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BTU
Schriftliche Befragungen gibt es in der heute bekannten Form seit den 1970er Jahren [1]. Inzwischen stellen Befragungen in der empirischen Forschung eine der häufig angewendeten Erhebungsmethoden dar [2]. Eine Vielzahl an Informationen existiert zum Thema Fragebogen und dessen Erstellung sowie zur Durchführung und Auswertung der Befragung. Immer wieder stellen sich ähnlichen Fragen, die in einem kleinen Leitfaden beantwortet werden sollen. Die Durchführung einer schriftlichen Befragung folgt häufig einem sehr ähnlichen Muster. Es existieren bereits Leitfäden wie „The Tailored Design Method“ nach DILLMAN ET AL [3]. Dieser Leitfaden leistet Hilfestellung bei der Erarbeitung eines Fragebogens und verspricht eine hohe Datenqualität und Ausschöpfungsquote. Der Leitfaden besitzt jedoch keinen Abschnitt über die Datenauswertung [3]. Auf der letzten GQW – Tagung stützte sich ein großer Teil der Beiträge auf Befragungen. Mithin stellte sich die Aufgabe zur Entwicklung eines Leitfadens für Befragungen. Darin werden typische Problemstellungen wie der repräsentative Stichprobenumfang, allgemeine Anforderungen an das Design und mögliche Fehler adressiert. Zu diesem Zweck wird zunächst die bereits vorhandene Literatur analysiert, zusammengefasst und anschließend ein Leitfaden daraus entwickelt. Ergebnisse einer Befragung sollten statistisch belastbar sein, damit abgesicherte Aussagen aus den Ergebnissen abgeleitet werden können. Der erstellte Leitfaden soll in die Lehrtätigkeiten eingebaut werden und Studierenden bei der Durchführung belastbarer Umfragen unterstützen. Auf diese Weise wird zur nachhaltigen Förderung des Qualitätsmanagements–Nachwuchses beigetragen.
FMEA Software comparison
(2017)
Purpose
Quality requirements, as per customer, are steadily rising. To meet these requirements it is extremely important for manufacturing and developing companies to implement an early detection and prevention of failures. A widely used method, the Failure Mode and Effects Analysis (FMEA) is used to detect and avoid potential errors in the early development process and as well as to optimize the system as a whole.
The FMEA team is led by a moderator, and is interdisciplinary and cross departmental. The FMEA is carried out according to a systematic approach. For the implementation and documentation of the results, special software is available. As a rule the system function and malfunction, structures of the product and or process are created in the form of tree diagram. Afterwards the failure, failure causes, failure outcome, and existing measures are recorded in a form. If necessary, other measures and responsibilities are defined.
The special software used for this purposes is criticized for the complicated user interface restricted access to the result and the inflexibility of the tree structure.
In 2005, the Chair of Quality Management developed an Excel template to carry out the FMEA and to document the results, and since then it has been constantly under development. Using standardized software, the training period should be reduced and the flexibility to the results should be increased. Instead of using tree structures, company specific product and process visual aids are implemented. Both methods are tested in order to see the suitability in different situations and to support the implementation of the FMEA as well as the documentation of the results. The programs IQ-RM PRO 6.5 from APIS and the Excel template Flex-FMEA 2.0 from the Chair of Quality Management are compared to each other.
Methodology
The investigation of the suitability for the methods to carry out the FMEA and the documentation of the results is done through student experimentation and followed by a written survey. The suitability assessment of the method is been investigated through the influence of the group size and the nature of the FMEA.
The students are divided into groups with one group testing a FMEA using the IQ-RM PRO 6.5 from APIS and the other group using the Excel template Flex-FMEA 2.0 from the Chair of Quality Management. The group size and the nature of the FMEA varies. The objects of observation in the FMEA are not very complex and everyday relatable so that every participant is actively involved.
Findings and Value of Paper
The results show the impact of group size and nature of the FMEA in relation to the suitability assessment of both methods.
It is interesting to examine the influence of other factors, for example, the experience of the participants or the complexity of the objects of observation on the suitability assessment.
Through the investigation, situational specific recommendations for both methods can be deduced.
Based on concepts, such as the Kano Model, it can be assumed that the customer needs for the same product, change over time. Furthermore, innovation and the continuous develop-ment of the state of the art change the demands on a product. This implies that it is neces-sary for companies to evaluate and develop their product audits. In a previous paper, the re-search need for product audit improvements based on changing customer requirements was investigated by a literature analysis and three expert interviews. The present study is the additional practice-oriented analysis of the need for further research.
The objective of this study is to uncover the practice-oriented need for research in compa-nies in order to develop methods and procedures based on a theoretical and scientific level.
Methodology/Approach:
A questionnaire investigates the state of the art application-oriented problem in different industrial branches. Based on previous research the survey was developed online, which was sent to different companies, shared on social media platforms, and was available online for several month.
Findings:
The survey confirmed the theoretically determined need for research. Approximately 90 percent of the respondents have the opinion that product audits have to be developed contin-uously based on changing customer requirements. About 54 percent of the participants wish to receive methodological support because they do not know how to carry out an analysis of changing customer requirements.
Research Limitation/implication:
These findings are limited to the considered companies and industrial branches.
Value of paper:
The study shows the need for research of product audit improvement as well as the need for developing methods to compare quality scales of various target groups. This is the basis for feasibility investigations.
Ein wichtiger Aspekt beim Kauf eines Neufahrzeugs ist u. a. die Wahl der Antriebsart des Automobils. Um den neuen Umweltanforderungen aus Politik und Gesellschaft gerecht zu werden, müssen Unternehmen der Automobilbranche Anpassungsstrategien entwickeln und sich mit ihren Produkten neu ausrichten. Besonders sichtbar wird die Diskussion in Anbetracht der Endlichkeit fossiler Ressourcen für die Automobilbranche beim Übergang auf alternative Antriebsarten. Beim Auswahlprozess eines Fahrzeugs ist für die KäuferInnen u. a., die Wahl der Antriebsart eine mittlerweile grundlegende Fragestellung, welche in Zukunft weiter an Bedeutung zunehmen wird. Dabei wirken verschiedene Einflüsse und Anforderungen auf den Auswahlprozess zur Antriebsart. Diese Einflüsse und Kriterien werden im Rahmen der vorliegenden Studie untersucht. Ziel ist es, Treiber für die Anforderungsverschiebung bei den KundInnen zu identifizieren und Handlungsempfehlungen für das Anforderungsmanagement der Automobilbranche abzuleiten. Dafür kommt neben einer Literaturrecherche eine Onlineumfrage zum Einsatz. In einer ersten Vorauswahl wurden mittels Literaturanalyse 11 Kriterien identifiziert. Zu diesen gehören unter anderem: die Wohnregion, das Geschlecht, die Zufriedenheit mit dem Versorgungsnetz und die Reichweite eines Automobils. Als Ergebnis aus der anschließenden Onlineumfrage kann festgehalten werden, dass die Wahl der Antriebsart von verschiedenen Faktoren abhängig ist und viel Spielraum für weitere Forschungsarbeiten bietet. Basierend auf der Datenauswertung
sind vor allem personenbezogene Daten, wie Alter und Wohnregion
eines Individuums, maßgebend bei der Wahl der Antriebsart. Zur Erreichung politischer Klimaziele, ist eine zukünftige nachhaltige Erhöhung der Akzeptanz alternativer Antriebe unumgänglich. Dafür bedarf es einer intensiven Einbindung der Nachfrageseite.
Veränderung von Kundenanforderungen in der Automobilindustrie - Analyse von Experteninterviews
(2019)
Sich verkürzende Produktlebenszyklen stellen Unternehmen vor große Herausforderungen. Durch den steigenden Wettbewerbsdruck und die zunehmende Vernetzung müssen Unternehmen in kurzer Zeit neue Innovationen generieren, um auf dem Absatzmarkt attraktiv zu bleiben. Die sich ändernde Dynamik von Kundenanforderungen stellt dabei einen schwer einzuschätzenden Einflussfaktor dar. Vor allem in der Automobilindustrie kann eine Verkürzung der Produktlebenszyklen beobachtet werden. Um individuelle Unternehmensziele, wie bspw. geringe Entwicklungskosten, niedrige Produktionskosten und hohe Qualitätsstandards einzuhalten, ist die gezielte Suche nach Optionen und Wegen zur Beherrschung von Variantenvielfalt und der Modellwechsel unerlässlich. Hierbei ist auch die Kenntnis über die Veränderung der Kundenanforderungen im zeitlichen Verlauf von Vorteil. Aus diesem Grund werden diese anhand der Automobilindustrie genauer untersucht.
In der vorliegenden Arbeit werden Expertinnen und Experten befragt um aktuelle Kundenanforderungen zu identifiziert und die Veränderung deren Bedeutung im Zeitverlauf zu bewerten. Hierzu wird das Kano-Modell herangezogen und eine Zuordnung zu den Klassen Begeisterungsanforderungen, Leistungsanforderungen und Basisanforderungen zu unterschiedlichen Zeitpunkten vorgenommen. Die Auswertung der Untersuchung lässt erste Rückschlüsse bezüglich der Auswirkungen der sich ändernden Kundeanforderungen auf die Dauer der Produktlebenszyklen in der Automobilindustrie zu.
Due to their versatile advantages, the use of additively manufactured components is growing. In addition, new additive manufacturing processes are constantly being developed, so that a wide range of printing processes are now available for metal. Despite the same starting material, the microstructure and thus also the final mechanical properties differ greatly compared to conventional processes. In most cases, only direction-dependent characteristic values from the uniaxial tension are used to qualify a printing process before it is used. The literature, on the other hand, demonstrates that the results are not transferable to other loading conditions. In this work, several engineering tests were integrated into a single test specimen so that they can be determined on the same specimen. The test specimen can be used to test tooth root strength, bending strength, notched bar impact energy, and thread strength depending on the mounting direction, thus representing industrial loading cases. In this study, test specimens were fabricated by conventional manufacturing (machining), L-PBF (Laser Powder Bed Fusion), and WA-DED (Wire Arc Direct Energy Deposition), and the results were compared using statistical methods. Factors to capture manufacturing influence and buildup direction were statistically validated on 316L. The work shows a benchmark with a typical initial microstructure of rolled and milled material, L-PBF, and WA-DED parts on loads close to the application and thus simplifies an industry-oriented evaluation of a new manufacturing process.
The Wire Arc Direct Energy Deposition (WA-DED) process is highly
regarded as part of additive manufacturing. Compared to other additive manufacturing
processes, it is characterized above all by its high deposition rate and low
system costs. Despite many years of experience in the build-up welding process,
WA-DED still holds a number of challenges in terms of process stability. This
article analyses the interactions in the WA-DED process. To this end, the process
was visualized and described with the help of Structured Analysis and Design
Technique (SADT). Building on this, a process Failure Mode and Effects Analysis
(FMEA) was presented to identify and priorities risks. Finally, the results of
the Taguchi tests were analyzed and visualized. The results illustrate the strong
interactions between the influencing factors. These have a material-specific effect
on the production results. Each new material composition therefore requires a
systematic analysis in order to determine quantitative correlations. In future, these
can be supported by machine learning approaches.
According to the Kano model, companies would be required to use a continuous adaptation of audit criteria. If the ever-changing customer necessities are not neglected, the relevancy of defined audit criteria and the framework conditions of the production start for product audits cannot be permanently ensured. For this reason, companies should compare and adjust the quality standards of all concerning employees with that of the customer, so that the audit criteria can also be reconciled and adjusted accordingly. In this respect, a procedure for matching quality standards has been developed together with a vehicle manufacturer and a feasibility study has been carried out. The focus of the study was on possible differences regarding the detection of defects between the employees, dealers, and customers, as well as the recording and analysis of the visual focus areas. For the study, the participants had to complete a written questionnaire and make a practical defect detection directly on the vehicle. The study results have shown a variety of potentials for action that can be applied at other companies. These include the regular internal matching of the quality standards, the continuous training of the employees as well as the integration of the customers and their changing product requirements after the start of product production.
New technologies have enabled additive manufacturing to construct components layer by layer using 3D model data. Machinery requirements for this are minimal, entailing only a welding device for energy input and a guiding machine to shape the component. Though there are clear benefits to the process, such as the cost-effective technology and high deposition rates, the complex interactions involved must receive due consideration.
Limits of Quality Management
(2011)
Approaches for Categorization of difficult to quantify Characteristics in Product Development
(2011)
The learning process can be divided into the sub-processes of understanding, storing, retrieving, and using the acquired knowledge. The acquisition of knowledge takes place through facts and statements based on the subject matter and by repetition in exercises. Providing game elements in university teaching, students should be more motivated and deal with the teaching content more intensively. The knowledge imparted is to be prepared more attractively for the students and a greater bond to the respective module is to be built up. Game-typical elements can efficiently link the individual sub-processes of learning with each other and thus maximize a student's performance, knowledge level and motivation. Due to the Covid19 pandemic and the ever-advancing technology development, digital teaching and learning have become essential components of university teaching in the long run.
Because quality management is a field that is closely related to practice, the focus is not only on teaching theoretical knowledge but also on practical relevance. The Chair of Quality Management offers the module Project Management every summer semester. The learning objective of the module is to enable students to plan projects and organize their implementation. The module Project Management consists of a lecture, a seminar, and a semester project. In the lecture, students are taught the basics of project management. In the seminar, students learn to select and apply project management methods for different problems. Practical exercises are supported by media and software demonstrations. In the semester project, students get together in groups and plan a project during the semester. The project is intended to help students practically implement the knowledge they have acquired in lectures and seminars. The topics are provided by the chair's corporate partners. To increase the realism of the projects, the handing out of an event card is linked to the interim deadlines. The event card implies an adjustment of already planned resources, activities and/or funds.
To optimally adapt the gamification elements for the module, a target group analysis was first conducted as part of the research work. Based on the findings, an action plan was created on how the gamification approach could be transferred into the teaching concept of the module. After implementation, the module was examined further in the course of a teaching evaluation and a survey of the participating students. The main goal of the investigation was to find out to what extent game-typical elements promote the learning process and how practical projects support the learning process. On the one hand, the survey confirmed the promotion of motivation and the learning process by means of game-typical elements among the students. The results show that the creative and diverse way of conveying the learning material is accepted by the students. On the other hand, the study showed that too many of these elements can have a negative effect and a possible saturation effect occurs. Furthermore, the authenticity of the module or the chair may decrease. The results and knowledge from the research work flow into the adjustments of the module and are to be transferred to further modules of the chair in the future.
Zeit ist Trumpf - Schnellere Fehlerkorrektur in der Produktion durch Analyse von Feldausfällen
(2016)
In recent years, employees have increasingly been working remotely. Thus, virtual collaboration has continuously gained in importance and the associated change in work organization is realized in virtually collaborating teams. In particular, the communication that takes place under these conditions differs significantly from traditional face-to-face communication and plays a central role in virtual team collaboration. The challenges and opportunities that arise in this context were investigated in this study. The study focuses on identifying the challenges employees face at the communication level in their everyday work. To this end, opinion interviews were conducted with employees of virtually collaborating teams. Based on the identified challenges, a survey was carried out to initiate the analysis based on (quantitative) data collection. After data cleaning, a sample of 291 participants could be collected. From the results obtained, potential improvements for communication, both for the management positions as well as the employees of virtually collaborating teams were derived.
The research confirmed that the communication effort in virtual teamwork is higher than in real teamwork. Furthermore, virtual communication has a significant influence on the factors team identification, miscommunication and the decision-making processes in the team.
Other findings of the study are that individuals who work only in face-to-face teams are more skeptical of virtual collaboration. In contrast, individuals who work exclusively virtually are more open to virtual and face-to-face collaboration. The results suggest there are more challenges when comparing virtual to face-to-face communication. In addition to the broader findings, it can be seen that the increasingly digitized world of work impacts communication and poses challenges for virtually collaborating teams. In addition to media competence, it is additionally important in this context that individual team members have team- and technology-related skills. In addition to these prerequisites, virtually collaborating team members should be prepared for and continuously supported in virtual collaboration and virtual communication through training, workshops and courses. This can be counteracted by increased communication, soliciting feedback, and face-to-face meetings. The research suggests that transparent and traceable communication and collaboration processes should be implemented in practice.
Simplifying the use of quality management methods to increase the acceptance in group Meetings
(2006)
Purpose: The target of this study is to reveal which aids used are the best method for acquiring knowledge. Especially by the use of Quality management tools regarding spreadsheets and statistics software. Therefore video tutorials, personal support and written instructions, as aids, are compared with and without time pressure.
Methodology/Approach: Students of the quality management class participated in two tests in order to capture user behavior. In the first part the students (n = 56) were asked about their user behavior regarding aids after a project that lasted several months. In the second part the students (n = 40) were given two aids and captured which aids they are using. The duration period and the quality of the results were also documented. At the end of both tests, the students were asked about their future favorite aids.
Findings: The first test revealed that 73% of the students used the video tutorial as an aid for their work. In future situations the students would work with written instructions, as long as there is no time pressure. If time limitation is a factor, they would rather work with video tutorials again. The second test confirmed that using video tutorials allowed for a shorter duration period. 48% were using the video tutorial while 38% used the written instruction. The suitability rating of the aids as well as the quality of the result did not differ. In future situations, the students would work again with video tutorials with or without time pressure.
Research Limitation/implication: The usage of video tutorials, personal support and written instructions for the application of Quality management tools with the use of appropriate software has been examined. The results do not show conclusions about the extent to which the aids are used for the mediation of complex issues. Follow-up studies are required for this purpose.
Originality/Value of paper: Among these three aids with regard to time pressure, video tutorials as well as the personal support seem to be the most efficient. If time pressure was applied to the test setting, the video tutorial was preferred. In the considered setting the use of video tutorials is recommended.
In this article, the potential risks in wire arc additive manufacturing are analyzed using failure mode and effects analysis. To achieve this, 186 possible causes of risk were analyzed and the five most critical risks were discussed in detail. Four significant risk factors were identified in the construction process. The fifth risk relates to the shielding gas flow. This is only one influencing factor among the welding parameters, which have strong interactions with each other. Therefore, their relationships should be analyzed on the basis of numerous tests.
Das Wire Arc Additive Manufacturing, kurz WAAM, ist ein additives Fertigungsverfahren, welches metallische Bauteile auf Grundlage des Lichtbogenschweißens fertigt. Additive Fertigung ist laut DIN EN ISO/ASTM 52900 ein Prozess, welcher Bauteile aus 3D-Modelldaten schichtweise herstellt. Die grundlegenden Komponenten sind ein Schweißgerät, welches die benötigte Energie zum Schmelzen des Metalldrahts in den Prozess einbringt sowie eine Führungsmaschine, welche die vorgegebene Geometrie des Bauteils abfährt. Anwendungsbereiche sind Rapid Prototyping und Tooling, Direct Manufacturing und Additive Repair. Die größten Vorteile stellen die kostengünstige Anlagentechnik und die hohen Abscheidungsraten dar. Nachteilig am Verfahren sind die mangelnde Prozessstabilität und Wiederholgenauigkeit. Der Beitrag soll dazu dienen, den Fertigungsprozess des WAAM-Verfahrens übersichtlich darzustellen, und dabei auf die komplexen Wechselwirkungen eingehen.