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TQM could help your SMR
V
IEWPOINT
TQM could help your SMR
John Hayes is consultant and freelance journalist specializing in the plastics industry.
A m o n g s t the various fascinating items of statistical e r u d i t i o n performed by the UK g o v e r n m e n t d e p a r t m e n t responsible for p o p u l a t i o n censuses, is a n actuarial guide to life e x p e c t a n c y related to occupation. This is compiled as a r a t i n g with the r a t h e r sombre title of the S t a n d a r d i z e d Mortality Ratio (SMR). The general idea is t h a t a n SMR in excess of 100 indicates t h a t your work could adversely affect your life e x p e c t a n c y (a conclusion you have p r o b a b l y reached at some time!). The reason for m e n t i o n i n g SMRs is t h a t in the c u r r e n t data, the d i s t i n c t i o n of h e a d i n g the table for males, with a rating of 531, w e n t to 'foremen a n d inspectors involved in the m a n u f a c t u r e of plastic goods'. T h a t 531 gives cause for reflection when one considers t h a t m a r k e t i n g a n d sales executives, economists, a n d 'other professional m a n a g e m e n t ' rated 64-66 a n d t h a t financial m a n a g e r s a n d cost a c c o u n t a n t s , both fairly stressful occupations, one would think, get away with a comforting 43 a n d 50 respectively. But w h a t m a k e s it so p u n i s h i n g to be a n i n s p e c t o r or f o r e m a n in a plastics m o u l d i n g p l a n t ? Could it be difficult c u s t o m e r s d e m a n d i n g the impossible? Every t r a d e m o u l d e r knows t h a t miracles m u s t be performed weekly -- if not daily -- for some clients. Or could it have been t h a t s t a r t of w h a t has b e e n t e r m e d 'the q u a l i t y revolution'? There is no d o u b t t h a t the move to total quality m a n a g e m e n t (TQM) has had a significant i m p a c t on plastics processing generally, a n d not j u s t in those c o m p a n i e s where a Ford Q1 r a t i n g is m o r e s a c r o s a n c t t h a t the Ten Commandments. P r e s u m a b l y if everyone in the c o m p a n y has been involved in -- a n d is totally c o m m i t t e d to -the c o n c e p t of zero defect working a n d the idea t h a t all employees are suppliers to, a n d customers for, others in the firm, t h e n pressure on the f o r e m a n a n d inspectors should be reduced. But I bet it isn't. It is going to take at least a g e n e r a t i o n to e l i m i n a t e the i n h i b i t i o n s a n d practices associated with w h a t has been called ' m a n a g e m e n t by blame'. We have to encourage p e r s o n n e l to use i n i t i a t i v e . It p r o b a b l y m e a n s r e s t o r i n g t h a t q u a l i t y which some J e r e m i a h s say has b e e n totally lost by m a n y British workers -- pride in workmanship. It m e a n s g e t t i n g rid of all t h o s e s t a t u s divisions a n d symbols which still lurk in m u c h of British c o m p a n y life. E l i m i n a t e the %vorks versus m a n a g e m e n t ' s y n d r o m e a n d the departm e n t a l barriers, teach employees to use techniques like statistical process control, t r a i n t h e m how to talk to s u p p l i e r s a n d c u s t o m e r s a n d you s t a r t to get co-operation -- individually a n d collectively -- in the quest for quality improve-
REINFORCED PLASTICS MAY 1992
raent. People operating in self-directed teams, responsible for ordering their own materials a n d e s t a b l i s h i n g their own p r o d u c t i o n p r o g r a m m e s soon realize t h a t getting it right first time is a lot c h e a p e r t h a n p u t t i n g it right w h e n a n error is discovered. It m a y be argued t h a t m a n y of the a p p l i c a t i o n s for reinforced composites a r e short r u n s or oneoffs p r o d u c e d by small groups in which the designer is part of the m a n u f a c t u r i n g team. Not for t h e m the p r o b l e m s associated with volume p r o d u c t i o n by w h a t are d i s p a r a g i n g l y called ' b u t t o n pushers'. Obviously there are m a n y such applications: b u t increasingly sheet a n d bulk m o u l d i n g c o m p o u n d (SMC/BMC) is being injection m o u l d e d in q u a n t i t i e s which bring t h e m into the ' b u t t o n p u s h e r ' category. A criticism from a u t o m o b i l e m a n u f a c t u r e r s has been t h a t reinforced materials lack the physical properties a n d processing technology to ensure consistency in the m o u l d e d qualities needed for volume car production. So if zero defects p r o d u c t i o n t e c h n i q u e s a n d total quality m a n a g e m e n t is n o t already high on the priority list for c o m p a n i e s processing reinforced materials, there could be good reason for t h e m to make good the omission. C o m p u t e r algorithms for analysing composite l a m i n a t e s t r u c t u r e are commercially available. They allow a designer to e x a m i n e the stress/ s t r a i n b e h a v i o u r of a c o m p o n e n t section by section a n d to modify materials a n d reinforcem e n t lay-up u n t i l h e / s h e achieves the desired properties. If the design is too complex for l a m i n a t e analysis (e.g. where there are curved or closed shapes of variable thickness) it is p o s s i b l e to use a m o r e s o p h i s t i c a t e d finite e l e m e n t analysis (FEA). Either way the use of a c o m p u t e r p r o g r a m greatly reduces design unpredictability. It also makes it feasible to take a d v a n t a g e of the c o n s i s t e n t processing accuracy now available with improved p r o g r a m m a b l e control systems on modern injection machines and the more sophisticated loading a n d curing controls for resin t r a n s f e r m o u l d i n g (RTM). Moulds, too, are becoming less of a black art. Following successful a p p l i c a t i o n to f i l a m e n t winding, c o m p u t e r aided e n g i n e e r i n g (CAE) is now being used to predict the results of preform geometry a n d the influence of gate a n d vent location in RTM a n d s t r u c t u r a l reaction injection m o u l d i n g (SRIM). Which brings us back to the need to improve the h u m a n element. Because if we don't, plastic m o u l d i n g shop f o r e m a n a n d inspectors are still going to be carrying a n d actuarial h a n d i c a p w h e n the n e x t p o p u l a t i o n census is conducted.
John Hayes •
IEWPOINT
TQM could help your SMR
John Hayes is consultant and freelance journalist specializing in the plastics industry.
A m o n g s t the various fascinating items of statistical e r u d i t i o n performed by the UK g o v e r n m e n t d e p a r t m e n t responsible for p o p u l a t i o n censuses, is a n actuarial guide to life e x p e c t a n c y related to occupation. This is compiled as a r a t i n g with the r a t h e r sombre title of the S t a n d a r d i z e d Mortality Ratio (SMR). The general idea is t h a t a n SMR in excess of 100 indicates t h a t your work could adversely affect your life e x p e c t a n c y (a conclusion you have p r o b a b l y reached at some time!). The reason for m e n t i o n i n g SMRs is t h a t in the c u r r e n t data, the d i s t i n c t i o n of h e a d i n g the table for males, with a rating of 531, w e n t to 'foremen a n d inspectors involved in the m a n u f a c t u r e of plastic goods'. T h a t 531 gives cause for reflection when one considers t h a t m a r k e t i n g a n d sales executives, economists, a n d 'other professional m a n a g e m e n t ' rated 64-66 a n d t h a t financial m a n a g e r s a n d cost a c c o u n t a n t s , both fairly stressful occupations, one would think, get away with a comforting 43 a n d 50 respectively. But w h a t m a k e s it so p u n i s h i n g to be a n i n s p e c t o r or f o r e m a n in a plastics m o u l d i n g p l a n t ? Could it be difficult c u s t o m e r s d e m a n d i n g the impossible? Every t r a d e m o u l d e r knows t h a t miracles m u s t be performed weekly -- if not daily -- for some clients. Or could it have been t h a t s t a r t of w h a t has b e e n t e r m e d 'the q u a l i t y revolution'? There is no d o u b t t h a t the move to total quality m a n a g e m e n t (TQM) has had a significant i m p a c t on plastics processing generally, a n d not j u s t in those c o m p a n i e s where a Ford Q1 r a t i n g is m o r e s a c r o s a n c t t h a t the Ten Commandments. P r e s u m a b l y if everyone in the c o m p a n y has been involved in -- a n d is totally c o m m i t t e d to -the c o n c e p t of zero defect working a n d the idea t h a t all employees are suppliers to, a n d customers for, others in the firm, t h e n pressure on the f o r e m a n a n d inspectors should be reduced. But I bet it isn't. It is going to take at least a g e n e r a t i o n to e l i m i n a t e the i n h i b i t i o n s a n d practices associated with w h a t has been called ' m a n a g e m e n t by blame'. We have to encourage p e r s o n n e l to use i n i t i a t i v e . It p r o b a b l y m e a n s r e s t o r i n g t h a t q u a l i t y which some J e r e m i a h s say has b e e n totally lost by m a n y British workers -- pride in workmanship. It m e a n s g e t t i n g rid of all t h o s e s t a t u s divisions a n d symbols which still lurk in m u c h of British c o m p a n y life. E l i m i n a t e the %vorks versus m a n a g e m e n t ' s y n d r o m e a n d the departm e n t a l barriers, teach employees to use techniques like statistical process control, t r a i n t h e m how to talk to s u p p l i e r s a n d c u s t o m e r s a n d you s t a r t to get co-operation -- individually a n d collectively -- in the quest for quality improve-
REINFORCED PLASTICS MAY 1992
raent. People operating in self-directed teams, responsible for ordering their own materials a n d e s t a b l i s h i n g their own p r o d u c t i o n p r o g r a m m e s soon realize t h a t getting it right first time is a lot c h e a p e r t h a n p u t t i n g it right w h e n a n error is discovered. It m a y be argued t h a t m a n y of the a p p l i c a t i o n s for reinforced composites a r e short r u n s or oneoffs p r o d u c e d by small groups in which the designer is part of the m a n u f a c t u r i n g team. Not for t h e m the p r o b l e m s associated with volume p r o d u c t i o n by w h a t are d i s p a r a g i n g l y called ' b u t t o n pushers'. Obviously there are m a n y such applications: b u t increasingly sheet a n d bulk m o u l d i n g c o m p o u n d (SMC/BMC) is being injection m o u l d e d in q u a n t i t i e s which bring t h e m into the ' b u t t o n p u s h e r ' category. A criticism from a u t o m o b i l e m a n u f a c t u r e r s has been t h a t reinforced materials lack the physical properties a n d processing technology to ensure consistency in the m o u l d e d qualities needed for volume car production. So if zero defects p r o d u c t i o n t e c h n i q u e s a n d total quality m a n a g e m e n t is n o t already high on the priority list for c o m p a n i e s processing reinforced materials, there could be good reason for t h e m to make good the omission. C o m p u t e r algorithms for analysing composite l a m i n a t e s t r u c t u r e are commercially available. They allow a designer to e x a m i n e the stress/ s t r a i n b e h a v i o u r of a c o m p o n e n t section by section a n d to modify materials a n d reinforcem e n t lay-up u n t i l h e / s h e achieves the desired properties. If the design is too complex for l a m i n a t e analysis (e.g. where there are curved or closed shapes of variable thickness) it is p o s s i b l e to use a m o r e s o p h i s t i c a t e d finite e l e m e n t analysis (FEA). Either way the use of a c o m p u t e r p r o g r a m greatly reduces design unpredictability. It also makes it feasible to take a d v a n t a g e of the c o n s i s t e n t processing accuracy now available with improved p r o g r a m m a b l e control systems on modern injection machines and the more sophisticated loading a n d curing controls for resin t r a n s f e r m o u l d i n g (RTM). Moulds, too, are becoming less of a black art. Following successful a p p l i c a t i o n to f i l a m e n t winding, c o m p u t e r aided e n g i n e e r i n g (CAE) is now being used to predict the results of preform geometry a n d the influence of gate a n d vent location in RTM a n d s t r u c t u r a l reaction injection m o u l d i n g (SRIM). Which brings us back to the need to improve the h u m a n element. Because if we don't, plastic m o u l d i n g shop f o r e m a n a n d inspectors are still going to be carrying a n d actuarial h a n d i c a p w h e n the n e x t p o p u l a t i o n census is conducted.
John Hayes •