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Tool replacement policy for one-sided processes with low fraction defective

Author

Listed:
  • W L Pearn

    (National Chiao Tung University)

  • Y-C Hsu

    (National Chiao Tung University)

  • J-J Horng Shiau

    (National Chiao Tung University)

Abstract

In most manufacturing industries, tool replacement policy is essential for minimizing the fraction defective and the manufacturing cost. Tool wear is caused by the action of sliding chips in the shear zone, and the friction generated between the tool flank and workpiece. This wear, apparently, is a dominant and irremovable component of variability in many machining processes, which is a systematic assignable cause. As the tool wear occurs in the machining processes, the fraction of defectives would gradually become significant. When the fraction defective reaches a certain level, the tool must be replaced. Therefore, detecting suitable time for tool replacement operation becomes essential. In this paper, we present an analytical approach for unilateral processes based on the one-sided process capability index C PU (or C PL ) to find the appropriate time for tool replacement. Accurate process capability must be calculated, particularly, when the data contains assignable cause variation. By calculating the index C PU (or C PL ) in a dynamical environment, we propose estimators of C PU (or C PL ) and obtain exact form of the sampling distribution in the presence of systematic assignable cause. The proposed procedure is then applied to a real manufacturing process involving tool wear problem, to demonstrate the applicability of the proposed approach.

Suggested Citation

  • W L Pearn & Y-C Hsu & J-J Horng Shiau, 2007. "Tool replacement policy for one-sided processes with low fraction defective," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 58(8), pages 1075-1083, August.
    • Handle: RePEc:pal:jorsoc:v:58:y:2007:i:8:d:10.1057_palgrave.jors.2602224
    DOI: 10.1057/palgrave.jors.2602224
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    References listed on IDEAS

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    1. Alwan, Layth C & Roberts, Harry V, 1988. "Time-Series Modeling for Statistical Process Control," Journal of Business & Economic Statistics, American Statistical Association, vol. 6(1), pages 87-95, January.
    2. K. Palmer & K.-L. Tsui, 1999. "A review and interpretations of process capability indices," Annals of Operations Research, Springer, vol. 87(0), pages 31-47, April.
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