【作者】 孙华；

【导师】 苗瑞； 朱相鹏；

【作者基本信息】 上海交通大学 ， 工业工程（专业学位）， 2017， 硕士

【摘要】 中国汽车市场的规模已经跃居全球第一,并为本土汽车零部件企业提供了良好的发展机遇。但本土中小型汽车零部件企业也面临着汽车行业及整车客户的要求不断提高,以及外资背景零部件企业强势争夺市场的双重压力。本土中小型企业在生产管理及产品质量水平上的劣势非常明显,导致在竞争中无法赢得更多的市场份额。数量占中国汽车零部件市场80%的本土企业,却只占30%的市场份额。如何按汽车行业体系要求推行质量工具的应用,提高产品质量水平,已经成为关系到本土中小型企业长远发展的重要任务。论文以本土中小型企业生产的对汽车行驶安全性、环保舒适性都极其重要的底盘用橡胶衬套为例,对橡胶衬套从原材料到成品的加工工艺进行了分析,确定了研究对象,识别出了各工序的关键控制点,找到了影响橡胶衬套质量的关键要素,并应用试验设计法重点优化了橡胶衬套的切管和电泳工序的工艺参数。论文应用工艺流程图和失效模式后果与分析方法,识别了生产过程中的潜在风险,详细分析了切管及衬套缩径这两道关键工序的失效模式及风险程度,提出了针对性的措施,并对橡胶衬套的零件及总成的整个生产过程应用了同样的方法,引入了风险预防措施,实现了风险的降低和规避,使得整个生产过程的质量水平大幅提升。论文应用了测量系统分析和统计过程控制方法,提高了关键的缩径工序的过程能力,提出的改善措施使橡胶衬套的缩径工序过程能力从0.5大幅提高到1.43,实现了橡胶衬套缩径尺寸的长期稳定。论文应用了控制计划方法,将上述各种工具进行了集成,制定了标准化文件,用于指导日常生产,实现了过程的持续稳定,质量问题数量大幅下降,由平均每月2.5起降低到了平均每月0.4起,改善效果显著。该方法帮助企业建立起了有效的用于批量生产的过程质量控制系统,降低了不良品率,避免了客户抱怨,实现了稳定的生产过程及可靠的产品质量,增强了企业的综合竞争力。更多还原

【Abstract】 Fast growing Chinese auto market tops U.S.auto market and became the first in the world years ago,and it’s bringing good opportunities for local automotive component companies.However,local small and medium automotive component companies are facing pressures both from higher requirement of OEMs and losing share of the market due to competitiveness from foreign-backgrounded component companies.Local companies account for around 80% of total number,only have 30% of the whole market share due to weaknesses of product quality and production management.How to implement quality tools according to industrial criteria to improve product quality has become an urgent task for local small and medium automotive component companies’ long term development.In this paper,a rubber bush in chassis,which is important for safe and comfortable driving,and manufactured by a typical local small and medium component company,is taken as an object of study by analyzing the process from raw material to final product.Key points of process are identified,and parameters of tube-cutting and e-coating are optimized by using Design of Experiment(DOE).Flow Chart and Failure Mode Effects and Analysis(FMEA)are introduced to predict kinds of failures in the process and risk-proofing actions are figured out accordingly and making the whole process getting more robust.Two critical processes,tube-cutting and swaging are studied and improved by using FMEA.Measuring System Analysis(MSA)and Statistics Process Control(SPC)are introduced to study the measuring system and manufacturing process capability,which are improved from 0.5 to 1.43 after taking actions,and long-term stability is realized.By using Control Plan(CP)to integrate all quality tools above,a robust quality control system is formed up.All of these analysis and studies,are helping this company decreasing NG parts as well as customer complaints from 2.5 incidents per month to 0.4.Manufacturing process stability and overall competitiveness with better quality performance are finally realized in this company.更多还原