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Research Papers

Integrative Technology and Inspection Planning—A Case Study in Medical Industry

[+] Author and Article Information
Fritz Klocke, Patrick Mattfeld

Chair of Manufacturing Technology,
Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Aachen 52074, Germany

Johannes Müller

Chair of Manufacturing Technology,
Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Aachen 52074, Germany
e-mail: jo.mueller@wzl.rwth-aachen.de

Jan Kukulies, Robert H. Schmitt

Chair of Production Metrology
and Quality Management,
Laboratory for Machine Tools and
Production Engineering (WZL),
RWTH Aachen University,
Aachen 52074, Germany

1Corresponding author.

Manuscript received July 31, 2017; final manuscript received January 12, 2018; published online February 15, 2018. Assoc. Editor: Dragan Djurdjanovic.

J. Manuf. Sci. Eng 140(5), 051002 (Feb 15, 2018) (11 pages) Paper No: MANU-17-1489; doi: 10.1115/1.4039114 History: Received July 31, 2017; Revised January 12, 2018

In most trendsetting industries like the aerospace, automotive and medical industry functionally critical parts are of highest importance. Due to strict legal requirements regarding the securing of the functionality of high-risk parts, both production costs and quality costs contribute significantly to the manufacturing costs. Thus, both types of costs have to be taken into consideration during the stage of technology planning. Due to the high variety of potential interactions between individual component properties as well as between component properties and manufacturing processes, the analysis of the influence of the manufacturing history on an efficient design of inspection processes and inspection strategies is extremely complex. Furthermore, the effects of inspection strategies and quality costs on the planning of manufacturing process sequences cannot be modeled to date. As a consequence, manufacturing and inspection processes are designed separately and thus a high cost reduction potential remains untapped. In this paper, a new approach for an integrative technology and inspection planning is presented and applied to a case study in medical industry. At first, existing approaches with regard to technology and inspection planning are reviewed. After a definition of relevant terms, the case study is introduced. Following, an approach for an integrative technology and inspection planning is presented and applied to the case study. In the presented approach, the complex causalities between technology planning, manufacturing history, and inspection planning are considered to enable a cost-effective production process and inspection sequence design.

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Figures

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Fig. 1

Lower case of the LVAD

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Fig. 2

Approach for the presented integrative planning process

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Fig. 3

Defined features and functions of the lower case of the LVAD

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Fig. 4

Identification and reduction of production and inspection processes

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Fig. 5

Potential production and inspection processes

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Fig. 6

Differentiation between direct technology impact and side effects

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Fig. 7

Identification of process effects and their depiction in modules

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Fig. 8

Depiction of the feature relations in a feature-feature-matrix

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Fig. 9

Depiction of the process relations in a process-process-matrix

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Fig. 10

Depiction of the manufacturing history of a production sequence

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Fig. 11

Transfer of the manufacturing history into a probability matrix

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Fig. 12

Determination of strategy dependent probabilities of scrap

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Fig. 13

Procedure to calculate the expected production costs

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Fig. 14

Procedure to calculate the expected inspection costs

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Fig. 15

Exemplary result of the manufacturing cost modeling

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