Manufacturing block diagrams and optimal adjustment procedures

This paper introduces a technique for modeling manufacturing systems using block diagrams. The blocks represent linens transformations of dimensionles s noise vectors to normalized quality characteristic vectors. These block d iagrams are used to model on-line adjustment procedures using generalized i nverses. This adjustment strategy is shown to guarantee minimum quality los s as defined by Taguchi if the required adjustments have no active constrai nts. and is effective for coupled linear systems. The surface mount of larg e body packages serves as an example of the modeling techniques. Block diag rams of the surface mount process are developed for a production system inc orporating on-line adjustments and for the same system without adjustments. Data from preproduction runs support the model's predictions of bias, vari ance, and yield.