This book shows how to improve manufacturing by the use of process control. It shows specifically how improved economic performance in chemical manufacturing can be achieved and sustained through the application of process control and statistics to reduce process variability and improve quality, yield, throughput, energy utilization, and cycle time --i.e., the world class performance metrics in manufacturing. Because the technique is used to identify and assess process control improvements in terms of meeting business needs, it can also be directly applied to related processes in such industries as food and drugs, agricultural products, rubber, plastics, fibers, petroleum refining and petrochemicals, and film. Covers topics such as assessing variability; assessing control performance; process analysis to identify control opportunities; estimating benefits; prioritizing improvements for reduced resources; implementing automatic controls for reducing variability; inferential measurements; sustaining the benefits; and process design for improved controllability. For business managers, manufacturing supervisors, process engineers and applied statisticians responsible for improving the performance of their business.

Explaining how to implement and sustain a top-down strategy for manufacturing excellence, The 12 Principles of Manufacturing Excellence: A Leader’s Guide to Achieving and Sustaining Excellence provides a comprehensive, proven approach for delivering world-class performance while also cultivating the right culture through leadership and mentoring. Tapping into four decades of leadership experience, 35 years of it in the manufacturing industry, Larry Fast explains how to achieve vertical and horizontal alignment across your organization. He details a clear pathway to excellence via the 12 Principles of Manufacturing Excellence and provides a method for tracking progress—plant by plant and function by function. Emphasizing the importance of using Lean and Six Sigma tools to improve your business, the book: Integrates strategy and leadership development Paves a path for culture change–Operator-Led Process Control (OLPC)—that prepares hourly employees to take control of their processes and prepares management to enable them to do it Details an audit process for tracking progress and ensuring sustainability Includes a CD with color versions of the images in the book as well as a sample Manufacturing Excellence Audit, a sample Communications Plan, and a sample Training Plan that can all be easily customized for the reader’s use This resource-rich book will allow you to spell out leadership expectations and provide your employees and associates with a clear understanding of their individual roles. Helping you keep everyone in your organization focused during the quest towards sustainable manufacturing excellence, the accompanying CD supplies the tools you and your team will need to pursue it with passion, confidence, and urgency. Listen to what Larry Fast has to say about his new book, The 12 Principles of Manufacturing Excellence. Part One — Part Two

In his best-selling book Japanese Manufacturing Techniques, Richard J. Schonberger revolutionized American manufacturing theory and, more important, practice. In that breakthrough book, he revealed that Japanese manufacturing excellence was not culturally bound. Offering the first demystified explanation of the simple techniques that fueled Japan's industrial success, he demonstrated how the same methods could be put to work as effectively in U.S. plants.

Master Process Control Hands On, through Updated Practical Examples and MATLAB® Simulations Process Control: Modeling, Design, and Simulation, Second Edition, is a complete introduction to process control and has been fully updated, integrating current software tools to enable professionals and students to master critical techniques hands on through simulations based on modern versions of MATLAB. This revised edition teaches the field's most important techniques, behaviors, and control problems with even more practical examples and exercises. Wide-ranging enhancements include safety considerations, an expanded discussion of digital control, additional process examples, and updates throughout for newer versions of MATLAB and SIMULINK. Fundamentals of process control and instrumentation, including objectives, variables, block diagrams, and process flowsheets Methodologies for developing dynamic models of chemical processes, including compartmental models Dynamic behavior of linear systems: state-space models, transfer function-based models (including conversion to state space), and more Empirical and discrete-time models, including relationships among types of discrete models Feedback control; proportional, integral, and derivative (PID) controllers; and closed-loop stability analysis Frequency response analysis techniques for evaluating the robustness of control systems Improving control loop performance: internal model control (IMC), automatic tuning, gain scheduling, and enhanced disturbance rejection Split-range, selective, and override strategies for switching among inputs or outputs Control loop interactions and multivariable controllers An introduction to model predictive control (MPC), with a new discrete state-space model derivation exercise Bequette walks step by step through developing control instrumentation diagrams for an entire chemical process, reviewing common control strategies for individual unit operations, then discussing strategies for integrated systems. This edition also includes 16 learning modules demonstrating how to use MATLAB and SIMULINK to solve many key control problems, including new modules on process monitoring and safety, as well as a detailed new study of artificial pancreas systems for Type 1 diabetes. Register your book for convenient access to downloads, updates, and/or corrections as they become available. See inside book for details.

In this volume of the Six Sigma and Beyond series, quality engineering expert D.H. Stamatis focuses on how Statistical Process Control (SPC) relates to Six Sigma. He emphasizes the "why we do" and "how to do" SPC in many different environments. The book provides readers with an overview of SPC in easy-to-follow, easy-to-understand terms. The author reviews and explains traditional SPC tools and how they relate to Six Sigma and goes on to cover the use of advanced techniques. In addition, he addresses issues that concern service SPC and short run processes, explores the issue of capability for both the short run and the long run, and discusses topics in measurement.

This book is a practical guide to the application of control benchmarking to real, complex, industrial processes. The variety of industrial case studies gives the benchmarking ideas presented a robust real-world attitude. The book deals with control engineering principles and economic and management aspects of benchmarking. It shows the reader how to avoid common problems in benchmarking and details the benefits of effective benchmarking.

The concept of Quality Management began in the manufacturing sector, but a growing concern with quality in other areas of the economy has led to its wider application in service industries, government, education, and other not-for-profit agencies. A great quantity of material related to quality management has been produced in recent years, much of it by small presses, professional and trade associations, and consultants. The Quality Management Sourcebook is the first in-depth, international guide to the most useful material and sources of information. The book begins with the origins of quality management, explains how it evolved, examines its current situation, and explores the future. The book is divided into five main sections: * Introduction: General sources for information * Applications of total quality management * Focus on specific aspects of quality management * Quality in the future * Resource materials The Quality Management Sourcebook is an essential reference for everybody involved in either the theory or practice of quality management: in manufacturing, retail, banking, and insurance, the utilities industry, the transportation industry, health, education and other public services. Over 900 citations cover books, journal articles, technical reports, video training materials and software. Each is followed by a descriptive annotation. Resource materials include strategies for locating additional information; training materials; organizations; and consultants. The book concludes with a glossary of quality management terms, a name index, a title index, and a detailed subject index.