Abstract:
The lamination process is the core in the manufacture of carbon fibre
composites. This thesis is a detailed study of the manner in which in-process
inspection can be organised so that process flaws that subsequently result in
defects can be eliminated or minimised. The quality management system and
the inspection methods in force at Lola are thus subjected to intensive scrutiny
so as to identify opportunities for improvement.
A review of relevant literature on quality management, continuous improvement,
mistake-proofing and zero defect initiatives helped map out a methodology for
the research. The literature has also looked at the human issues that influence
quality and inspection methods.
The approach to the study has been to establish quality performance in the past
and at present, establish quality attitudes and evaluate inspection methods.
Visual inspection is the widely used method of inspection within the industry and
instrument aided methods are still an area for research. Ways in which defects
may be prevented from occurring and analysing the defects when they occur so
as to get to the root causes have been suggested.
This study has highlighted the need to adhere to standard operating procedures
which account for errors that are avoidable. Motivation and inspiration can only
be cultivated into workers through recognition and rewards. Employee
engagement is very crucial and workers need to be supported with focussed
training and appropriate working aids.
Recommendations have been made on involving workers right from the design
stage through the manufacturing process right to the customer. Customer requirements will need to be executed with certainty and all necessary
information deemed useful will must be input at the design stage. In-process
inspection must take a holistic approach i.e. both horizontal and vertical
inspection. A point worth noting is that visual inspection accounts for at least
80% of inspections carried out in the manufacture of carbon fibre composites.
