Verification

Introduction In the IDOV methodology this step comes after the Optimization step where the first level of design verification, through design axioms, design guidelines, FEA/FEM analysis, DFX analysis, Design and Process FMEA and concept verification through testing is already done and the design proved for its intended function and reliability through accelerated tests- as a subsystem or as two related subsystems. Operation definition Verification in this V step of IDOV is the first part of Verification and Validation. This step is to verify the following process in the prototype: 1. 2. 3. 4. The design process in integrating all subsystems verifies the DFMEA Initial manufacturing process for the prototype verifies the PFMEA The assembly process The fit between customer requirements and the test protocols.

Verification parameters Where do we start: QUALITY Description Customer requirements as per the eight dimension of Measure-Impact to Function test customer Acceptable output Loss study-the six in absolute terms big losses and *OEE in %age (Overall Equipment Effectiveness ) further defined as the multiplication of AxPxQ Availability % Equipment efficiency or breakdowns Set up and adjustment between batches Performance % Reduced speed Idling and minor stoppages Quality % Start up and shut down losses Yield lossesprocess defects Tools to validate

Performance

Check sheet, Pareto chart in case of deviations and SEDAC tools for any problem solving and Hypothesis tests for performance measures that are enhanced. Multivary study and DOE

Description Features

Measure-Impact to customer Improvement in quality parameters

Function test Specify the improvement over the previous machine and the customer requirement impact Specify the improvement over the previous machine and the customer requirement impact Specs versus actual Dust levels (/cubic mtr) Specs versus actual Functions and hazard level Protocol testing of subsystems and the entire system Quality and Output levels for the verification running hours What is the improvement from the previous machine-what are the values

Tools to validate Hypothesis test after the test protocol

Features

Improvement in flexibility What is inbuilt level of **visual management systems Sound level-dBA

Specify the improvement over the previous machine and the customer requirement impact Xbar chart Check sheet Check sheet Check sheet and job hazard score card MTBF confidence intervals Process Capabilityxbar r charts , standard deviation-bell curve Check list and times

Compliance

Air quality-dust particles/cm3 Vibration levelm/sec Safety needsaccident points No equipment failures-MTBF No loss in performanceprocess capability index

Reliability

Maintainability and serviceability

Durability

Ease of maintenance, Autonomous Maintenance scores for COT, MTTR, -link to equipment failure, MMTS for critical subsystems Planned maintenancefrequency and life cycle costs

Aesthetics

Ergonomics for operation Color impact in terms of appeal Any questionnaire

O V

What is the improvement from the previous machine-what are the durable parts and wear and tear parts What is the improvement from the previous machine..what are the aesthetic parts

Check list and times and cost comparison

Scores as possible

Description

Measure-Impact to customer base index Look good Feel Good Use good Abuse/abnormal conditions of usage

Function test or form What is the improvement from the previous machine-key attributes

Tools to validate Scores through survey

Customer perception

*OEE definitions Overall Equipment Effectiveness defined by the multiplication of Availability % x Performance % x Quality % Availability = Planned run time breakdown time-set up and adjustments time X 100 Planned time Planned time = 24 hrs x 60 minutes any cleaning time &/or planned downtime Performance = actual output on available time 100 Standard output (based on rated speed) on available time Quality = OEE Calculation example Calendar time: 24 hrs x 30 days Operating time: 24hrs x 27 days ( 3 days equivalent for planned down time etc) Therefore A. Availability = (24*27/24*30)*100= 90% Standard Production rate: 1000t/day Actual Production Volume: 1. (500t/day*1 day) + (1000t/day*6 days)+(800t/day*5 days)+(400t/day*1 day)=10900t 2. (500t/day*1 day) + (1000t/day*12 days) + (500t/day*1 day) =13000t Total: 10900+13000= 23900t
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(Total output waste) i.e acceptable output Total output

x 100

Therefore Actual production rate =23900/27=885t/day B: Performance rate = (885/1000) * 100=88.5% If 100t of rejectable product is produced (i.e. yield loss or waste) C. Quality rate :( 23800/23900)*100=99.6% D. Overall Equipment Effectiveness= (A)* (B) *(C) * 100 = (0.9)*(0.885)*(0.966)*100 = 79.3%

** Visual Management Systems

Poka Yoke Jidoka ANDON Standardisation

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Salient Features linked to the 8 dimensions of Quality Notes Descriptor & Verification tool impact location Performance Process capability studies CpK Quantity of yield over previous machine and verify through actual results and hypothesis tests Design efficiency, DFA format Pl mention the design process being verified

Higher production

Upto 1000kg/hr

Modified angle Link to quality Yield grids for better less loss of improvement cleaning good fibre -a feature (gravity extraction)

Less number of moving parts in feeding and dedusting

Earlier and DFM indexcurrent part cost count reduction reduction and through part assembly time count reduction reduction, assembly time reduction Maintainabili ty index i.e reduction in # of parts to be maintained Auto grid Set up time Performance beater setting reductionenhancemen machine t. how much? availability
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Simulation with existing machine and verify the

Notes

Descriptor & Verification tool impact location

Pl mention the design process being verified

improvement Feed roller trio- Presentation for better enhancement compacting for sliver formation? Machine can be installed as stand alone with in built panel arrangement Can accommodate CUBICSACN as optional Continuous suction system What are the drawbacks with existing machine? Is this a delighter? Not now possible

improvement as yes and if so how much. Improving Verify functions performance with existing Yield or parts quality measure and Flexibility Earlier to New feature-time time measure to install is reduced and # of vertical start touches/steps up is a measure? possibility (reduction) Compatibility Space in sq m and space rduction.. reduction? U kg reduction maintainabili ty Feature? Or maintainabili ty How much and hypothesis test and cleanliness index Reduction of strain? Better ergonomics time saving? Cost benefit analysis and efficacy

Current system?

Single platform for coarse and fine cleaning position Replaceable Why nose type feature? beating delighter elements for coarse beater (optional) Specification-dimensions

this Feature A

New Machine Working width Beater diameter Feed rollers diameter Beater type Beater speed
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Earlier machine

Benefit and will be eliminate any dissatisfier, enhance satisfaction and enable delight?

1600 mm 585 mm 100 & 120 mm Pinned/Saw tooth/Optio nal coarse 400750
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New Machine rpm 10.2 kw

Earlier machine

Benefit and will be eliminate any dissatisfier, enhance satisfaction and enable delight?

Power (approx) Overall dimensions

1400x2600 x3500 (LxWxH) Applicable for all Yes type of cottons and MMF upto 60 mm SL

No

Performance as in output consistency, safety and vertical start up after planned maintenanceElectrical Parameters Measure for Earlier verification Amperes New Benefit/improvem ent

Normal functioning of opening roller motor, feed roller motor and flap motor Speed variation of the opening roller through display Speed variation of the feed roller through display Grid movement control through display Material flow based on the feed truck photo cells Option for feeding 1 line and feeding 2 lines Functioning of feed roller safety limit switch Functioning of
I D O

rpm vs time graph consistency and display readability? rpm vs time graph consistency and display readability?

What is the Reduction? variation?

Repeatability

What is the Reduction? variation?

Repeatability

Repeatability?

Start and stop- Not test protocol provided? Feature for flexibility Not provided

Provided and reliable Provided and reliable

What is the What is the fragility and improveme weakness? nt and robustness?
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Measure for Earlier verification beater safety switch lock limit Check vertical start up and simulation Functioning of under stress door safety and abuse and cabinet conditionsafety limit define these conditions..the switches Functioning of conditions to create failures regulating safety limit switch Functioning of beater proximity safety limit switch Functioning of safety actuator at waste collection side Feed roller rpm vs time reverse graph operation consistency through and display display readability? Shift report, What is the fault report in value add and the display to how is be checked diagnostics facilitated?

New Benefit/improvem ent

What is the Reduction? variation?

Repeatability

Not available

available

Test protocol Key Machine Specification and preparation for test Sl No. 1 2 3 4 5 6 7 8 Information for check Is equipped with pinned beater Total # of pins PPSI Pin projection Pin angle Staring suction pressure Microdust suction control WCS suction Measure Yes/no 22135 5 7.5 ? 20 200 pascal Only bleeding air? 1000 pascal How to check Visual check list Count? Count? Vernier if in mm Protractor? Gauge-visual ? Gauge visual

Verification Parameters
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Sl No. 1

Information verification

for Measure @ 400, 600, 800 and 1000 kg/hr

How to verify and charts

Production and quantity details

1.1 1.2

2 3 4

5 6 7 8 9 10

Xbar-r charts and CpK index .Hypo thesis test in comparison with earlier Card Effect of grid setting (1-3 On a check sheet and As 1 above mm) DOE Suitability of 1 or 3mm Hypothesis test grid between 1 and 3 grid on the measures of output and quality Performance of gravity Output? And DOE Hypothesis test on grid over normal grid mean and standard deviation Functioning of automatic Reliability# of MTBF? grid setting continuous running hours before failure? Functioning of flaps in the DOE and Hypothesis test feed duct and effect of performance? between flap and no not using it flap grid on the measures of output and quality? Pressure at outlet at Correlation Repeatable results various production rates coefficient CpK? Pressure at feeding Correlation Repeatable results chamber at various coefficient CpK? production rates Pressure at microdust Correlation Repeatable results extraction at various coefficient CpK? production rates Functioning of safety Reliability# of # of repeated switch in the back swing continuous safe operations-Histogram cover operations? Functioning of beater lock Reliability# of # of repeated continuous safe operations-Histogram operations? Quality with self locking Quality parameters CpK saw tooth beater results..hypothesis tests with and w/o the feature

Accessibility feature- maintainability Sl No. 1 2 3 Information for verification To grids via swing cover comp To photo sensors and limit switches To other machine elements
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Measure Efforts in kgs, or visual One touch, one look, one motion? Without bending, at eye level, within

How to verify and charts Operator feedback? Time and motion study? Ergonomic factors? Tome to set and time

elbow reach etc

to remove and reassemble serviceability index?

Validation

After the verification phase is over for the prototype, the design if necessitated is revised based on inputs from manufacturing and assembly process and results from testing at pilot mill. The prototype is not to be built somehow, but more of what will the mass production represent. Operation definition
Validation in this V step of IDOV is the second part of Verification and Validation. This step is to validate the following process in the building of pilot batch (say 10 and testing: 1. Any design change based on verification 2. Vendor supply consistency quality and quantity 3. Manufacturing process validation for mass production 4. Assembly process validation for mass assembly- confirmation of PFMEA and control plans 5. The relationship between key process input variables and key process output variables in meeting customer requirements. 6. The serviceability aspects Validation protocol Product requirement validation design 1.1 The protocol will be similar to the verification protocol for machines with the related upstream and down stream machines for one year or one cycle of seasons. The statistical tools will be Xbar- r charts, standard deviation, multi vary analysis and of needed DOE and hypothesis tests. It has to be investigated whether response surface modeling will help in maximizing yield. 1.2 Adherence to target cost Vendor supplies 2.1 Capability of vendor to supply consistent quality, in time and target cost Manufacturing Process-suitability for mass production 3.1 Confirmation of manufacturing PFMEA and control plans-CpK index and adherence to optimized manufacturing process 3.2 Capability to manufacture to design
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3.3 Manufacturing time and cost (throughput) Assembly Process suitability for mechanized assembly &/or within standard assembly times 4.1. Confirmation of assembly PFMEA and control plans-adherence to time and motion study based assembly times 4.2 Capability to assemble right first time

4.3 Assembly time and cost (throughput) After the validation phase 1. The knowledge data bank on the design process and guidelines evolved has to be updated 2. Time line achieved through concurrent engineering 3. Standard operating procedure for manufacturing and assembly and procurement items 3. Things gone right and things gone wrong and key learnings to reduce design errors, time to market along with emerged themes and avenues for ideation. After the validation the product can be released for commercialization.

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