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How can you make your fabrication process reliable and repeatable?

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If you are an electrical engineer involved in fabrication, you know how important it is to ensure that your process is reliable and repeatable. This means that you can produce consistent and high-quality products that meet your specifications and customer expectations. In this article, we will discuss some tips and best practices that can help you achieve this goal.

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1 Define your requirements

Before you start your fabrication process, you need to clearly define your requirements and objectives. What are the design specifications, performance criteria, and quality standards that you need to meet? What are the materials, tools, and equipment that you need to use? What are the risks and challenges that you need to anticipate and mitigate? By defining your requirements, you can set the scope and boundaries of your fabrication process, and avoid unnecessary changes, errors, or rework.

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Dr. Muhammad Salman, PhD

Deputy Controller of Examinations / Associate Professor of Electrical Engineering & Control Systems
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The typical steps involved in defining requirements and objectives before a fabrication process can be: 1. Defining the Need * Identify the problem or opportunity the product aims to address * Determine its intended use and target audience 2. Establishing Requirements * Functional requirements: Specify what the product must do * Non-functional requirements: Define limitations and constraints 3. Setting Objectives * Define measurable performance goals * Establish success criteria 4. Design Specifications * Develop detailed technical drawings and specifications outlining the product's design & construction * Include material selection, dimensions, tolerances, & assembly instructions 5. Performance Criteria * Define measurable parameters

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Alexander Coffman

Engineer & Speaker | Mentoring young professionals to increase productivity and develop professionally | Exploring emerging technology, economic, and policy solutions to the polycrisis
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Clearly defining the technical and quality requirements of your product is the first step to ensuring a reliable and repeatable fabrication process. Understand the specifications your product must meet, including dimensions, tolerances, materials, and finish. This clarity forms the basis for planning and executing your fabrication process.

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2 Plan your process

Once you have defined your requirements, you need to plan your fabrication process in detail. This means that you need to identify and document the steps, procedures, and parameters that you need to follow and control. You also need to determine the roles, responsibilities, and skills of the people involved, and the communication and collaboration methods that you need to use. By planning your process, you can optimize your workflow, resources, and time, and ensure that everyone is on the same page.

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Alexander Coffman

Engineer & Speaker | Mentoring young professionals to increase productivity and develop professionally | Exploring emerging technology, economic, and policy solutions to the polycrisis
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Develop a detailed plan for each step of the fabrication process, from material selection and procurement to machining, assembly, and finishing. Identify critical process parameters that influence product quality and establish standard operating procedures (SOPs) to maintain consistency across production runs.

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3 Simulate your process

Before you execute your fabrication process, you need to simulate your process using software tools and models. This means that you need to test and verify your design, functionality, and performance under different conditions and scenarios. You also need to analyze and evaluate your results, and identify and resolve any issues or discrepancies. By simulating your process, you can validate your assumptions, reduce your uncertainties, and improve your outcomes.

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Alexander Coffman

Engineer & Speaker | Mentoring young professionals to increase productivity and develop professionally | Exploring emerging technology, economic, and policy solutions to the polycrisis
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Utilize simulation tools to model your fabrication process before physical production begins. This can help identify potential issues or bottlenecks and allows for the optimization of process parameters for efficiency and quality. Simulation aids in minimizing waste and ensures that the process is reliable before it's executed on the shop floor.

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4 Monitor your process

During your fabrication process, you need to monitor your process using sensors, instruments, and data. This means that you need to measure and record your inputs, outputs, and variables, and compare them with your expectations and standards. You also need to detect and report any deviations, anomalies, or failures, and take corrective actions if needed. By monitoring your process, you can track your progress, performance, and quality, and ensure that you are on the right track.

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Alexander Coffman

Engineer & Speaker | Mentoring young professionals to increase productivity and develop professionally | Exploring emerging technology, economic, and policy solutions to the polycrisis
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Implement real-time monitoring of your fabrication process using sensors and data analytics tools. Monitoring critical parameters such as temperature, pressure, and feed rates allows for immediate adjustments to maintain process control and product quality. This ongoing oversight is key to detecting deviations early and ensuring repeatability.

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5 Review your process

After your fabrication process, you need to review your process using feedback, evaluation, and improvement. This means that you need to collect and analyze your data, results, and outcomes, and assess how well you met your requirements and objectives. You also need to identify and document your strengths, weaknesses, opportunities, and threats, and implement any changes or improvements if needed. By reviewing your process, you can learn from your experience, enhance your skills, and increase your efficiency.

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Alexander Coffman

Engineer & Speaker | Mentoring young professionals to increase productivity and develop professionally | Exploring emerging technology, economic, and policy solutions to the polycrisis
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Regularly review the performance of your fabrication process against your defined requirements. Conduct audits and quality checks to assess compliance with SOPs and product specifications. Use this review to identify areas for improvement and implement corrective actions to refine your process.

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6 Repeat your process

Finally, you need to repeat your process using standardization, documentation, and automation. This means that you need to establish and follow consistent and reliable methods, practices, and protocols for your fabrication process. You also need to document and share your process, data, results, and outcomes, and use them as references or benchmarks for future projects. By repeating your process, you can ensure that you can produce the same or better products every time, and satisfy your customers and stakeholders.

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Alexander Coffman

Engineer & Speaker | Mentoring young professionals to increase productivity and develop professionally | Exploring emerging technology, economic, and policy solutions to the polycrisis
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Consistency is crucial for reliability and repeatability. Once your process has been optimized and validated, ensure that it is followed precisely for each production run. Continuous training for operators on the SOPs and frequent recalibration of equipment can help maintain this consistency.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Alexander Coffman

Engineer & Speaker | Mentoring young professionals to increase productivity and develop professionally | Exploring emerging technology, economic, and policy solutions to the polycrisis
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Beyond the immediate fabrication process, consider the impact of supply chain management, equipment maintenance, and workforce skills on the reliability and repeatability of your process. A holistic approach that includes regular supplier evaluations, preventive maintenance schedules for equipment, and ongoing training programs for staff will contribute to the overall success and sustainability of your fabrication operations.

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How can you make your fabrication process reliable and repeatable?

1

2

3

4

5

6

7

1 Define your requirements

2 Plan your process

3 Simulate your process

4 Monitor your process

5 Review your process

6 Repeat your process

7 Here’s what else to consider

Electrical Engineering

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How can you make your fabrication process reliable and repeatable?

1

2

3

4

5

6

7

1 Define your requirements

2 Plan your process

3 Simulate your process

4 Monitor your process

5 Review your process

6 Repeat your process

7 Here’s what else to consider

Electrical Engineering

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