A hybrid rough-cut process planning for quality

This paper proposes a hybrid approach to develop a rough-cut process planning for quality. The approach aims to determine key process alternatives with an adequate process capability by systematic quality planning and assessment methods during the initial planning stage of the product development cycle. It consists of four steps: (1) identification of quality characteristics (2) planning of the process quality by combining quality function deployment (QFD) with the process failure mode and effect analysis (FMEA) (3) a selection of process alternatives, and (4) an assessment of process quality through a quality measure index, called the composite process capability (CCP). The process alternatives with an adequate CCP selected during the early design stage can then be not only used as the guidelines for detailed process planning but also as feedback for the product design and other functions for design evaluation and improvement. This approach is helpful to reduce or even eliminate the iterations of modification of process plans. A prototype system called the rough-cut process planning for quality (RPPFQ) has been developed for validation. A case study concerned with a satellite frame part is presented to illustrate the approach and prototype system in this paper.