High Defect Rates Research Articles

DSS-Based Process Control and FMEA Studies for Different Processes in the Field of Textile

Today, in many textile firms, high defect rates and inefficiency stand out due to the intensive labor in the production processes. For this reason, to be able to detect failure modes and effects, number of defects and defect rates fast and intervene in the process just in time is vital for textile firms. Accelerating feedback by producing accurate and effective quality reports and helping senior management's decision processes will reduce appraisal costs and delivery time. In this study, Failure Mode and Effect Analysis and Statistical Process Control techniques have been integrated with a Decision Support System for different processes of textile. Thanks to the proposed integrated system in the fast fashion/textile sector, defect and/or failures will be prevented or detected on time by determining the sources of error with an effective database and monitoring system. So, process capability will increase by preventing material, operations and human-induced scraps.

Quality Improvement of NH1X36B Pre-Printed Box with QM-CRISP DM Approach at PT X

PT X is a manufacturer of cardboard box whose products are indispensable for various fields. The problem identified in NH1X36B pre-printed box, which is a shoes box, is the high defect rate that exceed company target of 2%. This study aims to reduce the defect rate of the product. The Quality-Management (QM) and Cross Industry Standard Process for Data Mining (CRISP-DM) approach was conducted by integrating Six Sigma and data mining. The Business Understanding phase was intended to define business and data mining objectives, SIPOC (Supplier-Input-Process-Output-Customer) diagram, and Critical-to-Quality (CTQ). In Data Understanding phase, it is known that the Defects Per Million Opportunities (DPMO) value is 1210.12. Data preparation phase was carried out with data cleaning, reduction, and discretization. Based on the Modeling result using Decision Tree C4.5 and FP-Growth algorithm, it is known that the dominant attributes causing high rejection are smeared ink, white spots, uneven varnish, and delamination. Decision Tree model accuracy of 90.24% indicates that the model is performing well. Analysis using FMEA yielded priority correction to the causes of smeared ink, uneven varnish, and delamination. Process improvement in Deployment phase was the application of plate cleaning and mounting form, printing process checklist, and SOP for sheet inspection. The improvement plans managed to improve the quality by rising sigma level from 4.533 to 4.648 sigma and decrease defect rate to 1.559%.

SPINAL EPIDURAL ABSCESS ET CAUSA STAPHYLOCOCCUS PSEUDINTERMEDIUS: A RARE CASE REPORT

Background: Spinal epidural abscess (SEA) is a rare disease, difficult to detect, high defect rate, and can be lifethreatening. It is characterized by accumulation of pus in the epidural space causing suppression of the spinal cord and spinal roots. This study will describe a case of a 35-year-old man with SEA in Indonesia. Case presentation: A 35-year-old male with pain in the lumbar region 1, radicular pain according to thoracic dermatome 10, flaccid inferior paraplegia, hypoesthesia as high as thoracic dermatome 10, and retention of alviet uri due to SEA caused by Staphylococcus pseudintermedius confirmed by abscess culture. Management of this patient was through an operation, debridement, and administration of antibiotic. Conclusion: This patient was diagnosed with SEA from anamnesis, physical examination, laboratory finding, and radiology finding. This case is rarely found and is a big problem for neurologists due to the difficulty of early diagnosis.

Mechanical Properties of White Metal on SCM440 Alloy Steel by Laser Cladding Treatment

The bearing is a machine element that plays an important role in rotating the shaft of a machine while supporting its weight and load. Numerous bearings have been developed to improve durability and life, depending on the functions and operating conditions in which they are desired. White metal is one of method to improve durability that is soft and bonded to the inner surface of the bearing to protect the bearing shaft. Currently, the centrifugal casting process is used as a white metal lamination method, but it involves problems such as long processing times, high defect rates and harmful health effects. In this paper, a laser cladding treatment is applied to bond powdered white metal to SCM440 alloy steel, which is used as bearing material in terms of replacing the risks of a centrifugal process. In order to understand whether laser cladding is a suitable process, this paper compares the mechanical properties of white metal produced on SCM440 alloy steel by centrifugal casting and the laser cladding process. The laser power, powder feed rate and laser head speed factors are varied to understand the mechanical properties and measure the hardness using micro Vickers and conduct field emission scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction and friction testing to understand the mechanical properties and surface characteristics. Based on the results, the hardness values of the cladding (white metal) layer ranged between 24 and 26 HV in both the centrifugal casting and laser cladding methods. However, the hardness of the white metal produced by laser cladding at about a depth of 0.1 mm rose rapidly in the cladding process, forming a heat-affected zone (HAZ) with an average hardness value of 200 HV at a laser power of 1.1 kW, 325 HV at 1.3 kW and 430 HV at 1.5 kW. The surface friction testing results revealed no significant differences in the friction coefficient between the centrifugal casting and laser cladding methods, which allows the assumption that the processing method does not significantly influence the friction coefficient.

Injectable In Situ Induced Robust Hydrogel for Photothermal Therapy and Bone Fracture Repair

AbstractMalignant bone tumors are often accompanied by osteolytic destruction and severe pathological fractures. Current therapeutic strategies can largely inhibit tumor proliferation, but the high recurrence rate of tumors and related bone defects remain a significant challenge. This study aims to address these issues by developing a novel near‐infrared (NIR) light‐responsive and a mechanically strong hydrogel that offers excellent photothermal tumor therapy and bone fracture repair capabilities. The as‐prepared hydrogel exhibits good biocompatibility and an ultra‐strong photothermal effect due to the formation of a complex network with up‐conversion lanthanide‐Au hybrid nanoparticles and alginate molecules. A subcutaneous tumor model is used to demonstrate that tumors can be efficiently eradicated via local photothermal treatment, where there is no tumor recurrence within the observation period. Moreover, the injected hydrogel becomes mechanically strong due to in situ Ca2+ crosslinking, which provides a supportive matrix to promote the repair of bone defects via stabilization of the fractured bone structure. The high photothermal effect and robust support offered by this single material demonstrate the potential of using the proposed hydrogel for the simultaneous treatment of bone tumor removal and bone healing.

Nanocrystalline equiatomic CoCrFeNi alloy thin films: Are they single phase fcc?

The bulk quaternary equiatomic CoCrFeNi alloy is studied extensively in literature. Under experimental conditions, it shows a single-phase fcc structure and its physical and mechanical properties are similar to those of the quinary equiatomic CoCrFeMnNi alloy. Many studies in literature have focused on the mechanical properties of bulk nanocrystalline high entropy alloys or compositionally complex alloys, and their microstructure evolution upon annealing. The thin film processing route offers an excellent alternative to form nanocrystalline alloys. Due to the high nucleation rate and high density of defects in thin films synthesized by sputtering, the kinetics of microstructure evolution is often accelerated compared to those taking place in the bulk. Here, thin films are used to study the phase evolution in nanocrystalline CoCrFeNi deposited on Si/SiO2 and c-sapphire substrates by magnetron co-sputtering from elemental sources. The phases and microstructure of the films are discussed in comparison to the bulk alloy. The main conclusion is that second phases can form even at room temperature provided there are sufficient nucleation sites.

Improving Production System Performance Using Overall Equipment Effectiveness

In the competition among organization on the global market, no organization will tolerate losses. Overall Equipment Effectiveness (OEE) overall is a new process in which the efficiency of a system is calculated and complicated manufacturing issues are truly simplified to simple and intuitive knowledge delivery. It thinks about the exceptionally important measures of productivity. An endeavour has been done to measure and analyse existing Overall Equipment Effectiveness (OEE) at company Kirino in hope to reduce unplanned downtime losses on equipment failure and tooling damage to maximize the productivity. The methods used to analyse these various causes were analysis tools and Intelligence Systems. After knowing the causes of various activities that leads to high rates of defects, then recommendations for improvements that could be used by company Kirino were ready to be made using intelligent system as a medium of solution.

Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study

Product quality has now become one of the main factors that every company must have to compete globally. One way is to reduce the number of defective products in the production process. This method is a continuous improvement effort made by PT Toyota Motor Manu­fac­turing Indonesia and companies engaged in the automotive sector that produces cars. One of the processes is packing roof panels whose output will be sent to importing countries where the number of re­quests per month is relatively high but still has a high defect rate. Based on production data and defect data for the January-February 2019 period, roof panel packaging production has a 1% -3% defect rate. This company must reduce the defect rate to achieve the com­pany target of zero defects. This study aims to improve the quality of the packaging process by minimizing the number of defective products. This study uses the Six Sigma method with DMAIC phases. This method has several phases, namely, Define, Measure, Analysis, Improvement, and Control. Corrective action to reduce product defects based on 5W + 1H is to formulate a repair plan at the upgrade phase, namely by making SOPs spraying anti-rust and supervising operators who produce roof panel packaging. The improvement results reduced the DPMO value from 33,500 units to 2,050 units and increased the sigma level from 3.33 to 4.37. The DMAIC phase effectively controls and improves product quality levels in the automotive industry.

DENT-seq for genome-wide strand-specific identification of DNA single-strand break sites with single-nucleotide resolution.

DNA single-strand breaks (SSBs), or “nicks,” are the most common form of DNA damage. Oxidative stress, endogenous enzyme activities, and other processes cause tens of thousands of nicks per cell per day. Accumulation of nicks, caused by high rates of occurrence or defects in repair enzymes, has been implicated in multiple diseases. However, improved methods for nick analysis are needed to characterize the mechanisms of these processes and learn how the location and number of nicks affect cells, disease progression, and health outcomes. In addition to natural processes, including DNA repair, leading genome editing technologies rely on nuclease activity, including nick generation, at specific target sites. There is currently a pressing need for methods to study off-target nicking activity genome-wide to evaluate the side effects of emerging genome editing tools on cells and organisms. Here, we developed a new method, DENT-seq, for efficient strand-specific profiling of nicks in complex DNA samples with single-nucleotide resolution and low false-positive rates. DENT-seq produces a single deep sequence data set enriched for reads near nick sites and establishes a readily detectable mutational signal that allows for determination of the nick site and strand with single-base resolution at penetrance as low as one strand per thousand. We apply DENT-seq to profile the off-target activity of the Nb.BsmI nicking endonuclease and an engineered spCas9 nickase. DENT-seq will be useful in exploring the activity of engineered nucleases in genome editing and other biotechnological applications as well as spontaneous and therapeutic-associated strand breaks.

다공성 알루미늄 소재를 적용한 진공 박막성형 금형개발

In an injection-molding operation that applies vacuum technology, the thin-film sheet product must be molded to a uniform thickness. However, the dike part of the indoor panel of a refrigerator undergoes large variations in its thickness and a high defect rate. Therefore, porous aluminum was used so that a uniform distribution of vacuum pressure can be applied to the entire acrylonitrile butadiene styrene resin in the indoor panel. The pore density of porous aluminum was determined using finite-element analysis, and the products from the developed mold were inspected for corner thickness, cotton flannel marks, and air-hole marks. The defect rate was significantly reduced, and the appearance quality of the product was improved. The improved thin-film-forming technology is expected to greatly contribute to the development of the mold industry.

Test Case Prioritization—ANT Algorithm With Faults Severity

Abstract Regression testing is applied whenever a code changes, ensuring that the modifications fixed the fault and no other faults are introduced. Due to a large number of test cases to be run, test case prioritization is one of the strategies that allows to run the test cases with the highest fault rate first. The aim of the paper is to present an optimized test case prioritization method inspired by ant colony optimization, test case prioritization–ANT. The criteria used by the optimization algorithm are the number of faults not covered yet by the selected test cases and the sum of severity of the faults. The cost, i.e. time execution, for test cases is considered in the computation of the pheromone deposited on the graph’s edges. The average percentage of fault detected metric, as best selection criterion, is used to uncover maximum faults with the highest severity, and reducing the regression testing time. Several experiments are considered, detailed and discussed, comparing various algorithm parameter’s alternatives. A benchmark project is also used to validate the proposed approach. The obtained results are encouraging, being a cornerstone for new perspectives to be considered.

Defective cell reuse based defect-tolerance method for CMOL cell mapping optimization

Due to the high defect rate of nanodevices and nanowires in the process of manufacturing, the defect-tolerance mapping in CMOS/nanowire/molecule hybrid (CMOL) circuit is a key step to achieve the correct logic function. However, a high defect rate may reduce the success rate of defect-tolerance mapping because of the shortage of mapping resources. In this paper, a defective cell reuse based defect-tolerance mapping optimization method is proposed to address the mapping problem under limited mapping resources in defective CMOL circuits. First, stuck-at-close defect is analyzed and the constraint of reusing defective cells is proposed. Second, the logic hierarchy based mapping framework is undertaken to improve the mapping success rate and the performance of mapped CMOL circuit. Finally, the method is embedded into Tabu Search (TS) algorithm to verify the feasibility and efficiency. Experimental evaluation on ISCAS benchmark shows that compared with the existing methods, the proposed method has a higher defect-tolerance mapping success rate and a better mapped performance.

MAGAN: A masked autoencoder generative adversarial network for processing missing IoT sequence data

Abstract Missing sequence data prevent local data from reflecting the overall distribution of a sample, hindering data analysis. The problem of missing data during actual production is a serious issue and results in a high defect rate, low dimensionality, and high noise level. In this study, a Masked Generative Adversarial Network (MAGAN) model is proposed that is less affected by the data loss rate than a baseline comparison model, and at an 80% missing data rate, the model can still better reflect the distribution of real data. MAGAN shows better results than a traditional processing method for dealing with missing data.

Major birth defects in the Brazilian side of the triple border: a population-based cross-sectional study

BackgroundMajor birth defects increase the risk of fetal death and pediatric hospitalization, which also impact on healthcare costs. Sociodemographic factors can drastically affect reproductive health and be used to discriminate the exposure to hidden risk factors. Foz do Iguassu is a Brazilian city located in the triple-border region of Brazil / Paraguay / Argentina with high rates of birth defects. However no study aimed to verify factors associated with this incidence or preventive care is reported. The current work investigated the prevalence of major birth defects and its association with maternal sociodemographic factors in Foz do Iguassu.MethodsIn this population-based cross-sectional study we used data of all live births occurred in Foz do Iguassu from 2012 to 2017. The associated sociodemographic variables such as maternal age, maternal education, maternal race, country of residence, maternal parity and onset of prenatal care were analyzed. Each major birth defect was described according to absolute and relative frequencies, Kruskal-Wallis and logistic regression models were used to evaluate variables associated with selected birth defects.ResultsThe most prevalent major birth defects were Cleft Lip and/or Palate (9.5/10,000), gastroschisis (6.93/10,000), spina bifida (5.53/10,000), hydrocephalus (5.53/10,000), hypospadias (4.55/10,000), Down syndrome (4.23/10,000), anencephaly (2.93/10,000), anorectal atresia / stenosis (1.95/10,000), undetermined sex (1.95/10,000), esophageal atresia / stenosis with or without fistula (1.63/10,000) and limb reduction defects (1.30/10,000). Maternal age was associated with gastroschisis and Down syndrome. Only maternal education up to 7 years was statistically associated with major birth defects considering all other sociodemographic variables.ConclusionCleft Lip and/or Palate and Gastroschisis prevalence were higher than those found in the literature. This findings may suggest a distinct epidemiological behavior regarding major birth defects in the region. The work opens new perspectives for birth defects risk factors in the triple-border.

SUN-595 Comparative Comorbidity Burden Among Patients with Prader-Willi Syndrome: A Population-Level Cohort Study

Prader-Willi syndrome (PWS) is a rare, complex multi-system genetic disorder characterized by hyperphagia and abnormal food-related behaviors that contribute to severe morbidity and early mortality and to a significant burden on patients and caregivers. The hyperphagia seen in people with PWS can result in significant obesity. This study assessed rates of comorbidities associated with obesity, including type II diabetes (T2D), cardiovascular disease (CVD), and sleep apnea (SA) in a large US PWS vs. a non-PWS cohort. Methods: T2D, CVD, and SA conditions for privately insured PWS and non-PWS patients aged <65 years were identified via ICD diagnosis codes in deidentified medical claims provided by IQVIA™ Health Plan Claims Data (1/2006 - 11/2018). Patients were grouped into age-bands of 0–2, 3–8, 9–17, 18–26, 27–34, 35–49, and 50–64 years. Patients were required to have ≥12 months of enrollment, and observations were segmented into 12-month patient years. Due to patient privacy, figures that represent fewer than 11 patients are not shared and are represented as a non-zero figure (NZF). Results: 5,060 PWS and 31,093 non-PWS patient years representing 1,461 and 9,656 unique patients were eligible for analysis. T2D was detected in 8% of PWS patients age 9–17 (vs a NZF in non-PWS), 19% (vs 1%) in ages 18–26, and 27% in ages 27–34, 35–49, and 50–64 (vs 2, 5, and 13%, respectively). Comorbid CVD was detected in 25% of PWS patients age 0–2 (vs 1% in non-PWS), 11% (vs 1%) in ages 3–8, 15% (vs 1%) in ages 9–17, 29% (vs 4%) in ages 18–26, 44% (vs 11%) in ages 27–34, 60% (vs 27%) in ages 35–49, and 78% (vs 53%) in ages 50–64. Sleep apnea was detected in a NZF of non-PWS patients aged 0–2 and in all age groups 3–8, 9–17, and 18–26, compared to 37%, 22%, 17%, and 18% of PWS patients, respectively. Sleep apnea prevalence in PWS patients was 18% (vs 1% in non-PWS) in ages 27–34, 15% (vs 3%) in ages 35–49, and 16% (vs 4%) in ages 50–64.The largest disparities between PWS and non-PWS T2D prevalence was observed in the 9–17 and 18–26 age groups. Manifestations of CVD in PWS patients ages 0–2 was characterized by high rates of congenital atrial septal and patient ductus arteriosus defects, and in adolescent and adult PWS patients featured markedly higher rates of hypertension and hyperlipidemia than non-PWS cohorts. The proportion of PWS patients with SA that also received continuous positive airway pressure or oxygen monitoring ranged from 38% to 71%. Conclusions: Across all age groups, compared to non-PWS subjects, individuals with PWS experience markedly higher rates of CVD, T2D, and SA. The increased rate of CVD in the earliest age groups is consistent with previously observed increases in congenital heart defects with PWS. The frequency and early age of onset of hypertension, hyperlipidemia, T2D and SA emphasize the need for even more aggressive management of underlying drivers such as hyperphagia and the resulting obesity and metabolic dysfunction.

Improving Production System Performance Using Overall Equipment Effectiveness

In the competition among organization on the global market, no organization will tolerate losses. Overall Equipment Effectiveness (OEE) overall is a new process in which the efficiency of a system is calculated and complicated manufacturing issues are truly simplified to simple and intuitive knowledge delivery. It thinks about the exceptionally important measures of productivity. An endeavour has been done to measure and analyse existing Overall Equipment Effectiveness (OEE) at company Kirino in hope to reduce unplanned downtime losses on equipment failure and tooling damage to maximize the productivity. The methods used to analyse these various causes were analysis tools and Intelligence Systems. After knowing the causes of various activities that leads to high rates of defects, then recommendations for improvements that could be used by company Kirino were ready to be made using intelligent system as a medium of solution

Improving Production System Performance Using Overall Equipment Effectiveness

In the competition among organization on the global market, no organization will tolerate losses. Overall Equipment Effectiveness (OEE) overall is a new process in which the efficiency of a system is calculated and complicated manufacturing issues are truly simplified to simple and intuitive knowledge delivery. It thinks about the exceptionally important measures of productivity. An endeavour has been done to measure and analyse existing Overall Equipment Effectiveness (OEE) at company Kirino in hope to reduce unplanned downtime losses on equipment failure and tooling damage to maximize the productivity. The methods used to analyse these various causes were analysis tools and Intelligence Systems. After knowing the causes of various activities that leads to high rates of defects, then recommendations for improvements that could be used by company Kirino were ready to be made using intelligent system as a medium of solution

Kaizen in quality improvement at SPBV factory

The ultimate objective of manufacturing industries is to increase productivity with high quality. At present, many manufacturing companies are facing problems such as high defect rate, high inventories, high lead time, high costs of production, and inability to cope with customer orders. Kaizen is one of the powerful tools of lean manufacturing. Kaizen refers to continuous improvement in performance, cost, and quality. The main objective of this paper is to provide a background on kaizen, steps for kaizen implementation, and then a case study of Kaizen implementation has been discussed. This case study is to present an application of Kaizen to reduce cap defects at SPVB factory. The 10-step Kaizen method of SBF Group has been applied for an improvement project. Based on the company’s strategy, the project has identified the main problem of Oolong Tea + cap defects and found out the factors of the machine that were the root causes of this problem. Two groups of solutions have been proposed and implemented to overcome these causes: Restoration solution and Kaizen solution. As a result of the improvement project, the Oolong Tea + cap defect rate has decreased from 0.14% to 0.03%. Then the project has recommended the activities that need to standardize and identified future challenges for improvement.

Uncertainty in gap filling and estimating the annual sum of carbon dioxide exchange for the desert Tugai forest, Ebinur Lake Basin, Northwest China.

In most eddy covariance (EC) studies, carbon flux measurements have a high defect rate for a variety of reasons. Obtaining the annual sum of carbon dioxide exchange requires imputation of data gaps with high precision and accuracy. This study used five methods to fill the gaps in carbon flux data and estimate the total annual carbon dioxide exchange of the Tugai forest in the arid desert ecosystem of Ebinur Lake Basin, Northwest China. The Monte Carlo method was used to estimate the random error and bias caused by gap filling. The results revealed that (1) there was a seasonal difference in the friction velocity threshold of nighttime flux, with values in the growing season and non-growing season of 0.12 and 0.10 m/s, respectively; (2) the five gap-filling methods explained 77–84% of the data variability in the fluxes, and the random errors estimated by these methods were characterized by non-normality and leptokurtic heavy tail features, following the Laplacian (or double-exponential) distribution; (3) estimates of the annual sum of carbon dioxide exchange using the five methods at the study site in 2015 ranged from −178.25 to −155.21 g C m−2 year−1, indicating that the Tugai forest in the Ebinur Lake Basin is a net carbon sink. The standard deviation of the total annual carbon dioxide exchange sums estimated by the five different methods ranged from 3.15 to 19.08 g C m−2 year−1, with bias errors ranging from −13.69 to 14.05 g C m−2 year−1. This study provides a theoretical basis for the carbon dioxide exchange and carbon source/sink assessment of the Tugai forest in an arid desert ecosystem. In order to explore the functioning of the Tugai forest at this site, a greater understanding of the underlying ecological mechanisms is necessary.

Quality of brown-shelled eggs marketed in different commercial establishments

This study aimed at evaluating the internal and external quality of brown-shelled eggs commercialized in the municipality of Parintins-AM. A total of 540 eggs were evaluated and distributed in a completely randomized design, which consisted of three treatments and six replications of 30 eggs each. The treatments were: eggs sold in supermarkets; in grocery stores; and eggs sold directly at the farm. The age of the eggs from supermarkets and grocery stores was unknown, however, the eggs bought at the farm were marketed as being from the day of laying. The collected data were submitted to analysis of variance and Tukey test at 5% probability. There were no differences (p &gt; 0.05) of treatments in the percentage of dirty eggs, however, grocery and farm eggs presented higher (p &lt; 0.05) crack percentage. The eggs at the farm presented higher incidence (p &lt; 0.05) of internal stains of blood. The weight of the egg and albumen presented no differences (p &gt; 0.05). However, the albumen percentage of the farm eggs was higher than the other treatments (p &lt; 0.05). The percentages for yolk and eggshell weight from the farm eggs were lower than the supermarket and grocery eggs (p &lt; 0.05). For the variables albumen height, Haugh unit, albumen index, yolk and albumen pH, the best results were observed for the farm eggs, however, regarding these variables, eggs sold in supermarkets and grocery stores did not differ from each other. The brown shell eggs sold in the city of Parintins/AM have high rates of external defects, and the eggs bought directly from the farm presented better internal quality, when compared to eggs sold in different establishments.