Increase production reliability - reduce rejects.
One of the central tasks of preventive reliability engineering is the reduction of production waste. This idea is based on the realization that incompetent manufacturing processes lead to large variations in product characteristics and quality features.
High initial variations – for example in the capacitance of capacitors – often also cause large fluctuations in service life. If the rejects are not detected by end-of-line testing, this results in high initial field failure rates. By using statistical tolerancing methods, scrap rates can be significantly reduced – often combined with a noticeable reduction in costs.
Principles of statistical tolerancing
A key principle is to take the actual machine and process capabilities into account when defining tolerances. This ensures that manufacturing processes are optimally utilized from a quality perspective without overtaxing them.
A second principle is the system approach: the definition of tolerances for individual parts or features is based on the entire chain of effects – right up to the quality feature that the customer perceives. Only this holistic view enables overall optimization. If it is neglected, developers tend to specify tolerances that are too tight for their area (“gold-plated components”) in order to supposedly ensure system quality – but this usually results in unnecessary costs.
Our services
- Calculation of expected preventive scrap rates based on specification limits and production scatter for various technical systems (mechanical, electrical, electronic)
- Optimization of tolerance allocations to reduce manufacturing costs
- Identify which tolerances can or must be adjusted in order to reduce rejects cost-effectively
In combination with other methods
