Product reliability–oriented optimization design of time-between-events control chart system for high-quality manufacturing processes

Chen, Zhaoxiang; He, Yihai; Cui, Jiaming; Han, Xiao; Zhao, Yuan; Zhang, Anqi; Zhou, Di

doi:10.1177/0954405419863219

Cited by 10 publications

(6 citation statements)

References 28 publications

(30 reference statements)

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“…If a failure occurs under warranty, the company must replace or repair it according to its policy. 35 Thus, the warranty is a more concrete specification of the lower limit of the product's lifetime. By substituting 𝐿 with the warranty, symbolised as 𝑊, Equation ( 5) can be rewritten as follows:…”

Section: Lifetime Capability Index With Weibull-distributed Accelerat...mentioning

confidence: 99%

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A modified reliability acceptance sampling plan with warranty return rate consideration under Weibull‐distributed accelerated lifetime data

Wang,

Shu

2024

Quality & Reliability Eng

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Warranty is a standard and essential policy for today's products. The period and cost of warranty are majorly affected by the reliability of products. Therefore, validation and verification of product reliability are required to control warranty costs and sustain the brand reputation. In this paper, we propose a modified reliability acceptance sampling plan (MRASP) for product reliability validation. The operating characteristic function of the MRASP is derived by considering the accelerated time‐to‐failure data with Type‐II censoring, which follows a Weibull distribution. To minimize the number of failures required for the accelerated life test and consider the sampling risk constraints, we constructed an optimization model to determine the optimal plan design of the proposed MRASP. Following the optimal plan design, practitioners can set the number of failures required in the accelerated life test to estimate the lifetime capability of the submitted lot and decide the lot disposition using the acceptance benchmark. In addition, the lifetime capability estimation can be used to infer the warranty return rate and warranty cost of the lot, which is valuable for practitioners to formulate the warranty budget. Finally, we illustrate a real‐world case to demonstrate the practicality and applicability of the proposed method.

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Section: Lifetime Capability Index With Weibull-distributed Accelerat...mentioning

confidence: 99%

“…The warranty is an assurance of the product's reliability. If a failure occurs under warranty, the company must replace or repair it according to its policy 35 . Thus, the warranty is a more concrete specification of the lower limit of the product's lifetime.…”

Section: Lifetime Capability Index With Accelerated Life Test Under A...mentioning

confidence: 99%

A modified reliability acceptance sampling plan with warranty return rate consideration under Weibull‐distributed accelerated lifetime data

Wang,

Shu

2024

Quality & Reliability Eng

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“…In the earliest studies of manufacturing management, production scheduling, maintenance and quality control have been extensively investigated separately in the literature. 1–3…”

Section: Introductionmentioning

confidence: 99%

A two-stage integrating optimization of production scheduling, maintenance and quality

Zheng

Yang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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During the process of actual production, production scheduling, preventive maintenance and quality control have a close interaction with each other and thus need to be integrated for improving manufacturing system performance. The aim of this article is to jointly optimize the job sequence, the preventive maintenance locations, the preventive maintenance interval and decision variables of control chart such that the expected cost per unit time and penalty cost due to schedule delay are minimized. A two-stage integrating optimization model of production scheduling, maintenance and quality in a single machine system is developed. A control chart is adopted to monitor the whole process with Taguchi’s loss function estimating the quality cost of each condition and perfect preventive maintenance activity is conducted at the end of each interval. A genetic algorithm is designed to solve this model in order to obtain the optimal job sequence and the locations of preventive maintenance. Numerical examples and thorough sensitivity analyses are provided to illustrate the proposed integrated model. Finally, the efficiency of the proposed two-stage integration model is verified by the comparison of the stand-alone model under the same condition. Compared with the stand-alone model, the proposed integrated method can save the cost rate by 12%–42% under five different situations.

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“…Thus, quality control is an increasingly important component of competitiveness, especially for the manufacturing industry. 1,2 Process quality not only affects a product's value but is also a crucial determinant of client satisfaction. When Motorola was threatened by competition on the ''process quality'' front, it rolled out a Six Sigma campaign with the goal of improving its process quality, effectively lowering its product defect rate, and raising profitability.…”

Section: Introductionmentioning

confidence: 99%

A fuzzy approach to determine process quality for one-sided specification with imprecise data

Chen

Chang

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Process quality is a crucial determinant of client satisfaction and affects a product’s value; therefore, maintaining quality control is a vital aspect of corporate sustainability and development. Many researchers have developed evaluation models for process quality. The majority of such research assumes that collected measurement data are precise, but fuzziness and stochastic uncertainty are unavoidable features of any collected data. When the measurements of a quality characteristic are insufficiently precise, a crisp-based approach is not suitable for the assessment of process quality. This study endeavored to use one-sided Six Sigma quality indices as measurement tools to accurately reflect process yield and quality levels. Taking Buckley’s approach into consideration, we extend the crisp estimators from the indices into fuzzy estimators. We then develop a fuzzy hypothesis testing method for one-sided Six Sigma quality indices, with the intent of increasing reliability of evaluation for process quality levels. Finally, we present a real-world case to illustrate implementation of the proposed approach, demonstrating its effectiveness and practical applicability.

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Product reliability–oriented optimization design of time-between-events control chart system for high-quality manufacturing processes

Cited by 10 publications

References 28 publications

A modified reliability acceptance sampling plan with warranty return rate consideration under Weibull‐distributed accelerated lifetime data

A modified reliability acceptance sampling plan with warranty return rate consideration under Weibull‐distributed accelerated lifetime data

A two-stage integrating optimization of production scheduling, maintenance and quality

A fuzzy approach to determine process quality for one-sided specification with imprecise data

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