Rekayasa Kualitas. Materi ke 1 Pendahuluan.

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Rekayasa Kualitas

Materi ke – 1

Pendahuluan

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Agenda

Agenda Hari

Hari Ini

Ini



Tentang kuliah ini



Tentang saya

Pendahuluan

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Tentang kuliah ini

 Waktu kuliah : Senin, 09.20 – 11.05  Waktu konsultasi : Senin, 11.10 – 11.45 Senin, 11.10 – 11.45  Homepage kuliah : eko.staff.uns.ac.id/rekayasakualitas

 Silabus, Penilaian and Referensi  Jadwal kuliah

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Silabus, Penilaian and Referensi

 Prasyarat :

Probabilitas dan Statistik Industri, Pengendalian Kualitas , Desain Eksperimen

 Tujuan :

Membantu mahasiswa untuk memahami dan mengaplikasi metoda Taguchi. Beberapa studi kasus masalah industri diberikan untuk

memahami aplikasi metoda Taguchi secara sistematik.

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Silabus, Penilaian and Referensi

Isi Mata kuliah :

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

Proses Perancangan : proses perancangan , prinsip 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

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Silabus, Penilaian and Referensi

Isi Mata kuliah :

Mengelola Eksperimen : proses menyelesaikan masalah, eksperimen perancangan kokoh , eksperimen industri

Modifikasi Orthogonal Array : perancangan multi Modifikasi Orthogonal Array : perancangan multi

level, perancangan dummy level , perancangan combination factor , perancangan nested-factor , perancangan idle-column , interaksi distribusi

Strategi Perancangan Kokoh

Konsep dan Aplikasi Rekayasa Kualitas Multi Respons State of the art quality engineering

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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

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Silabus, Penilaian and Referensi



Unsur Penilaian

 KD1 = Nilai 100  ( Ujian Tulis )

 KD2 = Nilai 100  ( Ujian Tulis)

 KD3 = Nilai 100  ( Tugas Kelompok dan

Presentasi )

 KD4 = Nilai 100  ( Ujian Akhir Semester )

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Silabus, Penilaian and Referensi

Aturan Tambahan

 Mahasiswa yang tidak mengikuti salah satu KD1, KD2, KD3

dan KD4 yang diadakan dengan ijin yang sah masih mungkin lulus dengan penilaian sebagai berikut :

lulus dengan penilaian sebagai berikut :

 Nilai Akhir ( NA ) = 1.2 x ( jumlah nilai KD yang ikuti )  Mahasiswa yang yang tidak ikut 2 KD dengan ijin yang sah

atau/dan nilai-nya E atau/dan D , WAJIB mengikuti ujian perbaikan dengan nilai maksimum C .

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Silabus, Penilaian and Referensi

Unsur Penilaian Kelompok

Peer 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

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Silabus, Penilaian and Referensi

Angka dan Huruf

NA ≥ 80 A 4

70 ≤ NA < 80 B 3

60 ≤ NA < 70 C 2

40 ≤ NA < 60 D 1

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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.,

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Tentang saya

Academics Background

1993 : Undergraduate, Mathematics ITB

1998 : Graduate , Industrial Engineering ITB

2012 : Doctoral , Mechanical Engineering, UGM 2012 : Doctoral , Mechanical Engineering, UGM Research Interest : Biomaterial , Quality Engineering and Optimization

Status : Married , 4 boys

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Posisi mata kuliah ini

Statistik I Statistik I Statistik II Statistik II Pengendalian Kualitas Pengendalian Kualitas Perancangan Perancangan Statistik II Statistik II Perancangan Eksperimen Perancangan Eksperimen Rekayasa Kualitas Rekayasa Kualitas OR I-II OR I-II Matriks dan Vektor Matriks dan Vektor

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Definition

Definition of

of Quality

Quality



Quality means different things to different

people ( Juran, Deming, Crosby, Garvin and

Feigenbaum )



Taguchi



Taguchi

“We measure the quality of a product in

terms of the total loss to society due to

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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

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Quality Engineering

Course dan Research

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Quality Engineering

Course 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.

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Quality Engineering

Course 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.

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Quality Engineering

Course 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 berbagai alat statistik untuk keperluan pengendalian dan peningkatan kualitas, serta implementasi konsep Total Quality Management, Six Sigma, dan

perbaikan berkelanjutan. S2 - ITS

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Batasan Rekayasa Kualitas

Dalam Kuliah Ini

 Membantu mahasiswa untuk memahami dan

mengaplikasi metoda Taguchi.

 Beberapa studi kasus masalah industri diberikan

untuk memahami aplikasi metoda Taguchi untuk memahami aplikasi metoda Taguchi secara sistematik.

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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

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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.

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Who is Taguchi?

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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.

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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

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WHAT’S NEW? Philosophy !





Traditionally, quality activities took

place only at the production end.



Dr. Genichi Taguchi proposed that a



Dr. Genichi Taguchi proposed that a

better way to assure quality is to build it

in the product by designing quality into

the product

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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

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

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WHAT’S NEW? Philosophy !

 A few popular techniques used in different phases of

engineering activities

Phases of

engineering activities

Techniques engineering activities

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

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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. all activities mentioned above.

The Biggest Bang For Your Buck

A B C D

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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

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WHAT’S NEW? Loss Function!

$Loss

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

Target y

L=K(y -Y_o)

Yo

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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.

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WHAT’S NEW? Definition of Quality!



CONSISTENCY OF PERFORMANCE

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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

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WHAT’S NEW? Definition of Quality!

Target

What you want to become

m

Mean What you are now

Target

m

To improve quality (Q)

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WHAT’S NEW? Discipline!



 BRAINSTORMING: Plan experiments and follow

through.

 TEAM WORK: Work as a team and not alone.

CONSENSUS DECISIONS: Make decisions

 CONSENSUS DECISIONS: Make decisions

democratically as a team. Avoid expert based decisions.

 COMPLETE ALL EXPERIMENTS planned before

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WHAT’S NEW? Discipline!

Typical Old Approach

(Series Process) Some thinking

Try this

Some more thinking

Try this

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New Approach (A Parallel Process) Do Lots Of Thinking (Brainstorming) Trial#1 Trial#2 I. Planning II. Designing Application Steps

- What are we after?

- How do we measure results? - etc. Analyze Results III. Doing IV. Analyzing V. Confirming Run confirmation Experiments Conduct Experiments

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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.

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WHY TAGUCHI APPROACH?



Experimental Efficiency



Easy Application And Data Analysis



Higher Probability Of Success



Higher Probability Of Success



Option To Confirm Predicted

Improvement



Quantified Improvement

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WHEN and WHERE to apply



Solve manufacturing and production

problems



Optimize process designs



Optimize process designs



Optimize product designs



Apply when more than one factor

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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

 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

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Pertemuan Selanjutnya



Dasar-dasar rekayasa kualitas



Metoda Taguchi



Kualitas dan kemampuan proses



Kualitas dan kemampuan proses

Referensi :

Belavendram , hal 1 – 40