Capability Analysis of Drift-Inherent Processes: Case of Nail Wire Drawing

Abstract

Purpose: The central purpose of the study is to model the process capability of drift-inherent manufacturing processes by testing the efficacy of a novel approach that filters trend from raw process data before applying statistical process control tools. A secondary aim was to ascertain the intrinsic capability of the process following the filtering.

Design/Methodology/Approach: Specifically, the study focused on processes in a nail-wire drawing and tested a method for analysing data from naturally-drifting processes that involves filtering trends from data before applying appropriate tools to verify the state of statistical control and capability of the process. The physical foundation for this work is based on data collected from a nail-wire drawing process A total of 250 data points were gathered over 50 days in two successive instances of 125 points, each spanning 25 days. Data were checked for normality followed by mathematical conditioning to filter out the wear trend before analysis by normal statistical process capability and control chart procedures.

Findings: Results show that the proposed method is effective for tracking hidden effects in steadily drifting processes such as those associated with wear. After filtering, the data is found to fall within product specifications, though robust statistical control was still required through appropriate measures.

Research Limitation: To investigate the intrinsic nature of the process outside of the process, material wear is assumed to be the sole source of the inherent drift. In processes where several sources of inherent drift are present, this may pose a problem. Additionally, the study focused on just one plant; however, data from other similar plants will be needed to buttress the findings and widen the scope of applicability of the findings.

Practical implication:  The competitive pressures of today’s marketplace are increasingly forcing companies to place premium emphasis on product quality while aiming at the lowest costs possible. The study recommends continuous and sustained efforts to reduce variation in manufacturing processes to brighten firms’ competitive survival.

Social implication: The study will bring new knowledge to metal product manufacturers that can help them deliver high-quality products and value for money to consumers.  

Originality / Value: New insights afforded by the study’s approach include revelations of otherwise hidden measurement errors as well as undersized finishing-die. Any other out-of-control occurrences can then be more easily tracked and identified and root-cause analysis applied to eliminate them.  This is a practical study that seeks to develop an innovative way to monitor the quality of processes whose tracking is made difficult by inherent drift. The easy-to-adopt methodology can be implemented by metal product manufacturers grappling with drift-inherent processes.