Big data analytics for quality variation over work shifts in manufacturing systems

Abstract

ABSTRACT In the manufacturing industry, mass production enables manufacturers to produce parts with high precision and lower costs. Multiple shifts operate production processes to maximize efficiency. Several researches have been conducted on the impact of shift work on labor’s health and habits. However, there have been few studies on the influence of shift work on the consistency of product quality. This paper provides a methodology to analyze the impact of different work shifts in a real electronic board manufacturing industry. The study uses big data and analytics to assess product quality from data. Non-parametric kernel density estimation is used to approximate the distribution of good products in each work slot. Then several metrics are used to measure the dissimilarity between the estimated densities. The approach can be leveraged in various problems related to process performance and quality. The obtained results show that there is no significant difference in terms of product quality between work shifts. These prove the consistency of the manufacturing processes and the homogeneity of performance across work shifts in the studied factory. Compared to the literature, the paper presents the first quantitative analysis to compare production process performance and product quality over shift works.