In-Process Quality Control

forManufacturing

WILLIAM E. BARKMAN Martin Marietta Systems, Inc.

Oak Ridge, Tennessee

MARCEL DEKKER, INC. New York and Basel

Contents

Preface iii

1. Introduction

2. Statistical Descriptions of Process Quality 9

Introduction 9 Populations and Samples 17 Probability Distributions 21 External Reference Distribution 29 Summary 30

3. Deterministic Manufacturing 31

Introduction 31 Types of Manufacturing Operations 35 Machine Accuracy 37 Tooling Accuracy 42

vii

VIM Contents

Error Sources 44 Process Parameters 48 Error Conditions 51 Operating Strategy 60 Summary 68 References 69

4. Statistical Control of Manufacturing Processes 71

Introduction 71 Random Sampling for Acceptance 72 Confidence Limits 75 Control Charts 76 Error Budgets 89 References 92

Sensors 93

Introduction 93 Position Sensors 98 Condition Sensors 109 Sensor Interfaces 114 Sampling Theorem 118 Machine Vision Systems 120 References 122

6. Process Monitor ing 123

Introduction 123 Postprocess Monitoring 129 In-Process Monitoring 130 Process Models 145 References 151

7. Computer-Controlled Manufacturing 153

Introduction 153 Set-Point Control 156 Programmable Logic Controllers 159

Conten ts

Numerical Control Computer Numerical Control Direct Numerical Control Computer-Aided Manufacturing Computer-Integrated Manufacturing Knowledge-Based Systems References

8. Computer Networks

Introduction Data Path Hardware and Associated Jargon Local and Host Computers Network Communications ISO Reference Model Manufacturing Automation Protocol System Reliability Enhancement References

9. System Software

Introduction Computer Control Executive Programs Direct Numerical Control Software Process Monitoring Software Data Base Software Process Analysis Software Error Compensation Software Modeling Software References

10. System Integration

Introduction Hardware Integration Software Integration Integration of Statistical Methods Facility Integration Summary References

X Contents

Factory of the Future

Introduction Manufacturing Cells Flexible Manufacturing Systems Material Handling Fault Tolerance References

255

255 258 265 267 269 272

Index 275