Browse Topic: Quality control

Items (2,246)
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Mello Filho, Luiz Vicente Figueira deCanteras, Felippe BenaventeMeyer, Yuri AlexandreEmiliano, William MachadoJúnior, Vitor Eduardo MolinaGabriel, João CarlosIano, Yuzo
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Mendonça, Arthur S.Michelotti, Alvaro CantoBerto, Lucas F.Salvaro, Diego B.Binder, Cristiano
Additive manufacturing is one of the pillars of technologies of the industry 4.0 and enables rapid prototyping, testing of new materials, and customized manufacturing of parts with personalized design. Poly(lactic acid) (PLA) is a bio-based and biodegradable polymer that is used in packaging, medical applications, and consumer goods. However, it presents low mechanical strength and thermal stability, which limits its use in automotive parts. The use of reinforcement materials such as cellulose nanofibers (CNF) aim to increase the mechanical strength and thermal stability of PLA without reducing its ecological appeal. However, the addition of nanofibers in the 3D printing process can lead to reproducibility problems and constant clogging of the extruder nozzle due to the material’s lower printability. These difficulties may restrict its application to industrial processes due to reduced productivity. To address the challenges in the production of automotive parts with PLA/CNF composites
Oliveira, ViníciusHoriuchi, Lucas NaoGonçalves, Ana PaulaSouza, MarianaPolkowski, Rodrigo
This study presents the results of applying a Lean Six Sigma-based analytical approach to optimize the manufacturing of automotive coatings, specifically in a PU primer filling process. Through production flow mapping and the Define, Measure, Analyze, Improve, and Control (DMAIC) methodology, unplanned stoppages in the filling line were significantly reduced, addressing critical inefficiencies in automotive coating production. The research was driven by the need to enhance manufacturing productivity and ensure process reliability in the production of coatings used in the automotive sector. To achieve this, Quality Management tools, such as Pareto Analysis and the Cause-and-Effect Diagram, along with Lean Manufacturing techniques, including Kaizen Blitz, were applied. These methods facilitated the identification and mitigation of key causes of unplanned downtime, improving process efficiency and reliability. The results demonstrated a significant reduction in downtime, enhanced
Filho, William Manjud MalufRodrigues, Mateus FerreiraCarriero, Emily AmaralYoshimura, Sofia LucasMarini, Vinicius KasterSiqueira, GonçaloAlves, Marcelo Augusto Leal
In recent years, the market size of cold chain transportation in China has been expanding, but the industry has problems such as low cold chain circulation rate, low efficiency, high damage rate, and high cost. Under the background of reducing costs and improving quality and efficiency in transportation and logistics, an index set for operational analysis covering average freight rates, daily average number of over-temperature alarm incidents, daily average driving distance, and daily average driving time was established from the perspectives of economic efficiency, quality, and efficiency. Based on data from a third-party platform, including vehicle trajectories, temperatures, speeds, and freight rates, the running situation of road cold chain transportation industry was analyzed. The analysis results show that in 2023, the average freight rate of China’s highway cold chain will rebound, the fluctuation range will significantly narrow, the standardization level of temperature control
Li, SicongYe, JingCao, Mengfei
With the continuous improvement of information technology in aerospace manufacturing enterprises, the need for the integration and connection of various links in the product development process is becoming increasingly urgent. This article mainly introduces the research on BOM product structure, BOM effectiveness management, and product dataset management solutions for electromechanical products, and elaborates on the key technical content involved in detail, providing a basic capability framework for the comprehensive implementation of XBOM construction in the future.
Zhang, DongZhou, WenzaoZhou, Huachuang
Automating harvesters started out as a necessary solution to a severe labor shortage in 1990, Trebro Manufacturing states on its website. The Billings, Montana-based manufacturer has been producing turf harvesting machines since 1999, and its automated sod harvesters and entire harvesting process feature self-driving, automated-control functions. The company's tag line, “The Future of Turf Harvesting,” refers to its position of being the first in the industry to offer automated turf harvesting products. Trebro's AutoStack 3 harvester is an automated combine for turf that steers itself while an operator monitors and performs quality control actions when needed. The harvesting process combines several automated control processes.
This specification covers particle size classifications and corresponding particle size distribution requirements for metal powder feedstock conforming to a classification.
AMS AM Additive Manufacturing Metals
Accurate defect quantification is crucial for ensuring the serviceability of aircraft engine parts. Traditional inspection methods, such as profile projectors and replicating compounds, suffer from inconsistencies, operator dependency, and ergonomic challenges. To address these limitations, the 4D InSpec® handheld 3D scanner was introduced as an advanced solution for defect measurement and analysis. This article evaluates the effectiveness of the 4D InSpec scanner through multiple statistical methods, including Gage Repeatability and Reproducibility (Gage R&R), Isoplot®, Youden plots, and Bland–Altman plots. A new concept of Probability of accurate Measurement (PoaM)© was introduced to capture the accuracy of the defect quantification based on their size. The results demonstrate a significant reduction in measurement variability, with Gage R&R improving from 39.9% (profile projector) to 8.5% (3D scanner), thus meeting the AS13100 Aerospace Quality Standard. Additionally, the 4D InSpec
Aust, JonasDonskoy, Gene
This standard is for use by organizations that procure and integrate EEE Parts. These organizations may provide EEE Parts that are not integrated into assemblies (e.g., spares and/or repair EEE Parts). Examples of such organizations include, but are not limited to, the following: Original Equipment Manufacturers; contract assembly manufacturers; maintenance, repair, and overhaul (MRO) organizations; and suppliers that provide EEE Parts or assemblies as part of a service. These requirements are intended to be applied (or flowed down as applicable) through the supply chain to all organizations that procure and integrate EEE Parts and/or systems, subsystems, or assemblies. The mitigation of Counterfeit EEE Parts in this standard is risk based. These mitigation steps will vary depending on the criticality of the application and desired performance and reliability of the equipment/hardware. The requirements of this document are used in conjunction with the organization’s higher-level
G-19 Counterfeit Electronic Parts Committee
Imagine a user opening a technical manual, eager to troubleshoot an issue, only to find a mix of stark black-and-white illustrations alongside a few color images. This inconsistency not only detracts from the user experience but also complicates understanding. For technicians relying on these documents, grayscale graphics hinder quick interpretation of diagrams, extending diagnostics time and impacting overall productivity. Producing high-quality color graphics typically requires significant investment in time and resources, often necessitating a dedicated graphics team. Our innovative pipeline addresses this challenge by automating the colorization and classification of colored graphics. This approach delivers consistent, visually engaging content without the extensive investment in specialized teams, enhancing the visual appeal of materials and streamlining the diagnostic process for technicians. With clearer, more vibrant graphics, technicians can complete tasks more efficiently
Khalid, MaazAkarte, AnuragKale, AniketRajmane, GayatriNalawade, Komal
In today’s competitive landscape, industries are relying heavily on the use of warranty data analytics techniques to manage and improve warranty performance. Warranty analytics is important since it provides valuable insights into product quality and reliability. It must be noted here that by systematically looking into warranty claims and related information, industries can identify patterns and trends that indicate potential issues with the products. This analysis helps in early detection of defects, enabling timely corrective actions that improve product performance and customer satisfaction. This paper introduces a comprehensive framework that combines conventional methods with advanced machine learning techniques to provide a multifaceted perspective on warranty data. The methodology leverages historical warranty claims and product usage data to predict failure patterns & identify root causes. By integrating these diverse methods, the framework offers a more accurate and holistic
Quadri, Danishuddin S.F.Soma, Nagaraju
Tool management remains a persistent challenge in manufacturing, where misplaced or poorly calibrated tools such as torque guns and screwdrivers cause downtime, quality defects, and compliance risks. The Internet of Things (IoT) is transforming tool management from manual entries in spreadsheets and logs to real-time, data-driven solutions that enhance operational efficiency. With ongoing advancements in IoT architecture, a range of cost-effective tracking approaches is now available, including Ultra-Wideband (UWB), Bluetooth Low Energy (BLE), Wi-Fi, RFID, and LoRaWAN. This paper evaluates these technologies, comparing their trade-offs in accuracy, scalability, and cost for tool-management scenarios such as high-precision station tracking, zonal monitoring, and wide-area yard visibility. Unlike prior work that focuses on asset tracking in general, this study provides an ROI-driven, scenario-based comparison and offers recommendations for selecting appropriate technologies based on
Patel, Shravani Prashant
This study demonstrates the application of the T-Matrix, a Total Quality Management (TQM) tool to improve thermal comfort in automotive climate control systems. Focusing on the commonly reported customer issue of insufficient cabin cooling, particularly relevant in hot and congested Indian driving conditions, the research systematically investigates 36 failure modes identified across the product lifecycle, from early design through production and post-sale customer usage. Root causes are first categorized using an Ishikawa diagram and then mapped using the T-Matrix across three critical stages: problem creation, expected detection, and actual detection. This integrated approach reveals process blind spots where existing validation and inspection systems fail to catch known risks, particularly in rear-seat airflow performance and component variability from suppliers. By applying this TQM methodology, the study identifies targeted improvement actions such as improved thermal targets
Jaiswara, PrashantKulkarni, ShridharDeshmukh, GaneshNayakawadi, UttamJoshi, GauravShah, GeetJaybhay, Sambhaji
Heavy-duty vehicles emissions are a serious problem, and remote monitoring platforms are a key means of emission control for heavy-duty vehicles. However, the frequent occurrence of anomalies in the remote monitoring data has seriously limited the monitoring efficiency of the remote monitoring platform. Therefore, this paper takes 500 National VI heavy-duty vehicles as the research object, and proposes a whole-process data quality control system of “anomaly identification-dynamic correction-accuracy verification”. First, four types of anomaly patterns, namely, lost, invalid, outlier and mutation, are defined, and polynomial fitting, median filtering and contextual interpolation are adopted to realize differentiated correction. Second, a data accuracy validation framework based on correlation analysis was constructed. The results show that the accuracy of key parameters is significantly improved after correction, and the data fitting degree R2 is greater than 0.97. The research results
Liu, YuZhang, ChengZhang, HaoYu, HanzhengnanLi, JingyuanAn, XiaopanMa, KunqiLiang, YongkaiXu, Hang
Target tracking is an important component of intelligent vehicle perception systems, which has outstanding significance for the safety and efficiency of intelligent vehicle driving. With the continuous improvement of technologies such as computer vision and deep learning, detection based tracking has gradually become the mainstream target tracking framework in the field of intelligent vehicles, and target detection performance is the key factor determining its tracking performance. Although remarkable progress has been made in current 3D object detection networks, a single network still struggles to provide stable detection for distant and occluded targets. Besides, traditional tracking methods are based on single-stage association matching, which can easily lead to identity jumps and target loss in case of missed detections, resulting in poor overall stability of the tracking algorithm. To solve the above problem, a hierarchical association matching method using a dual object
Wu, ShaobinChu, YunfengLi, YixuanSu, ShengjieLiu, ZhaofengLi, XiaoanSi, Lingrui
The United States Marine Corps enlists the JCB 4CX backhoe loader as its latest recruit. JCB recently announced that it has secured a contract to provide 4CX backhoe loaders to the United States Marine Corps. According to JCB, the agreement includes not only machines but also attachments testing and hands-on operator training. “The 4CX is the direct result of more than 70 years of continuous improvement,” said Chris Giorgianni, vice president of government and defense for JCB North America. “It's built to perform in the most demanding environments, whether that's military engineering missions or high-pressure construction jobsites.”
Wolfe, Matt
The effective reduction of particulate emissions from modern vehicles has shifted the focus toward emissions from tire wear, brake wear, road surface wear, and re-suspended particulate emissions. To meet future EU air quality standards and even stricter WHO targets for PM2.5, a reduction in non-exhaust particulate (NEP) emissions seems to be essential. For this reason, the EURO 7 emissions regulation contains limits for PM and PN emissions from brakes and tire abrasion. Graz University of Technology develops test methods, simulation tools and evaluates technologies for the reduction of brake wear particles and is involved in and leads several international research projects on this topic. The results are applied in emission models such as HBEFA (Handbook on Emission Factors). In this paper, we present our brake emission simulation approach, which calculates the power at the wheels and mechanical brakes, as well as corresponding rotational speeds for vehicles using longitudinal dynamics
Landl, LukasKetan, EnisHausberger, StefanDippold, Martin
Tire and road wear particles (TRWP) have emerged as air quality hazardous matters and significant sources of airborne microplastic pollution, contributing to environmental and human health concerns. Regulatory initiatives, such as the Euro 7 standards, emphasize the urgent need for standardized methodologies to quantify TRWP emissions accurately. Despite advancements in measuring tire abrasion rates, critical gaps persist in the characterization of airborne TRWP, particularly regarding the influence of collection system design and influencing parameters on measurement accuracy and repeatability. This study addresses these challenges by designing a controlled methodological framework that aims to minimize the influencing effects and ensure comparability in TRWP emission quantification results. At the German Aerospace Center (DLR) dynamometer testbench in Stuttgart, Germany, a methodical framework was established to ensure the repeatability and comparability of TRWP measurements
Celenlioglu, Melis SerenEpple, FabiusReijrink, NinaLöber, ManuelReiland, SvenVecchi, RobertaPhilipps, Franz
The continuous improvement of validation methodologies for mobility industry components is essential to ensure vehicle quality, safety, and performance. In the context of mechanical suspensions, leaf springs play a crucial role in vehicle dynamics, comfort, and durability. Material validation is based on steel production data, complemented by laboratory analyses such as tensile testing, hardness measurements, metallography, and residual stress analysis, ensuring that mechanical properties meet fatigue resistance requirements and expected durability. For performance evaluation, fatigue tests are conducted under vertical loads, with the possibility of including "windup" simulations when necessary. To enhance correlation accuracy, original suspension components are used during testing, allowing for a more precise validation of the entire system. Additionally, dynamic stiffness measurements provide valuable input for vehicle dynamics and suspension geometry analysis software, aiding in
Zahn, André N.Graebin, MatheusMalacarne, RodrigoToniolo, Juliano C.
This specification controls surface condition, manufacturing defects and inspection requirements, and defines methods of measurement for elastomeric toroidal sealing rings (O-rings) for static (including gasket) applications.
A-6C2 Seals Committee
Non-exhaust particle emissions, particularly those generated by brake wear, are a significant source of fine particulate matter in urban environments. These emissions contribute to air pollution and pose serious health risks, particularly in densely populated areas. While vehicle exhaust emissions have been extensively studied and regulated, the contribution of non-exhaust sources, including brake wear, remains a critical factor in air quality management. This paper presents a novel methodology for fast-running, time-resolved simulation of non-exhaust particle emissions, specifically those from brake wear abrasion. A 3D CFD model computes the turbulent flow field around the disc brake. The resulting information on the convective air cooling is applied as boundary conditions on a 3D thermal model. This thermal simulation setup is compared and verified with experimental data from literature. The 3D numerical models produce data and boundary conditions for an efficient 1D numerical
Herkenrath, FerrisLückerath, MoritzGünther, MarcoPischinger, Stefan
This specification covers grease for use on aircraft wheel bearings. It also defines the quality control requirements to assure batch conformance and materials traceability and the procedures to manage and communicate changes in the grease formulation and brand. This specification invokes the Performance Review Institute (PRI) product qualification process. Requests for submittal information may be made to the PRI at the address in 2.2, referencing this specification. Products qualified to this specification are listed on a qualified products list (QPL) managed by the PRI. Additional tests and evaluations may be required by individual equipment builders before a grease is approved for use in their equipment. Approval and/or certification for use of a specific grease in aero and aero-derived marine and industrial applications is the responsibility of the individual equipment builder and/or governmental authorities and is not implied by compliance with or qualification to this
AMS M Aerospace Greases Committee
This specification covers an aluminum bronze alloy in the form of centrifugal and chill castings (see 8.5).
AMS D Nonferrous Alloys Committee
This specification covers a leaded bronze in the form of sand and centrifugal castings (see 8.6).
AMS D Nonferrous Alloys Committee
The steering system is one of the most important assemblies for the vehicle. It allows the vehicle to steer according to the driver’s intention. For an ideal steering system, the steering angle for the wheel on the left and right side should obey the Ackman equation. To achieve this goal, the optimization method is usually initiated to determine the coordinates of the hard points for the steering system. However, the location of hard points varies due to the manufacturing error of the components and wear caused by friction during their working life. To decrease the influence of geometry parameter error, and system mass, and improve the robust performance of the steering system, the optimization based on Six Sigma and Monte Carlo approach is used to optimize the steering system for an off-road vehicle. At last, the effect is proved by the comparison of other methods. The maximum error of the steering angle is decreased from 7.78° to 2.14°, while the mass of the steering system is
Peng, DengzhiDeng, ChaoZhou, BingbingZhang, Zhenhua
Repartly, a startup based in Guetersloh, Germany, is using ABB’s collaborative robots to repair and refurbish electronic circuit boards in household appliances. Three GoFa cobots handle the sorting, visual inspection and precise soldering tasks enabling the company to enhance efficiency and maintain high quality standards.
The utilization of Inconel 718 is increasing daily in stringent operating conditions such as aircraft engine parts, space vehicles, chemical tanks, and the like due to its physical properties such as maintaining strength and corrosion resistance at higher temperature conditions. Besides, Inconel 718 is one of the difficult materials for machining because of maintaining its strength at elevated temperature, which generates higher cutting force leading to observed multiple tool wear mechanisms that affect the surface quality; lower thermal conductivity of materials produces high temperature generation that impacts the tool performance by reducing tool life. In addition, the presence of carbides and high hardness of IN 718 affects the machining performance. Therefore, in this view, this article describes the effect of cutting environments and machining parameters on the machining of Inconel 718 and optimizes the cutting conditions for sustainable machining. Three input parameters namely
Mane, Pravin AshokDhawale, Pravin A.Nipanikar, SureshKhadtare, Avinash N.
The active sound synthesis system of electric vehicles plays an important role in improving the sound perception and transmission of working condition information inside the vehicle. Nowadays, the active sound synthesis system inside the vehicle has become standard equipment in electric vehicles of major electric vehicle manufacturers to meet the user groups' demand for driving and riding experience. In order to enrich the driving experience of electric vehicles and automatic transmission vehicles, the sound performance should be close to the immersiveness and dynamic feedback brought by traditional manual transmission fuel vehicles. Based on the active sound synthesis algorithm in the car, this paper proposes an adaptive shift sound quality control strategy suitable for complex and changeable working conditions, with the aim of simulating the real shift sound of the engine. First, the motor speed offset is accurately calculated based on the transmission ratio of each gear of the
Zhou, XilongLiu, ZhienXie, LipingYu, ShangboLu, ChihuaGao, XiangYongsheng, Wang
Design verification and quality control of automotive components require the analysis of the source location of ultra-short sound events, for instance the engaging event of an electromechanical clutch or the clicking noise of the aluminium frame of a passenger car seat under vibration. State-of-the-art acoustic cameras allow for a frame rate of about 100 acoustic images per second. Considering that most of the sound events introduced above can be far less than 10ms, an acoustic image generated at this rate resembles an hard-to-interpret overlay of multiple sources on the structure under test along with reflections from the surrounding test environment. This contribution introduces a novel method for visualizing impulse-like sound emissions from automotive components at 10x the frame rate of traditional acoustic cameras. A time resolution of less than 1ms eventually allows for the true localization of the initial and subsequent sound events as well as a clear separation of direct from
Rittenschober, Thomas
A continuous effort to improve reliability and efficiency of processes is at the forefront of any successful business. One methodology that can have a crucial impact in this effort is Lean Six Sigma (LSS), which aims to reduce variability and wasteful activities within a company’s processes, in turn leading to improvements in areas such as customer satisfaction, employee morale, regulatory compliance, and profitability. In the medical device industry, where a seemingly minor error could be life-threatening, LSS can play a pivotal role in patient safety. This article presents a case study illustrating the benefits of LSS for a medical device manufacturing company, as well as one of its key customers.
This SAE Aerospace Standard (AS) establishes supplemental requirements for 9100 and 9145 and applies to any organization receiving it as part of a purchase order or other contractual document from a customer. AS13100 also provides details of the reference materials (RM13xxx) developed by the SAE G-22 AESQ committee and listed in Section 2 that can also be used by organizations in conjunction with this standard.
G-22 Aerospace Engine Supplier Quality (AESQ) Committee
Simulated distillation (SimDis) uses wide bore capillary gas chromatography (GC) to provide a detailed volatility profile of blended gasoline. The boiling point distribution from SimDis analysis is correlated to the hydrocarbon contents of spark ignition fuels and provide the resolution necessary to characterize the compositions of the fuel. Recent publications on simulated distillation applied to spark ignition fuel reveal the merits of indexing a gasoline fuel so that it can be correlated to the tendency of particulate emissions from vehicles. With this in mind, SimDis can be a useful and quick tool in assessing the PM-formation potential of market gasolines. Heavy aromatic compounds are compounds identified as having at least 10 Carbons and 1 aromatic ring. These compounds that are present in spark ignition fuels are major contributors to vehicle particulate emissions. These compounds can be found in the higher boiling portion (T70+) of the distillation profiles. As demonstrated in
Goralski, SarahGeng, PatDozier, JonButler, Aron
This paper addresses the need for improved material selection in parcel shelves, a key component in passenger vehicles used to conceal the trunk area. The focus is on weight optimization, structural integrity, and perceived quality improvement using sustainable and ultra-lightweight composite materials. Traditional materials such as PET Woodstock, while durable, contribute significantly to vehicle weight, which is a drawback in the context of electric vehicles (EVs). The proposed composite material alternatives offer a high strength-to-weight ratio and have been shown to improve the load vs. deflection ratio, enhance aesthetics, and reduce manufacturing complexity and costs. This study outlines the testing and evaluation process of varying GSM and thicknesses of composite materials, demonstrating superior stiffness, reduced deflection under load, and enhanced ease of assembly. This work contributes to the ongoing efforts to achieve lightweighting, cost efficiency, and sustainability in
Kinthala, Nareen KumarPatnaik, MangaKhandelwal, MohitKakani, Phani KumarPalaniappan, Elavarasan
In automotive engineering, seam welds are frequently used to join or connect various parts of structures, frames, cradles, chassis, suspension components, and body. These welds usually form the weaker material link for durability and impact loads, which are measured by lab-controlled durability and crash tests, as well as real-world vehicle longevity. Consequently, designing robust welded components while optimizing for material performance is often prioritized as engineering challenge. The position, dimensions, material, manufacturing variation, and defects all affect the weld quality, stiffness, durability, impact, and crash performance. In this paper, the authors present best practices based on studies over many years, a rapid approach for optimizing welds, especially seam welds, by adopting Design For Six Sigma (DFSS) IDDOV (Identify, Define, Develop, Optimization, and Verification) discrete optimization approach. We will present the case testimony to show the approach throughout
Qin, WenxinLi, FanPohl, Kevin J.Pentapati, Venkat
Cam gear is a critical component of the timing system in an internal combustion engine, ensuring the synchronized opening of the engine valves, pistons, and rotating parts, but their unavailability may result in long-term downtime or expensive replacement. Reverse engineering (RE) systems also play an important role in promoting sustainable practices projects in automotive technologies. The study focuses on presenting a proposed method for redesigning damaged parts in engines using image processing technology by creating an-accurate CAD model. In addition to clarifying of the expected causes that led to cam gear damage. The proposed method involves taking a high-resolution image of the damaged part, then applying advanced image processing algorithms to analyze and reconstruct the geometry of the part. The data is then converted into a high-resolution 3D CAD model. This approach aims to address the challenges of replicating worn or broken parts, providing a cost-effective maintenance
Ali, Salah H. R.Ehab, EslamBarakat, EbrahimYounes, AbdelrahmanAli, Amr S.H.R.
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