Advanced quality management system for product families in mass customization and reconfigurable manufacturing

Abstract

Purpose

Production of a high variety of products introduces complexities in the quality processes involved in a manufacturing system. Previous methods of quality assurance and control are not sufficient to manage the quality characteristics that are significant to each customer. Research into quality management for these environments has been isolated and segmented. No framework exists to holistically manage product quality within an unstable manufacturing environment. This paper seeks to propose a method of holistically managing product quality in a manufacturing environment with high customer input and product variety. The development of a reconfigurable inspection apparatus is discussed as a technological requirement for performing the quality control aspect of the management system.

Design/methodology/approach

The quality requirements of modern manufacturing systems were established. The required flow of information for an advanced quality management system was proposed and compared to the information flow in a traditional quality management system. The developed reconfigurable inspection apparatus was tested by performing an inspection of a product configuration within a part family of torches. Commercial products were used for the construction of the apparatus, including the electrical and software aspects. A commercially available simulation package was used to simulate the effects of a random customer order on production flow whilst implementing the developed apparatus.

Findings

Modular inspection equipment would prove essential to the implementation of quality control when considering advanced manufacturing environments. An overall management system is also needed for the verification of product quality as per individual customer requirements. Quality needs to be integrated as per TQM principles.

Research limitations/implications

Traditional quality control tools may not always be applicable for unstable market demand. The research indicated the required progression of quality systems to successfully manage the quality for advanced manufacturing. The widespread availability of commercial components for the inspection apparatus verified the shift in supplier focus to meet the needs of shifting manufacturing requirements.

Practical implications

The proposed approach to assure and control quality, as well as the researched inspection apparatus, provided the capability of being implemented in a manufacturing environment that involves production of a variety of products as opposed to being limited to one part family. The use of modular mechanical, electrical and software components will ease the implementation of reconfigurable inspection stations into existing manufacturing setups.

Originality/value

Research indicated that quality systems need to be further developed for assuring and controlling product quality of products with high customer input. No system existed that could holistically consider the quality requirements of a product from design to delivery.

Citation

Davrajh, S. and Bright, G. (2013), "Advanced quality management system for product families in mass customization and reconfigurable manufacturing", Assembly Automation, Vol. 33 No. 2, pp. 127-138. https://doi.org/10.1108/01445151311306636