Rekayasa Kualitas. Materi ke 1 Pendahuluan.

Transkripsi

1 Rekayasa Kualitas Materi ke 1 Pendahuluan eko@uns.ac.id

2 Agenda Hari Ini Tentang kuliah ini Tentang saya Pendahuluan

3 Tentang kuliah ini Waktu kuliah : Senin, Waktu konsultasi : Senin, Homepage kuliah : eko.staff.uns.ac.id/rekayasakualitas Silabus, Penilaian and Referensi Jadwal kuliah

4 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.

5 Silabus, Penilaian and Referensi Isi Mata kuliah : Pendahuluan : dasar-dasar rekayasa kualitas, kualitas dan kemampuan process 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

6 Silabus, Penilaian and Referensi Isi Mata kuliah : Mengelola Eksperimen : proses menyelesaikan masalah, eksperimen perancangan kokoh, eksperimen industri 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

7 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 dari 75%

8 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 ) Nilai Akhir ( NA ) = 0.25 KD KD KD KD4

9 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 : 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.

10 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 7. Overall evaluation team members performance for project

11 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 NA < 35 E 0

12 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, Genichi Taguchi, Subir Chowdhury, Yuin Wu, Taguchi s Quality Engineering Handbook, John Wiley & Sons, Inc., Hoboken, New Jersey, 2005

13 Rencana Kuliah

14 Rencana Kuliah

15 Tentang saya Academics Background 1993 : Undergraduate, Mathematics ITB 1998 : Graduate, Industrial Engineering ITB 2012 : Doctoral, Mechanical Engineering, UGM Research Interest : Biomaterial, Quality Engineering and Optimization Status Hobbies : Married, 4 boys : Iqro, Studying and Teaching

16 Posisi mata kuliah ini Statistik I Pengendalian Kualitas Statistik II OR I-II Perancangan Eksperimen Rekayasa Kualitas Matriks dan Vektor

17 Definition of Quality Quality means different things to different people ( Juran, Deming, Crosby, Garvin and Feigenbaum ) Taguchi We measure the quality of a product in terms of the total loss to society due to functional variation and harmful side effects

18 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 Engineer.

19 Quality Engineering Course dan Research

20 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.

21 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.

22 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 dan peningkatan kualitas, serta implementasi konsep Total Quality Management, Six Sigma, dan perbaikan berkelanjutan. S2 - ITS

23 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 secara sistematik.

24 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 simultaneously

25 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.

26 Who is Taguchi? Source :

27 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.

28 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 Approach is just one of the many tools.

29 WHAT S NEW? Philosophy! Traditionally, quality activities took place only at the production end. Dr. Genichi Taguchi proposed that a better way to assure quality is to build it in the product by designing quality into the product

30 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 The best way is to build quality into the design DO IT IN DESIGN. DESIGN QUALITY IN: Does not replace quality activities in production Must not forget to do quality in design

31 WHAT S NEW? Philosophy! A few popular techniques used in different phases of engineering activities Phases of engineering activities Design Development Test & Validation Production Techniques Design Reviews, DOE, Taguchi methods, etc. DOE, Taguchi Methods, Growth Modeling, etc. Reliability, Taguchi Methods SPC, DOE, Taguchi Methods, Loss Function

32 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. The Biggest Bang For Your Buck A B C D Design Development Test & Validation Production

33 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 quantify the cost of quality

34 WHAT S NEW? Loss Function! LOSS FUNCTION : A formula to quantify the amount of loss based on deviation from the target performance. $Loss 2 L=K(y -Y o ) Target y Y o

35 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.

36 WHAT S NEW? Definition of Quality! CONSISTENCY OF PERFORMANCE Target Target Target

37 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 deviation ().

38 WHAT S NEW? Definition of Quality! Target What you are now m What you want to become Mean Target To improve quality (Q) Q = + m

39 WHAT S NEW? Discipline! BRAINSTORMING: Plan experiments and follow through. TEAM WORK: Work as a team and not alone. CONSENSUS DECISIONS: Make decisions democratically as a team. Avoid expert based decisions. COMPLETE ALL EXPERIMENTS planned before making any conclusions.

40 WHAT S NEW? Discipline! Typical Old Approach (Series Process) Some thinking Try this Some more thinking Try that

41 New Approach (A Parallel Process) Do Lots Of Thinking (Brainstorming) - What are we after? - How do we measure results? - etc. Application Steps I. Planning II. Designing Trial#1 Trial#2 Conduct Experiments III. Doing Analyze Results IV. Analyzing Run confirmation Experiments V. Confirming

42 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.

43 WHY TAGUCHI APPROACH? Experimental Efficiency Easy Application And Data Analysis Higher Probability Of Success Option To Confirm Predicted Improvement Quantified Improvement Improve Quality And Profitability

44 WHEN and WHERE to apply Solve manufacturing and production problems Optimize process designs Optimize product designs Apply when more than one factor influences the outcome

45 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 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

46 Pertemuan Selanjutnya Dasar-dasar rekayasa kualitas Metoda Taguchi Kualitas dan kemampuan proses Referensi : Belavendram, hal 1 40 Phadke, hal 1 9 ( Jadi Tugas 1 )