Integrated Methodology for Stabilizing Quality in Manufacturing Processes
DOI:
https://doi.org/10.63728/riisds.v12i1.346Keywords:
Turning process, analysis (R&R), FMEA, turning variability, continuous improvementAbstract
This study implements an integrated strategy based on Gage Repeatability and Reproducibility (R&R), Failure Mode and Effects Analysis (FMEA), and Statistical Process Control (SPC). The experimental work involved three operators, ten workpieces, and two repeated measurements per sample, using Analysis of Variance to identify the magnitude and sources of process instability. The initial R&R study revealed 79.09% part-to-part variability and 44.66% operator-related variability, indicating an unstable measurement and machining system. Based on these results, an FMEA was developed to prioritize critical failure modes such as chip accumulation, tool wear, and inadequate calibration of the measuring instrument. Validation was conducted using the process capability index (Cp) and the process centering index (Cpk). The second R&R confirmed the effectiveness of the corrective actions, achieving total measurement system variation below 10% and Cp and Cpk values greater than 1.33, demonstrating a stable and capable process. The integrated R&R–FMEA–SPC methodology is presented as an effective and replicable strategy for custom machining environments.
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