Hinckley, C. Martin and Philip Barkan, "The
Role of Error, Variation, and Complexity in Manufacturing Defects," Journal
of Quality Technology, Vol 27, No 3, July 1995., pp. 242-249.
Description: Many events which result in
defects, such as omitting a part during assembly, can only be described in
terms of probability. Such errors occur more frequently than predicted based
on variation models using traditional Statistical Process Control. Reducing
product complexity eliminates opportunities for both error and excessive
variation. Based on strong correlation’s between defect rates and complexity,
a new method is presented for estimating and comparing the relative potential
defect rates of products during the earliest stages of concept development.
Hinckley, C. Martin and Philip Barkan,
"Quality Advisor-The Secret to Understanding Product Defects," Manufacturing
Engineering, Vol 112 No 4, April 1994, p. 10.
Description: Brief description of the
impact of error, variation, and product complexity on defects. A singular
focus on any one of these three sources of defects leads to diminishing
returns that will not achieve world class defect rates in the range of 1-10
ppm.
"Reducing product defects during design," Mechanical Engineering, Vol 116 No 4, April 1994, pp. 66-68.
Description: An interview by the Stanford
University News Service with Professor Barkan. The discussion provides a
general description of the concepts developed in the dissertation.
Hinckley, C. Martin, A Global
Conformance Quality Model-A New Strategic Tool for Minimizing Defects Caused by
Variation, Error, and Complexity, Mechanical Engineering Ph.D. Dissertation,
Stanford University, December 1993.
Description: The dissertation provides a
detailed discussion of the role of error, variation, and product complexity in
manufacturing defects. Toward the goal of relating complexity to defects,
Design for Assembly (DFA) methods are compared, and the distribution of
assembly operation times are shown to follow a Pareto Distribution. Defect
rates, which also follow a Pareto distribution, are shown to be highly
correlated with assembly complexity. New methods are given for, 1) estimating
and comparing defect rates of products in the earliest stages of concept
development, 2) characterizing the relative control of variation and error for
each organization, and 3) defining a Quality improvement strategy that
addresses error, variation and complexity.
Available through UMI or NTIS
(SAND94-8451, January 1994)
|
University Microfilms
International (UMI)
Department 77304
Detroit, Michigan
48277-0304
Phone No. (313)
761-4700
|
National Technical
Information Service (NTIS)
US Department of
Commerce
5285 Port Royal Road
Springfield, VA
22161
|
Barkan, Philip and C. Martin Hinckley, "The
Benefits and Limitations of Structured Design Methodologies," Manufacturing
Review, Vol. 6 No. 3, Sep. 1993, pp. 221-220.
Description: Using case studies, this
article demonstrates that poor design decisions have sometimes resulted from
blindly following popular Design for Manufacturability (DFM) rules. Correct
application of DFM concepts requires critical thinking. When applied with
sound judgment, DFM guidelines can have many benefits. For example, defect
rates at Motorola in this preliminary comparison have been found to be highly
correlated with complexity measured using Design for Assembly methods.
Barkan, Philip and C. Martin Hinckley,
"Selecting the Best Defect Reduction Methodology," Article accepted for
Publication in Quality and Reliability Engineering, 1996.
Description: Each quality control method
focuses on different aspects of quality control. Heretofor, selection of
quality control methods has been based on a general sense that the methodology
will improve quality. However, the selection of the best method for each
organization depends upon its specific strengths and weaknesses. This article
presents a comprehensive model which helps each organization identify its
quality strengths and weaknesses, and the best method for its specific needs.
Hinckley, C. Martin, "Defining the Best
Quality Control Systems by Design and Inspection, Article Selected for
Publication in Clinical Chemistry, 1997.
Description: This article describes the
evolution of inspection methods beginning with "judgment" inspections, and
inspections used in Statistical Quality Control which provide feedback
control. The difference between these inspection methods and Source
inspection, the most modern and effective quality control method, is
explained. Examples from the medical field illustrate the importance of source
inspection methods which can eliminate defects at their source.
Hinckley, C. Martin, Quality By Design -
Eliminating Defects through the Control of Variation, Mistakes, and Complexity,
Tutorial Manual, Assured Quality, Manteca 1996.
Description: An introduction to the
limitations of traditional quality control methods and the Zero Quality
Control concepts developed by Shigeo Shingo at Toyota, including
mistake-proofing (poka-yoke) and Source Inspection. The tutorial also
introduces the role of the product design and complexity in quality control.
Techniques for benchmarking quality control, predicting the defect rates of
new products, and comparing the quality potential of new product concepts are
presented.
Hinckley, C. Martin, "Statistical
Evaluation of the Variation in Laminated Composite Properties Resulting from Ply
Misalignment," SPIE, Vol 1303, Advances in Optical Structure Systems, 1990, pp.
497-511.
Description: Although thermally stable
structures can be constructed from composite materials, the sensitivity of
real structures to thermal strains is always greater than theoretically
predicted. Using Monte Carlo methods, this article demonstrates that the
deviations in laminate properties from the theoretically ideal state can be
predicted. This analysis has lead to a new method of forming composites which
minimizes the impact of layer to layer variations. The analytical and
fabrication techniques have become the standard for fabricating composite
structures requiring the highest level of structural stability.
