Integration vibration-based maintenance detecting quality deviation earlier than when using traditional diagram in the automotive industry: a case study

摘要

The biggest challenge for the companies in manufacturing industry is how to maintain and improve the performance efficiency and quality rate at a reduced cost. The problem addressed in this paper is how to utilise integrated vibration-based maintenance (VBM) for detecting deviations in product (technical specifications) quality, beofore the machine starts manufacturing defective items. Maintenance concept development and a new VBM concept, Total Quality maintenance (TQMain), are discussed. A technical analysis is conducted to identify quality problem causes when manufacturing crankshafts in Volvo, Motor, Skovde, Sweden. A factorial experiment is conducted to assess the effect of the suspected causes. Measurements are done to collect vibration signals and machine speed from 7 measuring points. The major conclusion of this study can be stated as; when using an effective integrated VBM, deviations in product quality can be detected at an earlier stage than that when using usual quality control diagrams. Manufacturing defective items can be reduced dramatically (or prevented) which will eliminate bad quality - related losses.