|M.Sc Thesis||Department of Quality Assurance and Reliability|
|Supervisor:||Dr. Jacqueline Asscher|
|Full Thesis text|
Carmel Forge factory is a forging house for the aerospace industry and producer of Nickel and Titanium Alloys parts in closed die forgings and seamless rolled rings. Founded in 1961 Carmel Forge has grown to become the preferred supplier of critical rotating parts to world major jet engine manufacturers. The company’s goal is to keep its global reputation by the ongoing enhancement of the performance of its production processes.
One of the ACE requirements is the individual certification of each process in the factory. One of non certified processes is the process of tensile tests. The goal of this project is to prepare the Tensile Laboratory for certification according the ACE standard.
After consultation with the quality assurance engineers of the factory and learning the ACE process certification directives, the following stages were defined and carried out:
· Defining the process. The process actions, facilities and resources were described and presented, the inputs and outputs were defined and listed. The process flow chart was drawn.
· Checking the existing measurement system in the machine testing laboratory. The critical measured values were chosen - Initial Diameter, Area Reduction and Elongation; the measurements of these values were described, and the GR&R studies were performed to ensure that each measurement system is adequate.
· Review the process. The relevant data was collected and prepared for statistical analysis . The present state of the process was assessed. The products were divided into families, the relationships and trends between different process characteristics critical to quality were analyzed.
· Capability analyses of the existing manufacturing. Current process performance was assessed and compared for different families.
· Quality control system for the laboratory measurements. On-line SPC (Statistical Process Control) of the measurements with appropriate control charts was proposed.
Most of the calculations and graphs were prepared using the program JMP for statistical analyses.
For every stage mentioned above, conclusions and recommendations were made where relevant. The following are the key findings: the measurements system was acceptable; for some products KPO (Key Process Outputs) exceeded the specification limits; manufacturing was unstable during the period of time studied; capability was below the ACE requirements for some products; resolution problems with the measurements system and with the recording of results were identified.
This project will be used for the future process certification.