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Quality Control in Production Process of Product-Service System: a Method Based on Turtle Diagram and Evaluation Model
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www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia
Procedia CIRP 00 (2017) 000–000 Procedia CIRP 83 (2019) 389–393 www.elsevier.com/locate/procedia
11th CIRP Conference on Industrial Product-Service Systems 11th CIRP Conference on Industrial Product-Service Systems
Quality Control in Production Process of Product-Service System: a Quality Control Production Process Product-Service System: a 28thin CIRP Design Conference, Mayof 2018, Nantes, France Method Based on Turtle Diagram and Evaluation Model Method Based on Turtle Diagram and Evaluation Model A new methodology to analyze the Chen functional andZou physical architecture a,c g f a,b Hongfei Guoa,b , Ru Zhang , Xiangyue , Zhengwei *, Ting Qu , Guoquan of a,c g a,b Hongfei Guoa,b , Rufor Zhang , Xiangyue Chen , Zhengwei Zouffamily *, Ting Qu , Guoquan existing products an assembly oriented product identification a,b g a,b a a,b d Huang , Jincheng Shi , Minshi Chen , Hao Gu , Yitao Lun , Jianke Li , Zhihui Hee Huanga,b, Jincheng Shi g, Minshi Chena,b, Hao Gua, Yitao Lun a,b, Jianke Lid, Zhihui Hee Institute of Physical Internet, Jinan University, , 519070,Ali ChinaSiadat Paul Stief *, Jean-Yves Dantan, AlainZhuhai Etienne, a
a School of Intelligent Science and Engineering, JinanZhuhai University, Zhuhai, 519070, China InstituteSystems of Physical Internet, Jinan University, , 519070, China b cInstitute of management science and engineering, Jinan University, 519070, China École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4Zhuhai, Rue Augustin Fresnel, Metz 57078, France School of Intelligent Systems Science and Engineering, Jinan University, Zhuhai, 519070, China d c Beijing Institute of Technology, Zhuhai School of Industrial Automation Zhuhai, 519088,China; Institute of management science and engineering, Jinan University, Zhuhai, 519070, China e d Zhuhai Hengqin Building &Construction Inspection Co.,Ltd, Zhuhai, 519031, China Beijing Institute of Technology, Zhuhai Quality School of IndustrialCentre Automation Zhuhai, 519088,China; * Corresponding author. Tel.: +33 87 37 54 30; E-mail address:and [email protected] e f 3Jiangxi University of Finance Economics School of Statistics, Nanchang , 330013, China Zhuhai Hengqin Building &Construction Quality Inspection Centre Co.,Ltd, Zhuhai, 519031, China g f Office of R&D, Jinan University Guangzhou, 510632, China Jiangxi University ofScientific Finance and Economics School of Statistics, Nanchang , 330013, China g * Corresponding author. E-mail address: [email protected] Office of Scientific R&D, Jinan University Guangzhou, 510632, China * Corresponding author. E-mail address: [email protected] b
Abstract
InAbstract today’s business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production Abstract systems as well as to choose optimal matches,system product analysis methods are needed. Indeed,and most of the known methods aim to To address the quality control the problems of product product-service (PSS), including job shop manufacturing customization of orders, disability analyze a product or one product familywe on the physical Different product families, however, may differ largely in terms oforders, the number and andaddress default of process quality control, a modellevel. ofsystem process quality control system, using improved turtle diagram and of evaluation method To the quality control problems of build product-service (PSS), including job shop manufacturing and customization disability nature of This fact impedes an efficient and of system, appropriate family for theand production based on components. VDA, for more achievement of sustainability through PSS. Wechoice show that the model ofproduct process quality control effective practical and default of process quality control, we build a modelcomparison of process quality control using improved turtlecombinations diagramisand evaluation method system. A VDA, new methodology is analyze existing in view ofthat their and physical architecture. The aim is topractical cluster for continuous improvement inproposed PSS, quality management andproducts sustainable development of enterprises. This study provides supplement for based on for more achievement of to sustainability through PSS. We show thefunctional model of process quality control is further effective and these products assembly product families for optimization of existingofassembly lines andstudy the creation future supplement reconfigurable existing theoryinimprovement ofnew enterprise quality and product-service system. for continuous in oriented PSS,management quality management andthe sustainable development enterprises. This providesoffurther for assembly systems. Based on Datum Chain, the structuresystem. of the products is analyzed. Functional subassemblies are identified, and existing theory of enterprise qualityFlow management andphysical product-service a©functional analysis performed. a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the Authors.isPublished Published by Moreover, Elsevier B.V. © 2019 2019 The The Authors. by Elsevier B.V. similarity between product families by providing design of support to both, production system planners and product designers. Peer-review under responsibility of the scientific committee of 11th CIRP Conference on Industrial Product-Service Systems.An illustrative © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee thethe 11th CIRP Conference on Industrial Product-Service Systems example of a under nail-clipper is used to the proposed methodology. industrial case on study on two Product-Service product familiesSystems. of steering columns of Peer-review responsibility ofexplain the scientific committee of the 11th An CIRP Conference Industrial thyssenkrupp Presta France is then carried out to give a firstprocess; industrial evaluation of the proposed approach. Keywords: Heavy truck enterprise; Quality control of production Turtle diagram analysis; Quality control capability evaluation model ©Keywords: 2017 TheHeavy Authors. Elsevier B.V. truckPublished enterprise;by Quality control of production process; Turtle diagram analysis; Quality control capability evaluation model Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. Keywords: Assembly; Design method; Family identification 1. Introduction
meet the needs of the PSS anymore. Therefore, for the above Introduction meet the needs of ittheis PSS anymore. Therefore, thequality above problems of PSS, necessary to put forward afornew problems of PSS, itmodel is necessary to put forward a new quality PSS is defined as ‘product(s) and service(s) combined in a control mechanism and apply it into practice. PSS is ‘product(s) service(s) in combined control andfew apply it into system to defined deliver as required user and functionality a way in thata In themechanism literature, model there are studies onpractice. the quality control 1.system Introduction product range and are characteristics manufactured and/or to user functionalityIninpractice, a way that In the literature, there few studies on the quality reduces thedeliver impactrequired on the environment’[1]. the of of the the production process of PSS. Most researches focuscontrol on the assembled in this system. In this context, the main challenge in reduces the impact on the environment’[1]. practice, of the production process management of PSS. Mostsystem researches focus on the process quality control in the product-serviceInsystems is the general and pure quality [2-14], focusing Due to the fast development in the domain of modelling and analysis is now not only to cope with single process quality control in the product-service general pure quality managementofsystem [2-14], focusing traditional functional quality management mode.systems is the on the and theoretical construction the general quality communication an ongoing trendof of and products, limited product range or manufacturing existing families, traditional functional quality management mode. on the atheoretical of the product general quality However, in and the actual operation thedigitization product service management system inconstruction automobile enterprises digitalization, manufacturing enterprises facing important to be able to analyze to compare products to define However, in the actual ofare the product service management system inon automobile manufacturing enterprises system, the traditional qualityoperation management system cannot well but andalso empirical research itsand macro-impact. There is a lack of challenges in today’s market environments: a continuing new product families. It can be observed that classical existing system, the traditional quality management system cannot well and itsapplication macro-impact. There lack of meet quality control requirements of PSS and cannot deal with new empirical theoreticalresearch researchon and analysis on is thea process tendency towards reduction product development times and familiesmechanism are regrouped in functionanalysis of clients meet quality control requirements of PSS cannot deal with new theoretical research andinapplication on or thefeatures. process the inherent quality controlofproblems ofand PSS, including job product quality control product-service systems. shortened product lifecycles. In addition, there is an increasing However, assembly oriented product families are hardly find. the qualityand control problems of oforders, PSS, including job quality control mechanism in product-service systems. shopinherent manufacturing customization disability and The research on process quality control in the field of to quality demand of customization, being at the same time in a global On the product family level, products differ mainly in two shop manufacturing customization orders, disability and The research process quality control in the of quality default of process and quality control. of The contract business management hason been fruitful, which shows thatfield the feasibility competition with competitors all over the world. This trend, main characteristics: (i) the number of components and (ii) the default of of process quality control. isThe contract management fruitful, which in shows that the feasibility complexity heavy truck enterprises increasing daybusiness by day, and validity has of been process method quality management which is inducing the development from macro to micro type of components (e.g. mechanical, electrical, electronical). complexity of heavy truck enterprises is increasing day by day, and validityin PSS, of process method in quality management and the original functional quality management model cannot application therefore, Therefore, this study proposes a markets, results in diminished lot management sizes due tomodel augmenting Classical in methodologies considering mainly singleproposes productsa and the original functional quality cannot application PSS, therefore, Therefore, this study product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the 2212-8271 © 2019 Theaugmenting Authors. Published by Elsevier To cope with this variety as wellB.V. as to be able to product structure on a physical level (components level) which Peer-review the scientific committee the 11th CIRP Conference Product-Service 2212-8271 possible ©under 2019responsibility The optimization Authors. of Published by Elsevier B.V. identify potentials in ofthe existing causeson Industrial difficulties regardingSystems. an efficient definition and doi:10.1016/j.procir.2017.04.009 Peer-review under responsibility of the scientific committee of the 11th CIRP Conference on Industrial Product-Service Systems.families. Addressing this production system, it is important to have a precise knowledge comparison of different product 1.
doi:10.1016/j.procir.2017.04.009
2212-8271©©2017 2019The The Authors. Published by Elsevier 2212-8271 Authors. Published by Elsevier B.V. B.V. Peer-reviewunder underresponsibility responsibility scientific committee of the CIRP Conference on 2018. Industrial Product-Service Systems. Peer-review of of thethe scientific committee of the 28th11th CIRP Design Conference 10.1016/j.procir.2019.04.090
Hongfei Guo et al. / Procedia CIRP 83 (2019) 389–393 Author name / Procedia CIRP 00 (2019) 000–000
390 2
PSS quality control model that integrates the improved turtle diagram and evaluation model of quality control mechanism , so as to realize real-time monitoring and continuous improvement in the process of PSS operation. 2.
Methodology
corresponding part of the quality control mechanism of the process system composed of sub-processes can be calculated by the following formula: EP (input ) + EP ( process ) + EP (output ) 100% 3
= E
2.1. Turtle diagram analysis of quality control process
(2)
Details of quality control ability score are shown in Table 1:
According to the theory of process method analysis, the quality control of sub-process is to identify the sub-process elements by using the process analysis tool - turtle diagram analysis. According to the characteristics and process characteristics of the products corresponding to the key contracts with the company, a turtle diagram model (as shown in figure 1) is formed to analyze the quality control process. Firstly, the input and output parts of the quality control process are confirmed, and the material resources and standard methods involved in the process are obtained. Then, combined with material resources and elements of standard methods, elements of process support are sorted out. Finally, the process performance indicators were determined.
Table 1. Quality controls ability scoring rules. Score
Scoring criteria
10 8
Fully meet the expected requirements of quality control
6
Part of them meet the expected requirements of quality control
4
A small part of them meet the expected requirements of quality control
0
Completely fail to meet the expected requirements of quality control
Most of them meet the expected requirements of quality control
In addition, in accordance with the way of Input - Quality Control - Output score, it still need to score the six parts of the process analysis of turtle diagram analysis model respectively: (Input (Input), with what (Material Resources), with the who (Process Support), Measure (Quality Control Standard), How (Quality Control Method), Output (Output)) , forming quality control mechanism analysis model based on radar map (see Figure 2).
Fig. 1. Turtle Diagram.
2.2. VDA-based quality control capability evaluation model According to “Key Contract Quality Control Project” and “List of Banned Fault” analysis risk control points, at the same time, based on the VDA 6.3-2010 process audit score grading rules, develop the detailed score of quality control ability, set up quality control ability score model, rate for sub-process quality control effect, the sub-process quality control ability scores can be calculated by the following equation: EP =
1 Ei 100% 10N i=1
(1)
N represents the number of steps in a sub-process, and Ei represents the score of each step. The capability score of the
Fig. 2. Quality control mechanism analysis model based on radar map.
3.
Process Quality control of PSS
During the operation of the product service system, enterprises conduct closed-loop management of quality problems, and establish a production process quality control mechanism with three modules: internal audit system, electronic management of quality control documents, qualityaudit and audit-double-audit system. The process analysis turtle diagram model of the production processes quality control mechanism is shown in Figure 3.
Hongfei Guo et al. / Procedia CIRP 83 (2019) 389–393 Author name / Procedia CIRP 00 (2019) 000–000
391 3
Fig. 4. Quality control capability evaluation model of production process.
Fig. 3. Process analysis turtle diagram model of the production processes quality control mechanism.
Correspondingly, the production processes quality control capability analysis model is shown in Figure 4, and the data onto the figure are assumed data.
The factors of quality control in the production process were analyzed by using the specialized turtle diagram analysis, and the ability evaluation was carried out to obtain the quality control ability score before improvement. After the implementation of the measures, the ability evaluation was carried out again, the quality control ability score of the production process before and after the improvement was compared to verify the actual effect after the improvement, and the PDCA cycle of the quality control of the production process was carried out to achieve the effect of continuous improvement. By automatically calling the part number, supplier, batch quantity and other information of the products submitted for inspection in the material procurement system to the collaborative parts acceptance management system, the inspectors can timely input the inspection results of appearance, size and other items through the on-site computer equipment into the system to form an electronic ledger. The material purchase system is unable to handle warehousing procedures for products that have not been checked and accepted by the inspectors or are not qualified. Thereby the system control of
392 4
Hongfei Guo et al. / Procedia CIRP 83 (2019) 389–393 Author name / Procedia CIRP 00 (2019) 000–000
the stored products can be realized, at the same time also realize systematic summary of the cooperative parts acceptance information, can collect and consult information of cooperative parts put in storage such as batch number and quantity, quantity of products rejected or accepted, manufacturer's name, qualified batch number and unqualified batch number at any time, and thus it is more convenient to make statistics and analysis on the quality of cooperative parts and formulate corresponding measures, so that improve the quality of collaborative product, and further strengthen enterprises’ ability of cooperative parts quality control. For the products of key contract projects, the enterprise should sort out and decompose the basic state of all vehicles on the basis of the original general assembly and acceptance documents, and issue the Vehicle Basic State Inspection Card to strengthen the inspection and control of the production process. At the same time, the Key Item Control Order is compiled and issued for vehicles of foreign trade products according to relevant documents such as technical agreement and design instruction. In the process of vehicle acceptance, the size of the upper interface, special configuration and other states of the physical product shall be inspected and controlled to strengthen the acceptance control of the process and final acceptance. Specific improvement measures are as follows: ⚫ Internal audit system Set up internal audit expert team, make internal audit plan and implement, check whether the quality management process regulations are appropriate, check whether the process execution is in place, find the management reasons behind the problems, and improve the system operation quality. Then conduct centralized audit, special audit and supervision and inspection, discuss with the department being audited, put forward Suggestions, formulate the rectification plan, and ensure the closed-loop implementation of problems. For major design projects, special personnel station, direct and inspect; involve procurement in the evaluation of new suppliers, carry out PPAP audit in coordination with SQE, and let supplier audit as the second party; in addition, carry out production according to key contracts, carry out routine supervision and inspection and special supervision and inspection, and strictly carry out the assessment on the responsibility for the violation of the quality process and process provisions. Further strengthen the quality system construction and the enforcement and effectiveness of documents in the audit process. ⚫ Quality review and audit After the first vehicle production is off line, on the basis of product conformity inspection and acceptance, improving customer satisfaction as the ultimate goal, the quality management department shall organize the design, process, material and production departments to review or audit the physical quality of the vehicle, in addition to reviewing quality issues in the Quality Control Measures and Plan and List Of Banned Fault again, also propose the deficiencies of the product from the user's perspective. For the quality problems raised by the review, the quality management department shall release the rectification notice in time after decomposition, and the relevant units shall formulate the improvement plan
or control measures, and carry out key control and inspection in the subsequent production process of vehicles. 4.
Application cases
This study conducted a practical application of this quality control mechanism in cooperation with a large Chinese heavy truck enterprise from 2014 to 2016. Within the scope of the enterprise PSS operation period, this study adopts professional achievements direct determination method in the economic calculation system of Chinese enterprise management innovation achievements, to determine the production process quality control, quality control measures are taken after implementation of the measured benefits minus the implementation of the real benefits of the former data, and further converted into value and deduct the cost of implementation, get economic benefit of enterprise value, calculation method as shown in the following type: n
Em = (Q1 − Q0 ) r − F − [ Ca + I ]
(3)
a =1
The meanings of the symbols are shown in Table 2. Table 2. Symbol description. Symbol
Meaning
Unit
Q0
The actual completion in the previous year
Ten thousand yuan
Q1
The actual completion within the implementation year
Ten thousand year
r
The conversion coefficient of non-value quantity Q into value quantity
/
F
The annual benefit of nonfactor production of this management system
Ten thousand yuan
n
C a =1
a
The sum cost of the implementation of several management measures
I Em
Ten thousand yuan Implementation management loss cost
From 2014 to 2016, the implementation of this quality controls mechanism enabled the enterprise to achieve a total annual benefit of 181.86 million yuan and an average annual benefit of 60.62 million yuan. In terms of production efficiency, energy saving and environmental protection, the quality control mechanism also plays a good role. The productivity of a company is measured by the total labour productivity in its main economic indicators. From 2014 to 2016, the labour productivity of all employees increased from 5,800 yuan/per person to 17,700 yuan/per person year by year, and the production efficiency increased steadily and effectively. Similarly, the energy saving efficiency of the enterprise is measured by the energy consumption per ten thousand yuan of output value in the main economic index of
Hongfei Guo et al. / Procedia CIRP 83 (2019) 389–393 Author name / Procedia CIRP 00 (2019) 000–000
the enterprise. From 2014 to 2016, the energy consumption per ten thousand yuan of output values decreased from 0.039 tons of standard coal to 0.0387 tons of standard coal year by year. The actual energy saving effect is remarkable. The production processes quality control system also reduces the production cost. According to the statistics of after-sales service cost of 2016, the actual gross loss of a single service unit is 37.4% lower than that of 2014, and the actual net loss of a single service unit is 21.1% lower than that of 2014, which reduces the quality loss of enterprises and improves the economic benefits of enterprises. 5.
Conclusion
This paper proposes a PSS process quality control model based on process method, which can be effectively applied to the PSS operation process of enterprises. Combined with the process method, the improved turtle diagram analysis was proposed to analyse the factors and processes of the PSS process quality control system model, and the radar diagram model of the quality control ability score was established to evaluate the implementation effect of quality control and realize the continuous quality improvement. From the perspective of related cooperative heavy truck enterprises, this quality controls mechanism models also to achieve the purpose of improving the efficiency of PSS operation, energy saving and environmental protection ability, reducing the quality loss of enterprises and improving the economic benefits of enterprises. The proposed model will provide theoretical support and empirical guidance for the whole value chain systematic lean management strategy and PSS process quality control. Acknowledgements The research and publication of their article was supported by the Fundamental Research Funds for the Central Universities [grant number 21618412;grant number 21618804]; the National Natural Science Foundation of China [grant number 51475095]; Project of Guangdong ;Natural Science Foundation [grant number 2016A030311041]; 2015 Guangdong Special Support Scheme [grant number 2014TQ01X706]; High-level Talent Scheme of Guangdong Education Department [grant number 2014-2016]; the Guangdong Natural Science Foundation [grant number 2017A030313401]; Inner Mongolia Autonomous Region Science and Technology Innovation Guide Award Fund Project [grant number 103-413193]; Key Research Projects of Henan Higher Education Institutions[grant number 19A630037]. References [1] Mont, O.K.: Clarifying the concept of product-service system, J Clean Prod; 2002, 10, (3), p. 237-245. [2] Bittremieux, W., Valkenborg, D., Martens, L., and Laukens, K.: Computational quality control tools for mass spectrometry proteomics, Proteomics; 2017, 17, (3-4), p. 11. [3] Kuo, T., and Mital, A.: QUALITY-CONTROL EXPERTSYSTEMS - A REVIEW OF PERTINENT LITERATURE, J. Intell. Manuf.; 1993, 4, (4), p. 245-257.
393 5
[4] Westgard, J.O., and Westgard, S.A.: Quality control review: implementing a scientifically based quality control system, Ann. Clin. Biochem.; 2016, 53, (1), p. 32-50. [5] He, Y.H., Gu, C.C., He, Z.Z., and Cui, J.M.: Reliabilityoriented quality control approach for production process based on RQR chain, Total Quality Management & Business Excellence; 2018, 29, (5-6), p. 652-672. [6] Shih, N.H., and Wang, C.H.: Determining an optimal production run length with an extended quality control policy for an imperfect process, Applied Mathematical Modelling; 2016, 40, (4), p. 2827-2836. [7] Ozkal Yildiz, T., and Sahan Vahaplar, S.: AN APPLICATION ON FANCY SHIRTING FABRIC PRODUCTION THROUGH DISTRIBUTION-FREE QUALITY CONTROL CHARTS, Tekstil Ve Konfeksiyon; 2015, 25, (2), p. 97-103. [8] Tarrach, L.: The New Generation of Quality Control for Polymer Resin - Defect Detection and Sorting at the Production Scale, Materials Testing-Materials and Components Technology and Application; 2010, 52, (1112), p. 819-821. [9] Korytkowski, P., Wisniewski, T., and Zaikin, O.: Multicriteria approach to comparison of inspection allocation for multi-product manufacturing systems in make-to-order sector, Control and Cybernetics; 2010, 39, (1), p. 97-116. [10] Keser, T., Hocenski, Z., and Hocenski, V.: Intelligent Machine Vision System for Automated Quality Control in Ceramic Tiles Industry, Strojarstvo; 2010, 52, (2), p. 105114. [11] Zou, T., Wang, X.L., Shao, M., Sun, Y.J., Zhao, Y.E., Tang, H.H., Ming, Y., Guo, J.J., Zhang, Y.L., Li, C., Chen, H.F., Xu, Z.Z., and Zeng, H.: Quality control of MRPC mass production for STAR TOF, Nucl. Instrum. Methods Phys. Res. Sect. A-Accel. Spectrom. Dect. Assoc. Equip.; 2009, 605, (3), p. 282-292. [12] van der Bij, H., and van Ekert, J.H.W.: Interaction between production control and quality control, International Journal of Operations & Production Management; 1999, 19, (7), p. 674-690. [13] Djiev, S.N., and Pavlov, L.I.: Low-cost automated system for on-line quality and production control in textiles, Process Control and Quality; 1995, 7, (3-4), p. 179-183. [14] Jacobs, D., and Meerkov, S.M.: ASYMPTOTICALLY RELIABLE SERIAL PRODUCTION LINES WITH A QUALITY-CONTROL SYSTEM, Computers & Mathematics with Applications; 1991, 21, (11-12), p. 8590.
ScienceDirect ScienceDirect Available online atonline www.sciencedirect.com Available at www.sciencedirect.com Procedia CIRP 00 (2019) 000–000 Procedia CIRP 00 (2019) 000–000
ScienceDirect ScienceDirect
www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia
Procedia CIRP 00 (2017) 000–000 Procedia CIRP 83 (2019) 389–393 www.elsevier.com/locate/procedia
11th CIRP Conference on Industrial Product-Service Systems 11th CIRP Conference on Industrial Product-Service Systems
Quality Control in Production Process of Product-Service System: a Quality Control Production Process Product-Service System: a 28thin CIRP Design Conference, Mayof 2018, Nantes, France Method Based on Turtle Diagram and Evaluation Model Method Based on Turtle Diagram and Evaluation Model A new methodology to analyze the Chen functional andZou physical architecture a,c g f a,b Hongfei Guoa,b , Ru Zhang , Xiangyue , Zhengwei *, Ting Qu , Guoquan of a,c g a,b Hongfei Guoa,b , Rufor Zhang , Xiangyue Chen , Zhengwei Zouffamily *, Ting Qu , Guoquan existing products an assembly oriented product identification a,b g a,b a a,b d Huang , Jincheng Shi , Minshi Chen , Hao Gu , Yitao Lun , Jianke Li , Zhihui Hee Huanga,b, Jincheng Shi g, Minshi Chena,b, Hao Gua, Yitao Lun a,b, Jianke Lid, Zhihui Hee Institute of Physical Internet, Jinan University, , 519070,Ali ChinaSiadat Paul Stief *, Jean-Yves Dantan, AlainZhuhai Etienne, a
a School of Intelligent Science and Engineering, JinanZhuhai University, Zhuhai, 519070, China InstituteSystems of Physical Internet, Jinan University, , 519070, China b cInstitute of management science and engineering, Jinan University, 519070, China École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4Zhuhai, Rue Augustin Fresnel, Metz 57078, France School of Intelligent Systems Science and Engineering, Jinan University, Zhuhai, 519070, China d c Beijing Institute of Technology, Zhuhai School of Industrial Automation Zhuhai, 519088,China; Institute of management science and engineering, Jinan University, Zhuhai, 519070, China e d Zhuhai Hengqin Building &Construction Inspection Co.,Ltd, Zhuhai, 519031, China Beijing Institute of Technology, Zhuhai Quality School of IndustrialCentre Automation Zhuhai, 519088,China; * Corresponding author. Tel.: +33 87 37 54 30; E-mail address:and [email protected] e f 3Jiangxi University of Finance Economics School of Statistics, Nanchang , 330013, China Zhuhai Hengqin Building &Construction Quality Inspection Centre Co.,Ltd, Zhuhai, 519031, China g f Office of R&D, Jinan University Guangzhou, 510632, China Jiangxi University ofScientific Finance and Economics School of Statistics, Nanchang , 330013, China g * Corresponding author. E-mail address: [email protected] Office of Scientific R&D, Jinan University Guangzhou, 510632, China * Corresponding author. E-mail address: [email protected] b
Abstract
InAbstract today’s business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production Abstract systems as well as to choose optimal matches,system product analysis methods are needed. Indeed,and most of the known methods aim to To address the quality control the problems of product product-service (PSS), including job shop manufacturing customization of orders, disability analyze a product or one product familywe on the physical Different product families, however, may differ largely in terms oforders, the number and andaddress default of process quality control, a modellevel. ofsystem process quality control system, using improved turtle diagram and of evaluation method To the quality control problems of build product-service (PSS), including job shop manufacturing and customization disability nature of This fact impedes an efficient and of system, appropriate family for theand production based on components. VDA, for more achievement of sustainability through PSS. Wechoice show that the model ofproduct process quality control effective practical and default of process quality control, we build a modelcomparison of process quality control using improved turtlecombinations diagramisand evaluation method system. A VDA, new methodology is analyze existing in view ofthat their and physical architecture. The aim is topractical cluster for continuous improvement inproposed PSS, quality management andproducts sustainable development of enterprises. This study provides supplement for based on for more achievement of to sustainability through PSS. We show thefunctional model of process quality control is further effective and these products assembly product families for optimization of existingofassembly lines andstudy the creation future supplement reconfigurable existing theoryinimprovement ofnew enterprise quality and product-service system. for continuous in oriented PSS,management quality management andthe sustainable development enterprises. This providesoffurther for assembly systems. Based on Datum Chain, the structuresystem. of the products is analyzed. Functional subassemblies are identified, and existing theory of enterprise qualityFlow management andphysical product-service a©functional analysis performed. a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the Authors.isPublished Published by Moreover, Elsevier B.V. © 2019 2019 The The Authors. by Elsevier B.V. similarity between product families by providing design of support to both, production system planners and product designers. Peer-review under responsibility of the scientific committee of 11th CIRP Conference on Industrial Product-Service Systems.An illustrative © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific committee thethe 11th CIRP Conference on Industrial Product-Service Systems example of a under nail-clipper is used to the proposed methodology. industrial case on study on two Product-Service product familiesSystems. of steering columns of Peer-review responsibility ofexplain the scientific committee of the 11th An CIRP Conference Industrial thyssenkrupp Presta France is then carried out to give a firstprocess; industrial evaluation of the proposed approach. Keywords: Heavy truck enterprise; Quality control of production Turtle diagram analysis; Quality control capability evaluation model ©Keywords: 2017 TheHeavy Authors. Elsevier B.V. truckPublished enterprise;by Quality control of production process; Turtle diagram analysis; Quality control capability evaluation model Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. Keywords: Assembly; Design method; Family identification 1. Introduction
meet the needs of the PSS anymore. Therefore, for the above Introduction meet the needs of ittheis PSS anymore. Therefore, thequality above problems of PSS, necessary to put forward afornew problems of PSS, itmodel is necessary to put forward a new quality PSS is defined as ‘product(s) and service(s) combined in a control mechanism and apply it into practice. PSS is ‘product(s) service(s) in combined control andfew apply it into system to defined deliver as required user and functionality a way in thata In themechanism literature, model there are studies onpractice. the quality control 1.system Introduction product range and are characteristics manufactured and/or to user functionalityIninpractice, a way that In the literature, there few studies on the quality reduces thedeliver impactrequired on the environment’[1]. the of of the the production process of PSS. Most researches focuscontrol on the assembled in this system. In this context, the main challenge in reduces the impact on the environment’[1]. practice, of the production process management of PSS. Mostsystem researches focus on the process quality control in the product-serviceInsystems is the general and pure quality [2-14], focusing Due to the fast development in the domain of modelling and analysis is now not only to cope with single process quality control in the product-service general pure quality managementofsystem [2-14], focusing traditional functional quality management mode.systems is the on the and theoretical construction the general quality communication an ongoing trendof of and products, limited product range or manufacturing existing families, traditional functional quality management mode. on the atheoretical of the product general quality However, in and the actual operation thedigitization product service management system inconstruction automobile enterprises digitalization, manufacturing enterprises facing important to be able to analyze to compare products to define However, in the actual ofare the product service management system inon automobile manufacturing enterprises system, the traditional qualityoperation management system cannot well but andalso empirical research itsand macro-impact. There is a lack of challenges in today’s market environments: a continuing new product families. It can be observed that classical existing system, the traditional quality management system cannot well and itsapplication macro-impact. There lack of meet quality control requirements of PSS and cannot deal with new empirical theoreticalresearch researchon and analysis on is thea process tendency towards reduction product development times and familiesmechanism are regrouped in functionanalysis of clients meet quality control requirements of PSS cannot deal with new theoretical research andinapplication on or thefeatures. process the inherent quality controlofproblems ofand PSS, including job product quality control product-service systems. shortened product lifecycles. In addition, there is an increasing However, assembly oriented product families are hardly find. the qualityand control problems of oforders, PSS, including job quality control mechanism in product-service systems. shopinherent manufacturing customization disability and The research on process quality control in the field of to quality demand of customization, being at the same time in a global On the product family level, products differ mainly in two shop manufacturing customization orders, disability and The research process quality control in the of quality default of process and quality control. of The contract business management hason been fruitful, which shows thatfield the feasibility competition with competitors all over the world. This trend, main characteristics: (i) the number of components and (ii) the default of of process quality control. isThe contract management fruitful, which in shows that the feasibility complexity heavy truck enterprises increasing daybusiness by day, and validity has of been process method quality management which is inducing the development from macro to micro type of components (e.g. mechanical, electrical, electronical). complexity of heavy truck enterprises is increasing day by day, and validityin PSS, of process method in quality management and the original functional quality management model cannot application therefore, Therefore, this study proposes a markets, results in diminished lot management sizes due tomodel augmenting Classical in methodologies considering mainly singleproposes productsa and the original functional quality cannot application PSS, therefore, Therefore, this study product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the 2212-8271 © 2019 Theaugmenting Authors. Published by Elsevier To cope with this variety as wellB.V. as to be able to product structure on a physical level (components level) which Peer-review the scientific committee the 11th CIRP Conference Product-Service 2212-8271 possible ©under 2019responsibility The optimization Authors. of Published by Elsevier B.V. identify potentials in ofthe existing causeson Industrial difficulties regardingSystems. an efficient definition and doi:10.1016/j.procir.2017.04.009 Peer-review under responsibility of the scientific committee of the 11th CIRP Conference on Industrial Product-Service Systems.families. Addressing this production system, it is important to have a precise knowledge comparison of different product 1.
doi:10.1016/j.procir.2017.04.009
2212-8271©©2017 2019The The Authors. Published by Elsevier 2212-8271 Authors. Published by Elsevier B.V. B.V. Peer-reviewunder underresponsibility responsibility scientific committee of the CIRP Conference on 2018. Industrial Product-Service Systems. Peer-review of of thethe scientific committee of the 28th11th CIRP Design Conference 10.1016/j.procir.2019.04.090
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PSS quality control model that integrates the improved turtle diagram and evaluation model of quality control mechanism , so as to realize real-time monitoring and continuous improvement in the process of PSS operation. 2.
Methodology
corresponding part of the quality control mechanism of the process system composed of sub-processes can be calculated by the following formula: EP (input ) + EP ( process ) + EP (output ) 100% 3
= E
2.1. Turtle diagram analysis of quality control process
(2)
Details of quality control ability score are shown in Table 1:
According to the theory of process method analysis, the quality control of sub-process is to identify the sub-process elements by using the process analysis tool - turtle diagram analysis. According to the characteristics and process characteristics of the products corresponding to the key contracts with the company, a turtle diagram model (as shown in figure 1) is formed to analyze the quality control process. Firstly, the input and output parts of the quality control process are confirmed, and the material resources and standard methods involved in the process are obtained. Then, combined with material resources and elements of standard methods, elements of process support are sorted out. Finally, the process performance indicators were determined.
Table 1. Quality controls ability scoring rules. Score
Scoring criteria
10 8
Fully meet the expected requirements of quality control
6
Part of them meet the expected requirements of quality control
4
A small part of them meet the expected requirements of quality control
0
Completely fail to meet the expected requirements of quality control
Most of them meet the expected requirements of quality control
In addition, in accordance with the way of Input - Quality Control - Output score, it still need to score the six parts of the process analysis of turtle diagram analysis model respectively: (Input (Input), with what (Material Resources), with the who (Process Support), Measure (Quality Control Standard), How (Quality Control Method), Output (Output)) , forming quality control mechanism analysis model based on radar map (see Figure 2).
Fig. 1. Turtle Diagram.
2.2. VDA-based quality control capability evaluation model According to “Key Contract Quality Control Project” and “List of Banned Fault” analysis risk control points, at the same time, based on the VDA 6.3-2010 process audit score grading rules, develop the detailed score of quality control ability, set up quality control ability score model, rate for sub-process quality control effect, the sub-process quality control ability scores can be calculated by the following equation: EP =
1 Ei 100% 10N i=1
(1)
N represents the number of steps in a sub-process, and Ei represents the score of each step. The capability score of the
Fig. 2. Quality control mechanism analysis model based on radar map.
3.
Process Quality control of PSS
During the operation of the product service system, enterprises conduct closed-loop management of quality problems, and establish a production process quality control mechanism with three modules: internal audit system, electronic management of quality control documents, qualityaudit and audit-double-audit system. The process analysis turtle diagram model of the production processes quality control mechanism is shown in Figure 3.
Hongfei Guo et al. / Procedia CIRP 83 (2019) 389–393 Author name / Procedia CIRP 00 (2019) 000–000
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Fig. 4. Quality control capability evaluation model of production process.
Fig. 3. Process analysis turtle diagram model of the production processes quality control mechanism.
Correspondingly, the production processes quality control capability analysis model is shown in Figure 4, and the data onto the figure are assumed data.
The factors of quality control in the production process were analyzed by using the specialized turtle diagram analysis, and the ability evaluation was carried out to obtain the quality control ability score before improvement. After the implementation of the measures, the ability evaluation was carried out again, the quality control ability score of the production process before and after the improvement was compared to verify the actual effect after the improvement, and the PDCA cycle of the quality control of the production process was carried out to achieve the effect of continuous improvement. By automatically calling the part number, supplier, batch quantity and other information of the products submitted for inspection in the material procurement system to the collaborative parts acceptance management system, the inspectors can timely input the inspection results of appearance, size and other items through the on-site computer equipment into the system to form an electronic ledger. The material purchase system is unable to handle warehousing procedures for products that have not been checked and accepted by the inspectors or are not qualified. Thereby the system control of
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the stored products can be realized, at the same time also realize systematic summary of the cooperative parts acceptance information, can collect and consult information of cooperative parts put in storage such as batch number and quantity, quantity of products rejected or accepted, manufacturer's name, qualified batch number and unqualified batch number at any time, and thus it is more convenient to make statistics and analysis on the quality of cooperative parts and formulate corresponding measures, so that improve the quality of collaborative product, and further strengthen enterprises’ ability of cooperative parts quality control. For the products of key contract projects, the enterprise should sort out and decompose the basic state of all vehicles on the basis of the original general assembly and acceptance documents, and issue the Vehicle Basic State Inspection Card to strengthen the inspection and control of the production process. At the same time, the Key Item Control Order is compiled and issued for vehicles of foreign trade products according to relevant documents such as technical agreement and design instruction. In the process of vehicle acceptance, the size of the upper interface, special configuration and other states of the physical product shall be inspected and controlled to strengthen the acceptance control of the process and final acceptance. Specific improvement measures are as follows: ⚫ Internal audit system Set up internal audit expert team, make internal audit plan and implement, check whether the quality management process regulations are appropriate, check whether the process execution is in place, find the management reasons behind the problems, and improve the system operation quality. Then conduct centralized audit, special audit and supervision and inspection, discuss with the department being audited, put forward Suggestions, formulate the rectification plan, and ensure the closed-loop implementation of problems. For major design projects, special personnel station, direct and inspect; involve procurement in the evaluation of new suppliers, carry out PPAP audit in coordination with SQE, and let supplier audit as the second party; in addition, carry out production according to key contracts, carry out routine supervision and inspection and special supervision and inspection, and strictly carry out the assessment on the responsibility for the violation of the quality process and process provisions. Further strengthen the quality system construction and the enforcement and effectiveness of documents in the audit process. ⚫ Quality review and audit After the first vehicle production is off line, on the basis of product conformity inspection and acceptance, improving customer satisfaction as the ultimate goal, the quality management department shall organize the design, process, material and production departments to review or audit the physical quality of the vehicle, in addition to reviewing quality issues in the Quality Control Measures and Plan and List Of Banned Fault again, also propose the deficiencies of the product from the user's perspective. For the quality problems raised by the review, the quality management department shall release the rectification notice in time after decomposition, and the relevant units shall formulate the improvement plan
or control measures, and carry out key control and inspection in the subsequent production process of vehicles. 4.
Application cases
This study conducted a practical application of this quality control mechanism in cooperation with a large Chinese heavy truck enterprise from 2014 to 2016. Within the scope of the enterprise PSS operation period, this study adopts professional achievements direct determination method in the economic calculation system of Chinese enterprise management innovation achievements, to determine the production process quality control, quality control measures are taken after implementation of the measured benefits minus the implementation of the real benefits of the former data, and further converted into value and deduct the cost of implementation, get economic benefit of enterprise value, calculation method as shown in the following type: n
Em = (Q1 − Q0 ) r − F − [ Ca + I ]
(3)
a =1
The meanings of the symbols are shown in Table 2. Table 2. Symbol description. Symbol
Meaning
Unit
Q0
The actual completion in the previous year
Ten thousand yuan
Q1
The actual completion within the implementation year
Ten thousand year
r
The conversion coefficient of non-value quantity Q into value quantity
/
F
The annual benefit of nonfactor production of this management system
Ten thousand yuan
n
C a =1
a
The sum cost of the implementation of several management measures
I Em
Ten thousand yuan Implementation management loss cost
From 2014 to 2016, the implementation of this quality controls mechanism enabled the enterprise to achieve a total annual benefit of 181.86 million yuan and an average annual benefit of 60.62 million yuan. In terms of production efficiency, energy saving and environmental protection, the quality control mechanism also plays a good role. The productivity of a company is measured by the total labour productivity in its main economic indicators. From 2014 to 2016, the labour productivity of all employees increased from 5,800 yuan/per person to 17,700 yuan/per person year by year, and the production efficiency increased steadily and effectively. Similarly, the energy saving efficiency of the enterprise is measured by the energy consumption per ten thousand yuan of output value in the main economic index of
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the enterprise. From 2014 to 2016, the energy consumption per ten thousand yuan of output values decreased from 0.039 tons of standard coal to 0.0387 tons of standard coal year by year. The actual energy saving effect is remarkable. The production processes quality control system also reduces the production cost. According to the statistics of after-sales service cost of 2016, the actual gross loss of a single service unit is 37.4% lower than that of 2014, and the actual net loss of a single service unit is 21.1% lower than that of 2014, which reduces the quality loss of enterprises and improves the economic benefits of enterprises. 5.
Conclusion
This paper proposes a PSS process quality control model based on process method, which can be effectively applied to the PSS operation process of enterprises. Combined with the process method, the improved turtle diagram analysis was proposed to analyse the factors and processes of the PSS process quality control system model, and the radar diagram model of the quality control ability score was established to evaluate the implementation effect of quality control and realize the continuous quality improvement. From the perspective of related cooperative heavy truck enterprises, this quality controls mechanism models also to achieve the purpose of improving the efficiency of PSS operation, energy saving and environmental protection ability, reducing the quality loss of enterprises and improving the economic benefits of enterprises. The proposed model will provide theoretical support and empirical guidance for the whole value chain systematic lean management strategy and PSS process quality control. Acknowledgements The research and publication of their article was supported by the Fundamental Research Funds for the Central Universities [grant number 21618412;grant number 21618804]; the National Natural Science Foundation of China [grant number 51475095]; Project of Guangdong ;Natural Science Foundation [grant number 2016A030311041]; 2015 Guangdong Special Support Scheme [grant number 2014TQ01X706]; High-level Talent Scheme of Guangdong Education Department [grant number 2014-2016]; the Guangdong Natural Science Foundation [grant number 2017A030313401]; Inner Mongolia Autonomous Region Science and Technology Innovation Guide Award Fund Project [grant number 103-413193]; Key Research Projects of Henan Higher Education Institutions[grant number 19A630037]. References [1] Mont, O.K.: Clarifying the concept of product-service system, J Clean Prod; 2002, 10, (3), p. 237-245. [2] Bittremieux, W., Valkenborg, D., Martens, L., and Laukens, K.: Computational quality control tools for mass spectrometry proteomics, Proteomics; 2017, 17, (3-4), p. 11. [3] Kuo, T., and Mital, A.: QUALITY-CONTROL EXPERTSYSTEMS - A REVIEW OF PERTINENT LITERATURE, J. Intell. Manuf.; 1993, 4, (4), p. 245-257.
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