Initial Exercises—Quality Management 3 (Inventory)

Initial Exercises

Purpose: The purpose of these initial exercises is to demonstrate the basic functionality of Quality Management for Inventory. The following exercises are included:

IMPORTANT
These initial exercises are intended for instructor use.

If you are a student, it is extremely important that you set up and work within your own site to maintain your data integrity. If you work within any other site, you will compromise your own exercise data as well as the data of other students. Predictable exercise results require that your data be isolated in your own site.

Creating a Design Failure Modes and Effects Analysis (FMEA)

Purpose: The purpose of this exercise is to introduce the student to the basic functionality of design FMEAs. Note: The steps involved in setting up process FMEAs are similar to the ones described below.

Prerequisites: The part shown below is required for these exercises and has already been entered in the Racing TM database.

Part Name Part No. Operation Area of Concern
Intake Valve 29-521 Compression testing for valve seat leakage Poor performance due to compression escaping past the valve seats 

Menu Path: Failure Modes and Effects Analysis/FMEA Basic Data/Basic Data for FMEA
Manufacturing Standards/Structures/Product Structure
Manufacturing Standards/Design Failure Modes and Effects Analysis/Design FMEA Graphic
Manufacturing Standards/Design Failure Modes and Effects Analysis/Design FMEA Effects Analysis Graphic

Steps: To complete this exercise, perform the following steps.

  1. Setting up basic data—Open the Basic Data for FMEA window and click the Classification Criteria tab.
  2. Select a line and create a new record (F5).
  3. Enter a value in the Class Criteria field and a description in the Class Description field (for example, Critical, Major, Key, or Minor).
  4. Click the Checklist Templates tab.
  5. Select a line and create a new record (F5)
  6. Enter a sequence number, checklist question, and checklist comment.
  7. Save the information (F12).
  8. Creating an FMEA header—Open the Product Structure window.
  9. Query (F3) for part no. 29-521, Intake Valve.
  10. Click the Design FMEAs tab and create a new record (F5).
  11. In the Alternate field, select the a structure alternate from the List of Values (F8).
  12. In the FMEA Level list, select Component.
  13. Save the information (F12).
  14. Verify that the FMEA status shown in the Status field has changed to Created.
  15. Adding a checklist—Select a line on the Design FMEAs tab of the Product Structure window.
  16. Right-click and then click Design FMEA Checklist. The Design FMEA Checklist window appears.
  17. Enter at least one new checklist line. You can also delete checklist lines.
  18. Select the Item Approved check boxes to approve the respective checklist items. Then save the information (F12) and close the window.
  19. In the Product Structure window, verify that the checklist status has changed to Approved.
  20. Query (F3) for part no. 29-521, Intake Valve, in the Product Structure window. Verify that the checklist status has changed to Approved.
  21. Adding a function—Open the Design FMEA Graphic window and query (F3) for part no. 29-521, Intake Valve.
  22. Expand the graphic structure shown on the left and select the structure alternate. A window appears on the right.
  23. Select a line and create a new record (F5). Enter a function (for example, Seal) and a function description (for example, Maintain Pressure). 
  24. Save the information (F12). The function now appears in the graphic structure on the left.
  25. Entering a failure mode—In the Design FMEA Graphic window, select the Seal function you just created in the graphic structure on the left. A window appears on the right.
  26. Select a line and create a new record (F5).
  27. Enter a failure and a failure description (for example, Loss of Pressure). 
  28. In the Occurrence field, select a value from the List of Values (for example, 7– High – Repeated Failures).
  29. Save the information (F12).
  30. Entering a cause of failure—In the Design FMEA Graphic window, click the Causes tab.
  31. Select a line and create a new record (F5).
  32. Enter a cause and a cause description (for example, Machined Incorrectly).
  33. Save the information (F12).
  34. Entering an effect of failure—In the Design FMEA Graphic window, click the Effects tab.
  35. Select a line and create a new record (F5).
  36. Enter an effect and an effect description (for example, Valve Seat Leakage).
  37. Select a severity from the List of Values (F8) (for example, 8 – Very High).
  38. Select a classification criterion from the List of Values (F8).
  39. Save the information (F12).
  40. Expand the graphic structure on the left and verify that the causes and effects have been added.
  41. Entering controls and recommendations—In the Design FMEA Graphic window, select an effect in the graphic structure on the left (the lowest accessible level). A window appears on the right.
  42. On the Controls tab, select a line and then create a new record (F5).
  43. Enter a control and a control description (for example, Valve Seat Leak Check).
  44. In the Detection field , enter a value from the List of Values (F8) (for example, 2 – Very High).
  45. Save the information (F12).
  46. Verify that the risk priority number (RPN) is calculated in the RPN field. If you have used the examples in this exercise, the RPN should be 112 (8*7*2). (Severity = 8, Occurrence = 7, and Detection = 2).
  47. On the Recommendations tab, select a line and then create a new record (F5).
  48. Enter a recommendation and a recommendation description (for example, Inspection). 
  49. Enter a responsible person and a target completion date.
  50. Save the information (F12).
  51. Expand the graphic structure on the left and verify that the controls and recommendations have been added.
  52. Viewing the graphic analysis—Open the Design FMEA Effects Analysis Graph window and query (F3) for part no. 29-521, Intake Valve. A graph appears displaying severity and occurrence. The effects in the upper right corner are the most serious ones.
  53. Close all windows.

Creating a Control Plan for Inventory

Purpose: The purpose of this exercise is to familiarize the student with the basic functionality of Inventory control plans.

Menu Path: Quality Management/Control Plan/Control Plan – Inventory

Steps: To complete this exercise, perform the following steps in the sequence shown.

  1. Open the Control Plan – Inventory window.
  2. Query (F3) for the control plan for part no. 29-521, Intake Valve. 
  3. Point out the mandatory fields in the control plan header.
  1. Right-click in the header and then click Checklist to create a checklist. A new window appears.
  2. Show the students where to enter new checklist items. (Note: In this case, you cannot enter any new items since the control plan has Active status).
  3. Close the Checklist window.
  4. Verify that the checklist status is Approved (because all checklist items are selected).   
  5. Verify that the control plan status is Active.
  6. On the Control Plan Line tab, select a control plan line and point out the mandatory fields.
  1. Activate the control plan by right-clicking in the control plan header and then clicking Active. (Note: This control plan already has Active status.)
  2. Right-click on the control plan line and then click Setup SPC Data. A new window appears. Explain the different SPC setup options.

Creating an Analysis and Entering Test Results

Purpose: The purpose of this exercise is to familiarize the student with the basic functionality of creating analyses and entering test results for an inventory part.

Menu Path: Quality Management/Control Plan/Control Plan – Inventory

Steps: To complete this exercise, perform the following steps in the sequence shown.

  1. Open the Control Plan – Inventory window.
  2. Right-click in the header and then click Create Analysis. The Create Analysis – Inventory window appears.
  3. Select or clear the Print Test Instruction check box. Then click OK. 
  4. A message appears informing you that an analysis has been created and asking you whether you would like to enter test results. Click Yes. The Analysis Results – Inventory window appears.
  5. Verify that the status of the test operation line is Incomplete.
  6. Select the Attribute test operation line, and enter the number of defective parts in your sample in the Nonconforming (np, p) field.
  7. Right-click on the test operation line and then click Complete Registered Results. Verify that the status for the test operation line has changed to Complete.

  8. Right-click in the header and then click Confirm Registered Result. Verify that the status of the test operation line has changed to Confirmed.

Creating an Attribute Chart (p Chart) for an Inventory Part

Purpose: The purpose of this exercise is to familiarize the student with the basic functionality of creating control charts for an inventory part.

Menu Path: Quality Management/Control Plan/Control Plan – Inventory

  1. Open the Control Plan – Inventory window and query for part no. 29-521, Intake Valve.
  2. Verify that the control plan has Active status.
  3. On the Control Plan Line tab, select the Seat Leak Check control plan line. Then right-click and click Create SPC Chart. The Create SPC Chart window appears.
  4. Under Analysis Date, enter dates in the From and To fields.
  5. Click OK.
  6. A message will appear, and you will be asked whether you want to view the chart. Click Yes. The chart appears.
  7. View the chart. In accordance with the selection made during SPC setup, a p chart is shown. One point for each analysis appears on the x-axis.
  8. Verify that mean value, standard deviation, upper control limit (UCL), centerline (CL), and lower control limit (LCL) are calculated and shown in the left part of the window.
  9. Verify that the diagram status is Out of Control if at least one analysis falls outside the control limits, or that it is In Control if all analysis data is within the control limits.
  10. Take a closer look at the chart. Do you see any points out of control? Do you see any obvious non-random patterns?

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