Ensuring the reliability and reduction of quality control costs by minimizing process variability
			
	
 
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				Poznan University of Technology, Faculty of Mechanical Engineering, Poland
				 
			 
										
				
				
		
		 
			
			
		
		
		
		
			
			 
			Online publication date: 2023-03-26
			 
		 		
		
			
			 
			Publication date: 2023-03-26
			 
		 			
		 
	
							
																			
		
	 
		
 
 
Eksploatacja i Niezawodność – Maintenance and Reliability 2023;25(2):162626
		
 
 
    HIGHLIGHTS
    
    	
    	    	- Methodology of the planning the control while ensuring its reliability and minimizing costs.
- Maintaining the appropriate level of credibility of decisions.
- High variability of seat belts tensile strength.
- Definition of the scope of the acceptance control of belts tensile strength
 
 
KEYWORDS
ABSTRACT
This paper presents a method for planning the range of quality control
while ensuring its reliability and minimizing costs. The method is
dedicated to destructive inspection, in which the cost of performing the
measurement is significant in relation to the cost of manufacturing a part
or product. The methodology was divided into four main stages: (1)
selection of the measurement system and definition of the inspection
scope and sample size, (2) process control, (3) redefining the scope of
control and (4) verification of control cost and reliability after sample
size change. The article presents the results of applying the author's
procedure to the process of evaluating seat belts in automotive industry.
Belts are used in the process of controlling the final product, which is a
seat belt anchor plate. This approach allowed to reduce the number of
destroyed parts during control while maintaining the credibility of the
decision based on the assessment. As a result of double-decreasing the
sample size, the costs of seat belt quality control were reduced.
Assuming an average of 40 seat belt deliveries per year, the material cost
was reduced by 50%. Limiting the sample size to 15 pieces per delivery
would reduce the cost of testing from by 45%. It was achieved
maintaining the appropriate level of credibility of decisions made greater
than 0.8.
		
	
		
    
    ACKNOWLEDGEMENTS
    
    	The results presented in the paper come from the R&D project: 0613/SBAD/4710 by the Faculty of Mechanical Engineering, Poznan University of Technology, Poland.
     
 
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