Showing posts with label gbtu. Show all posts
Showing posts with label gbtu. Show all posts

Tuesday 13 September 2011

ACTIVITIES OF QUALITY

ACTIVITIES OF QUALITY

In the manufacturing industry, activities concerned with quality can be divided into six stages:

1. Product Planning:
planning for the function, price, life cycle, etc. of the product concerned.

2. Product Design:
designing the product to have the functions decided in product planning.

3. Process Design:
designing the manufacturing process to have the functions decided in the product design.

4. Production:
the process of actually making the product so that it is of the designed quality.

5. Sales:
activities to sell the manufactured product.

6. After-Sales Service:
customer service activities such as maintenance and product services.


It is important to note that company-wide activities are necessary to improve quality and productivity at each of the six stages mentioned above. A company needs to build an overall quality system in which all activities interact to produce products of designed quality with minimum costs.

Note that there are three different characteristics of quality in an overall quality system in the manufacturing industry:

1. Quality of Design:
Quality of product planning, product design and process design.
                              

2. Quality of Conformance:
Quality of production.


3. Quality of Service:
Quality of sales and after-sales services.


Nowadays, these three aspects of quality are equally important in the manufacturing company. If any one of them is not up to the mark, then the overall quality system is unbalanced, and the company will face serious problems.

Although these definitions are somewhat different, some common ideas run through them. Quality involves developing specifications to meet customer needs (quality of design), manufacturing products which satisfy those specifications (quality of conformance), and then providing after-sales services.

However, Taguchi’s definition of product quality is unusual. The loss he refers to may be caused by variability of function, or by harmful side-effects. Hence, if a product costs society no loss, the product is of the best quality, and the poorer the product’s quality is, the greater the cost of the product to the society.

An example of loss caused by variability of function would be an automobile tire that does not last long. The driver would suffer a loss if he replaced the flat tire in the middle of a highway at night because the tire has an unexpectedly short life.

An example of loss caused by a harmful side-effect would be a cold medicine which causes drowsiness in the person who takes it. Then the person would suffer a loss if this drowsiness caused him to be unable to work.

NEXT POST:  Taguchi’s concept of quality engineering from the standpoint of how quality can be designed, manufactured and measured.

Tuesday 30 August 2011

WHAT IS QUALITY OF A PRODUCT OR SERVICES?

EME-072: QUALITY MANAGEMENT
)))
|||---- WHAT IS QUALITY?
)))

Everyone has had experiences of poor quality when dealing with business organizations. These experiences might involve an airline that has lost a passenger’s luggage, a dry cleaner that has left clothes wrinkled or stained, poor course offerings and scheduling at your college, a purchased product that is damaged or broken, or a pizza delivery service that is often late or delivers the wrong order. So, what is the exact definition of Quality.

Although Quality is a vague concept up to some extent, but we can still define it. So, we define "Quality of a Product" as the degree of its excellence and fitness for the purpose.
Although, some of the quality characteristics can be specified in quantitative terms, but no single characteristics can be used to measure the quality of a product on an absolute scale. 

Quality of a product means all those activities which are directed to
  (i) Maintaining and improving such as setting of quality targets,
           (ii) Appraisal of conformance
          (iii) Taking corrective action where any deviation is noticed
          (iv) And planning for improvements in quality.

Quality is a measure of the user satisfaction provided by a product, it includes
            (i) Functional efficiency
           (ii) Appearance
          (iii) Ease of installation and operation
          (iv)  Safety reliability
           (v) Maintainability
          (vi) Running and maintenance cost
         (vii) Continued fault free service/ after-sales service.

There are two elements of quality, namely 

(i) Quality of Design
(ii) Quality of Conformance.

Quality is initially created by the designer in the form of product specifications and manufacturing instructions where as the design provides user satisfaction, the product must be conformed to the design.

Making quality a priority means putting customer needs first. It means meeting and exceeding customer expectations by involving everyone in the organization through an integrated effort. Total quality management (TQM) is an integrated organizational effort designed to improve quality at every level.

So, to be a successful brand a product must possess the best quality. But, how does one build quality into a product?

It is obvious that inspection alone can not build quality into a product unless quality has been designed and manufactured into it.

The quality of a product in a company is determined by the philosophy, commitment, and the quality policy of the top management and the extent to which these policies can be put into actual practice.

TQM is about meeting quality expectations as defined by the customer; this is called customer-defined quality. However, defining quality is not as easy as it may seem, because different people have different ideas of what constitutes high quality. Let’s begin by looking at different ways in which quality can be defined.

Total quality management (TQM):
"An integrated effort designed to improve quality performance at every level
of the organization."

Customer-defined Quality:
"The meaning of quality as defined by the customer."

Conformance to Specifications:
"How well a product or service meets the targets and tolerances determined by its designers."

Fitness for Use:
"A definition of quality that evaluates how well the product performs for its intended use."

Value for Price Paid:
"Quality defined in terms of product or service usefulness for the price paid."


Quality Control and User-defined Characteristics of Quality:

The perception of quality is heavily dependent upon the types of processes adopted to maintain the quality of the product during manufacturing and distribution of the product. Those processes are called as Quality Control processes. In modern concept of quality control, mainly TQC or Total Quality Control, Quality Assurance and Quality Management have been termed as "QUALITY CONTROL".

Quality of a product is determined by the combined effects of various departments such as Design, Engineering, Purchase, Production and Inspection.

Quality is perceived differently by different people, but understood by almost everyone. The customer as a user takes the quality of fit, finish, appearance and performance in a manufactured product where as service quality may be evaluated on the basis of the "degree of satisfaction".

As the customer has the final saying about the quality of a product; therefore, the measurable characteristics in a product or service are basically translation of the customer needs.

Once the specifications are developed depending upon the customer satisfaction, next the ways to measure as well as monitor the characteristics should be devised.

This becomes the basis of further improvement or continuous improvement of the product or the service.

The ultimate objective of all the processes is to ensure the customer satisfaction so that they become ready to pay for the product or the service.
 

Wednesday 24 August 2011

CENTROIDS OF LINES

CENTROID OF A STRAIGHT LINE


If we take a straight line of length (L), then its midpoint will be at a distance (L/2) from either end of the line. Let us denote the centroid as the point G(Xg,Yg).

Suppose we have a straight line AB of length (L) that makes an angle θ with X axis. Let the coordinate of point A is (Xo,Yo). Let the centroid be at G(Xg,Yg), then

Xg = Xo + (Lcos θ)/2
Yg = Yo + (Lsin θ)/2


                                                                                                                                                             

     Again, suppose the coordinate of B is given instead of point A. Let it is given as B(Xi,Yi). Then, it will be                                                       

Xg = X1 - (Lcos θ)/2
Yg = Y1 - (Lsin θ)/2

For Horizontal lines θ = 0° and for Vertical lines θ = 90°




CENTROID OF A CURVED LINE

The steps to derive the centroid of a quarter circular arc of radius R. 
 
Centroid of a curved line can be derived with the help of calculus.



i) Draw the figure in a X-Y coordinate system. Let the curved line has been represented by a function θ

ii) Take an arbitrary point P(X,Y) on the curve. Join the line OP, where O is the origin of the coordinate system. Let OP has a length L and makes an angle (θ) with X axis. Therefore, we can write

                  
                                   X = Rcosθ ----- (a)
                             Y = Rsinθ ----- (b)


iii) Let another point Q, such that PQ = dL where dL is very very small. Let the angle subtended by (dL) be (). So we can write

                                   dL = Rdθ ------ (c)

                             Xg = (1/L) ∫(XdL)
                                  = (1/L) ∫ Rcosθ.Rdθ
                                  = (1/L).R²  ∫ sinθ.dθ ------- (d)

                             Yg = (1/L) ∫ YdL
                                  = (1/L) ∫ Rsinθ.Rdθ
                                  = (1/L).R²  ∫ sinθ.dθ -------- (e)


CENTROID OF A QUARTER CIRCULAR ARC OF RADIUS R

Suppose we have a quarter circular arc in a co-ordinate system as shown in the figure. Total length of the arc AB = (πR)/2 . We take an arbitrarily small length of the arc CD and denote it as dL.

So,
           dL = Rdθ  ------ (iii)    [ as s=Rθ ]

where R = Radius of the quarter circular arc.
Let the co-ordinate of the point D be D(x,y) where
   
               X = Rcosθ -----(iv) and
            Y = Rsinθ -----(v)

Hence   Xg = (1/L)∫x.dL  ;  here  L = (πR)/2  ;        
                                           X = Rcosθ      
                                          dL = Rdθ
    

             Xg = (2/πR)   0π/2Rcosθ.Rdθ 

     =    (2/πR) R2  0π/2cosθ.dθ

 =      2R/π
   
   Yg = (2/πR)   0π/2Rsinθ.Rdθ 
     
 =      (2/πR) R2  0π/2sinθ.dθ

 =      2R/π


Hence, for a quarter circular arc of radius R will be G(2R/π,2R/π)                                                                

                                                                                      

CENTROID OF A COMPOSITE LINE


In the figure, a composite line A-B-C-D is made of three straight lines AB, BC, CD as shown in the figure.So, a composite line is consisted of several straight or curved lines.


Let a composite line is made of n number of lines, which may straight or curved lines.

STEP-ONE:

Draw the composite line and break it into n number of parts. Let the lengths of these lines are L1, L2,  L3 ........ Ln. Let the centroids of these lines are G1(X1,Y1),G2(X2,Y2), G3(X3,Y3) ........ Gn(Xn,Yn).

Calculate length (Li), and coordinates (Xi,Yi) for each and every parts.
 
Now, if the centroid of the composite line be G(Xg,Yg)

Xg = (∑LiXi)/(∑Li


    => (L1X1 + L2X2 + L3X3)/(L1 + L2 + L3)
   

Yg = (∑LiYi)/(∑Li)

    => (L1Y1 + L2Y2 + L3Y3)/(L1 + L2 + L3)
   

Friday 19 August 2011

CENTROID OF A COMPOSITE LINE

In the figure, a composite line A-B-C-D is made of three straight lines AB, BC, CD as shown in the figure. If the coordinate of point A is (5,5), find the centroid of the composite line.


Solution: At first, the composite line is divided into three parts.








Part -1 : The line AB : Let the centroid of the line be G1(X1,Y1)


length, L1 = 40 mm;                  


X1 = 4 + (40*cos 600)/2 = 14  
Y1 = 4 + (40*sin 600)/2 = 21.32








Part -2 : The line BC : Let the centroid of the line be G2(X2,Y2)


length, L2 = 15 mm; 


X2 = 4 + (40*cos 600) + 15/2 = 31.5 
Y2 = 4 + (40*sin 600) = 38.64




Part -3 : The line CD : Let the centroid of the line be G3(X3,Y3)


length, L3 = 20 mm; 

X3 = 4 + (40*cos 600) + 15 = 39 
Y3 = 4 + (40*sin 600) - 20/2 = 28.64



If the centroid of the composite line be G  (Xg,Yg)

Xg = (∑LiXi)/(∑Li



    = (L1X1 + L2X2 + L3X3)/(L1 + L2 + L3)
    = (40 x 14 + 15 x 31.5 + 20 x 39)/(40 + 15 + 20) 
    = 24.17
     

Yg = (∑LiYi)/(∑Li



    = (L1Y1 + L2Y2 + L3Y3)/(L1 + L2 + L3)
    = (40 x 21.32 + 15 x 38.64 + 20 x 28.64)/(40 + 15 + 20) 
    = 26.74



Wednesday 17 August 2011

CENTROID OF AN AREA





 
CENTROID OF AN AREA

Engineering Mechanics EME-102



Geometrical Center of an area (A) is often termed as Centroid or Center of an Area.

Suppose we have an area A in a certain X-Y coordinate system, we divide the area into n parts and named them as A1, A2, A3, .... An,. Let the coordinates of those tiny elemental areas are as (X1,Y1), (X2,Y2), (X3,Y3) ..... (Xn,Yn).



As area can be represented by a vector, hence, Area A can be treated as the resultant of the tiny elemental vectors A1, A2, A3, .... An... Let the direction of the resultant vector passes through the point G(Xg,Yg) on the plane of the area. The point G(Xg,Yg) is called the CENTROID of the area A. (The direction of any area is along the perpendicular to the area drawn at the centroid of the area).

Like other vectors, an area has a moment about an axis and be represented by the product of the radial distance between the area and the axis and the area itself. So if an elementary area A1 has a coordinate (X1,Y1) it means the area is at a distance X1 from the Y axis and Y1 from the X axis. Therefore the moment produced by A1 about Y axis is X1A1 and about X axis is Y1A1.

 Therefore the summation of all the moments produced by each and every elemental area about Y axis will be ∑AiXi and about X axis will be ∑AiYi.

Again, the resultant area A passes through the point G(Xg,Yg). Therefore the moment produced by the area A about Y axis will be AXg and about X axis will be AYg.

Like other vectors, it will obey the Moment Theorem which states the total moment produced by individual vectors will be exactly equal to the moment produced by the resultant vector about a certain axis.

Therefore,
AXg = A1X1 + A2X2 + A3X3 + ...... + AnXn

and
AYg = A1Y1 + A2Y2 + A3Y3 + ...... + AnYn


           

                 For an area, a centroid G(Xg,Yg) can be defined using calculus by the equations,
Xg = (1/A)x.dA   ------ (i)
Where dA = elemental area and A= total area.
Yg = (1/A)y.dA   ------ (ii)

HOW TO DERIVE THE VALUES OF Xg and Yg FOR BASIC GEOMETRIC FIGURE:

STEPS TO FIND Xg



i) Draw the figure in a Coordinate System.

ii) Draw a thin strip of area of thickness (dx) parallel to Y axis and at a distance (x) from Y axis.

iii) Find the height of the strip. Either the height will be constant or the height is a function of (x), that can be calculated from the equation of the figure.

iv) Calculate the elemental area of the strip, and named as dA. Hence, dA = hdx

v) integrate the expression ∫xdA, but dA = hdx. Therefore, we shall integrate  ∫hxdx over the total area.

vi) Xg = (∫ xdA)/A = (∫ hxdx)/A ; where A = total area = ∫dA = ∫hdx


STEPS TO FIND Yg

i) Draw the figure in a Coordinate System.

ii) Draw a thin strip of area of thickness (dy) parallel to X axis and at a distance (y) from X axis.

iii) Find the length (b) of the strip. Either the length will be constant or the length is a function of (y), that can be calculated from the equation of the figure.

iv) Calculate the elemental area of the strip, and named as dA. Hence, dA = bdy

v) integrate the expression ∫ydA, but dA = bdy. Therefore, we shall integrate ∫bydy over the total area.

vi) Yg = (∫ ydA)/A = (∫bydy)/A





CENTROID OF A COMPOSITE AREA:




HOW TO FIND THE CENTROID OF A COMPOSITE AREA

(a composite area consists of several straight or curved lines.)

(i) Draw the figure in a coordinate system. Draw the dimensions too. Every dimensions will be measured with respect to origin of the coordinate system


(ii) Divide the composite area into several parts of basic geometric areas. Lebel them as part-1, part-2, part-3, .......part-n. Let the corresponding areas are
A1, A2, A3, .... An. Let the centroids are G1(X1,Y1), G2(X2,Y2), G3(X3,Y3), ...... Gn(Xn,Yn).

(iii) Let the centroid of the composite area be G(Xg,Yg). Hence,

Xg =
(A1X1 + A2X2 +A3X3)/(A1 + A2 + A3)

Yg =
(A1Y1 + A2Y2 +A3Y3)/(A1 + A2 + A3)




(a) Suppose we have certain area of magnitude (A) in a coordinate system. The centroid of the area will be at its mid-point. A centroid is denoted by G.
 
                       In the figure we have a complex geometrical area composed of three basic geometrical areas. A rectangle, a semi circle and a isosceles triangle. Let us denote the centroids as G1, G2, G3 for the given areas in the figure.

We shall have to find the Centroid of the entire area composed of  A1, A2, A3

At first, the composite line is divided into three parts.



Part -1 : The semi-circle : Let the centroid of the area A1 be G1(X1,Y1)

Area, A1 = (π/2)x(25)² mm² = 981.74 mm²                  
          X1 = { 25 -  (4x25)/(3xπ)} mm = 14.39 mm
          Y1 = 25 mm

Part -2 : The Rectangle : Let the centroid of the A2 be G2(X2,Y2)

Area, A2 = 100 x 50  mm² = 5000 mm²                 
          X2 = 25 + (100/2) = 75 mm
          Y2 = 25 mm
Part -3 : The Triangle : Let the centroid of the area Area, A3 be G3(X3,Y3)

Area, A3 = (1/2) x 50 x 50 mm² = 1250 mm²                 
          X3 = 25 + 50 + 25 = 100 mm
          Y3 = 50 + (50/3) =  66.67 mm



If the centroid of the composite line be G  (Xg,Yg)
Xg = (∑AiXi)/(∑Ai

    = (A1X1 + A2X2 +A3X3)/(A1 + A2 + A3)
    = (981.74 x 14.39 + 5000 x 75 + 1250 x 100)/( 981.74 + 5000 + 1250)
    = 71.09
     
Yg = (∑AiYi)/(∑Ai

    = (A1Y1 + A2Y2 +A3Y3)/(A1 + A2 + A3)
    = (981.74 x 25 + 5000 x 25 + 1250 x 66.67)/ ( 981.74 + 5000 + 1250)
    = 32.20


Wednesday 27 July 2011

TRUSS ANALYSIS: THEORY OF TRUSS:

TRUSS ANALYSIS: THEORY OF TRUSS:

TRUSS :

Truss is a kind of framed structure made of entirely by rigid metallic rods joined by pin. The rods are called as Links or Linkages and the pins are called as joints. Their primary goal is to support the applied loads or we can say they are primarily load bearing structures. We often encounter trusses in our daily life as trusses are used to support roofs of various kinds of industrial sheds. Trusses are used as poles carrying high tension electricity.

LINK/ LINKAGES :

A link is a rigid rod which can bear any external load applied on it. A link can bear two types of forces.

COMPRESSIVE FORCES :

When the external forces applied on the link or rod tries to decrease the length of the rod, then they are called as External Compressive Forces. A truss in equilibrium counters this compressive force by inducing an internal force, equal and opposite the externally applied force. The internal force thus induced balancing the external compressive force is named as Internal Compressive Forces. Generally Compressive Forces are considered as negative in truss analysis.

TENSILE FORCES :

When external loads applied on a link try to increase the length of the link, we call them External Tensile Loads. To neutral the tensile load applied on a link, an equal but opposite internal force is generated named as Internal Tensile forces. Tensile forces are generally considered as positive internal forces.

THE SIMPLEST TRUSS:

A triangular shaped truss made of three linkages and three joints is the simplest type of truss. As it is the simplest geometric shape where there is no change in shape with the application of forces at the joints if the length of rods/ linkages remain unchanged / constant.

MAXWELL'S TRUSS EQUATION:

To distinguish between "statically determinate structure" and "statically indeterminate structure" Maxwell formulated an equation involving the number of linkages (m) and number of joints (j).

The trusses which satisfies the equation,
m = 2j - 3
are statically determinate structures and named as "Perfect Trusses".

If m > 2j - 3, then the number of linkages are more than required, hence, called as "Redundant Trusses".

Where as if m < 2j - 3 for any truss, then the number of linkages are less than that of a perfect truss. These kinds of trusses are called as "Deficient Trusses".



ASSUMPTIONS CONSIDERED WHILE ANALYZING TRUSSES :

While analyzing trusses, to simplify the analysis we often consider certain assumptions. The purpose of these assumptions are the simplification of a complex problems. The assumptions are

(i) The links are perfectly rigid bodies, ie there occurs no change in the dimensions of the links.

(ii) The pin joints are perfectly smooth, ie there is no friction in the each and every joints.

(iii) The mass and weights of the links are so small compare to the magnitudes of the applied forces, that for truss analysis we shall neglect them. It means the links are massless as well as weightless.

(iv) The cross-sections and material of the links are uniform by nature.

(v) The external loads are only applied on a joint in the truss, whenever we shall place any external load, we must place it one of the joints in the truss.

(vi) Stress in each member is constant along its length.

The objective of analyzing the trusses is to determine the reactions and member forces. The methods used for carrying out the truss analysis with the equations of equilibrium and by considering only parts of the structure through analyzing its free body diagram to solve the unknowns.



Method of Joints

 

 

The first to analyze a truss by assuming all members are in tension reaction. A tension member is when a member experiences pull forces at both ends of the bar and usually denoted as positive (+ve) sign. When a member experiencing a push force at both ends, then the bar was said to be in compression mode and designated as negative (-ve) sign.
In the joints method, a virtual cut is made around a joint and the cut portion is isolated as a Free Body Diagram (FBD). Using the equilibrium equations of ∑ Fx = 0 and ∑ Fy = 0, the unknown member forces could be solve. It is assumed that all members are joined together in the form of an ideal pin, and that all forces are in tension (+ve) of reactions.
An imaginary section may be completely passed around a joint in the truss. The joint has become a free body in equilibrium under the forces applied to it. The equations ∑ H = 0 and ∑ V = 0 may be applied to the joint to determine the unknown forces in members meeting there. It is evident that no more than two unknowns can be determined at a joint with these two equations.
 
Figure 1: A simple truss model supported by pinned and roller support at its end. Each triangle has the same length, L and it is equilateral where degree of angle, θ is 60° on every angle. The support reactions, Ra and Rc can be determine by taking a point of moment either at point A or point C, whereas Ha = 0 (no other horizontal force).
Here are some simple guidelines for this method of truss analysis:
  1. Firstly draw the Free Body Diagram (FBD),
  2. Solve the reactions of the given structure,
  3. Select a joint with a minimum number of unknown (not more than 2) and analyze it with ∑ Fx = 0 and ∑ Fy = 0,
  4. Proceed to the rest of the joints and again concentrating on joints that have very minimal of unknowns,
  5. Check member forces at unused joints with ∑ Fx = 0 and ∑ Fy = 0,
  6. Tabulate the member forces whether it is in tension (+ve) or compression (-ve) reaction.



 
Figure 2: The figure showing 3 selected joints, at B, C, and E. The forces in each member can be determine from any joint or point. The best way to start by selecting the easiest joint like joint C where the reaction Rc is already obtained and with only 2 unknown, forces of FCB and FCD. Both can be evaluate with ∑ Fx = 0 and ∑ Fy = 0 rules. At joint E, there are 3 unknown, forces of FEA, FEB and FED, which may lead to more complex solution compare to 2 unknown values. For checking purposes, joint B is selected to shown that the equation of ∑ Fx is equal to ∑ Fy which leads to zero value, ∑ Fx = ∑ Fy = 0. Each value of the member’s condition should be indicate clearly as whether it is in tension (+ve) or in compression (-ve) state.

* (Trigonometric Functions:
Taking an angle between member x and z…
  • Cos θ = x / z
  • Sin θ = y / z
  • Tan θ = y / x )


Method of Sections

 

 

The section method is an effective method when the forces in all members of a truss are being able to determine. Often we need to know the force in just one member with greatest force in it, and the method of section will yield the force in that particular member without the labor of working out the rest of the forces within the truss analysis.
If only a few member forces of a truss are needed, the quickest way to find these forces is by the method of sections. In this method, an imaginary cutting line called a section is drawn through a stable and determinate truss. Thus, a section subdivides the truss into two separate parts. Since the entire truss is in equilibrium, any part of it must also be in equilibrium. Either of the two parts of the truss can be considered and the three equations of equilibrium ∑ Fx = 0, ∑ Fy = 0, and ∑ M = 0 can be applied to solve for member forces.
 

Figure 3: Using the same model of simple truss, the details would be the same as previous figure with 2 different supports profile. Unlike the joint method, here we only interested in finding the value of forces for member BC, EC, and ED.
Few simple guidelines of section truss analysis:
  1. Pass a section through a maximum of 3 members of the truss, 1 of which is the desired member where it is dividing the truss into 2 completely separate parts,
  2. At 1 part of the truss, take moments about the point (at a joint) where the 2 members intersect and solve for the member force, using ∑ M = 0,
  3. Solve the other 2 unknowns by using the equilibrium equation for forces, using ∑ Fx = 0 and ∑ Fy = 0.
Note: The 3 forces cannot be concurrent, or else it cannot be solve.



 

Figure 4: A virtual cut is introduce through the only required members which is along member BC, EC, and ED. Firstly, the support reactions of Ra and Rd should be determine. Again a good judgment is require to solve this problem where the easiest part would be consider either on the left hand side or the right hand side. Taking moment at joint E (virtual pint) on clockwise for the whole RHS part would be much easier compare to joint C (the LHS part). Then, either joint D or C can be consider as point of moment, or else using the joint method to find the member forces for FCB, FCE, and FDE. Note: Each value of the member’s condition should be indicate clearly as whether it is in tension (+ve) or in compression (-ve) state.