Abstract
Using control and repairing loops to remove production errors is not the only solution to increase the manufacturing yield. The production of errors can also be directly avoided, prevented or eliminated, even as early as in the planning phase. This paper suggests that the idea of Process Signatures can help to achieve Loopless Production. Loopless Production offers an option to guarantee the production quality towards the vision of the zero-defect manufacturing. It is considered that closed loops are used in a production process chain to identify and to correct the unknown and the systematic errors. These errors can actually be avoided through specifically adjusted or optimal arranged production processes. This puts a higher demand on the understanding of processes, which involve various energy-material interactions. This demand can be met via Process Signatures which aims to develop a process-independent description method of effects of processes. A supportive relationship is foreseen between Process Signatures and Loopless Production. The combination of these two ideas shall allow the simplification of the work for the rationalization of process sequences, the streamlining of closed loops as well as the selection of optimal substitute processes.
Highlights
Material needs of humans stimulate the development of manufacturing industries, whereby epochal production philosophies are generated during the process of the improvement of the instrumental rationality
This paper suggests that the idea of Process Signatures can help to achieve Loopless Production
It is considered that closed loops are used in a production process chain to identify and to correct the unknown and the systematic errors
Summary
Material needs of humans stimulate the development of manufacturing industries, whereby epochal production philosophies are generated during the process of the improvement of the instrumental rationality. A process, which changes the material from an initial state to a final state, can be regarded as an imagined cause-effect chain within a control volume. It is considered that every process in a process chain makes its own contribution to changing a given initial state into a final state. Other unforeseeable deviations caused by the insufficient understanding of the functional mechanism or by the imperfect fulfillment of processes could be regarded as “unknown errors” These errors would be kept in the workpiece and could only be detected by the comparison of the processed workpiece with the reference ideal product. Errors in manufacturing could be overcome through rationally selected and coordinated processes rather than just using closed loops
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