESIGN QUALITY IN:

Does not replace quality activities in production

Must not forget to do quality in design

WHAT’S NEW? Philosophy !

A few popular techniques used in different phases of engineering activities

Phases of engineering activities

Techniques

Design Design Reviews, DOE, Taguchi methods, etc.

Development DOE, Taguchi Methods, Growth Modeling, etc.

Test & Validation Reliability, Taguchi Methods

Production SPC, DOE, Taguchi Methods, Loss Function

WHAT’S NEW? Philosophy !

How do you improve quality in Design, Development, and Validation and Production?

The Taguchi approach presents an attractive option in all activities mentioned above.

The Biggest Bang For Your Buck A B C D Design Development Test & Validation Production

WHAT’S NEW? Loss Function!

By measuring quality not by Rejection at production, but in terms of deviation from the target.

By using the Loss function formulation to quantify the cost of quality

WHAT’S NEW? Loss Function!

$Loss

Target y

L=K(y -Yo)

Yo

2

LOSS FUNCTION : A formula to quantify the amount of loss based on deviation from the target performance.

WHAT’S NEW? Definition of Quality!

CONSISTENCY OF PERFORMANCE : Quality may be viewed in terms of consistency of performance. To be consistent is to BE LIKE THE GOOD ONE’S ALL THE TIME.

WHAT’S NEW? Definition of Quality!

CONSISTENCY OF PERFORMANCE

Target TargetTarget

WHAT’S NEW? Definition of Quality!

REDUCED VARIATION AROUND THE TARGET: Quality of performance can be measured in terms of variations around the target.

Minimize variation around the target by reducing the distance of the mean to the target(m) and by reducing the standard deviation ().

WHAT’S NEW? Definition of Quality!

Target

Mean

What you are now

What you wantto become

Target

m

To improve quality (Q)

Q = + m

WHAT’S NEW? Discipline!

BRAINSTORMING: Plan experiments and follow through.

TEAM WORK: Work as a team and not alone.

CONSENSUS DECISIONS: Make decisions democratically as a team. Avoid expert based decisions.

COMPLETE ALL EXPERIMENTS planned before making any conclusions.

WHAT’S NEW? Discipline!Typical Old Approach (Series Process) Some thinking

Some more thinking

Try this

Try that

New Approach (A Parallel Process)

Do Lots Of Thinking (Brainstorming)

Trial#1 Trial#2

Analyze Results

I. Planning

II. Designing

III. Doing

IV. Analyzing

V. Confirming

Application Steps

Run confirmation Experiments

Conduct Experiments

- What are we after?

- How do we measure results?

- etc.

WHAT’S NEW? Simpler and Standardized DOE!

APPLICATION STEPS: Steps for applications are clearly defined.

EXPERIMENT DESIGNS: Experiments are designed using special orthogonal arrays.

ANALYSIS OF RESULTS: Analysis and conclusions follow standard guidelines.

WHY TAGUCHI APPROACH?

Experimental Efficiency

Easy Application And Data Analysis

Higher Probability Of Success

Option To Confirm Predicted Improvement

Quantified Improvement

Improve Quality And Profitability

WHEN and WHERE to apply

Solve manufacturing and production problems

Optimize process designs

Optimize product designs

Apply when more than one factor influences the outcome

Use of Statistical Technique - Old way Vs. New way

OLD WAY Quality belongs to a few Statistical tools used only when needed Applied with the help of resident experts Work alone or with smaller groups

NEW WAY Quality is everyone’s business Statistical techniques applied more often Everyone learns to apply it on their own Techniques used are easy to learn and apply Often work as a team

Pertemuan Selanjutnya

Dasar-dasar rekayasa kualitas

Metoda Taguchi

Kualitas dan kemampuan proses

Referensi :

Belavendram , hal 1 – 40

Phadke , hal 1 – 9 ( Jadi Tugas – 1 )