基于过程能力指数的工序质量控制研究
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摘要
质量管理与控制是企业实现预防原则、保持生产稳定的重要手段。只有工序质量满足制造要求,才能实现产品开发设计所设定的质量目标、生产出满足用户期望的优质产品。因此,在先进制造模式下,如何有效进行工序质量控制已成为当前产品质量控制领域的研究热点。
本文在归纳总结工序质量控制及过程能力指数相关理论的基础上,对基于过程能力指数的工序质量控制及抽样检验方案进行了研究,主要研究内容包括以下几个方面:
①工序质量控制的相关理论及控制系统研究。在回顾质量管理、工序质量和过程能力指数等基本理论与发展历程的基础上,对工序质量分析方法进行了探讨,建立了工序质量控制系统体系结构。
②基于过程能力指数的工序质量控制研究。在归纳分析几种基本过程能力指数的基础上,提出动态过程能力指数和动态修正过程能力指数、多工序过程能力指数等的概念,分析了动态过程能力指数与制造质量(合格率及废品率)之间的关系,并从质量损失的角度探讨了基于多工序过程能力指数的质量控制方法。分析了基于5M1E的过程能力指数改进关键因素,为从源头探究将过程能力指数持续维持在经济、合理范围奠定了基础。
③基于过程能力指数的抽样检验方案研究。考虑到过程能力指数在工序质量评价时使用的有效性和广泛性,建立了基于过程能力指数的抽样方案,研究了过程能力指数与抽样样本容量和不合格品率之间的关系,提出了在某一批量下,抽样样本容量和合格判定数的确定方法,并通过实例研究表明,该检验方法能够有效剔除不合格品、实现样本容量和合格判定数的正确确定。
Quality management and control are important means to realize the preventive principle and keep the stable production for enterprise. Only the process quality satisfies the manufacture demands, the quality aims of enactment during the products development and design can be realized and the high quality products satisfied the user desired can be produced. So, in Advanced Manufacturing condition, how to improve efficiently process quality has been the research focus in the current product quality control field.
In this paper, based on the correlation theories of the process quality control and the process capability indices induction and summarization, the process quality control and the sampling inspection plan are further studied based on the process capability indices. The mainly study is concerned about the following aspects:
①The correlation theories of the process quality control and control system are investigated. Biased on review the theories of quality control, the process quality control and the process capability indiceses and their development course, the methods of process quality analysis are discussed and the frame system of process quality control is founded.
②The process quality control based on the process capability indiceses is studied. Based on the basic process capability indiceses induction, the concepts of dynamic process capability indices, dynamic modify process capability indices and the multistage process capability indices are proposed. The relationship between dynamic process capability indices and manufacturing quality is analyzed. The method of quality control based on multistage process capability indices from quality loss is discussed.
③The products sampling inspection plan based on the process capability indiceses is researched. In view of prevent function of the process quality from the process capability indiceses, the products sampling inspection plan is established. The connections of the process capability indiceses with the sampling samples content and reject rate are studied. The in one batch is calculated. With the example investigate, the result shows that the inspection method can eliminate the reject and realize the sampling samples content and the number of eligibility products confirmation correctly.
本文在归纳总结工序质量控制及过程能力指数相关理论的基础上,对基于过程能力指数的工序质量控制及抽样检验方案进行了研究,主要研究内容包括以下几个方面:
①工序质量控制的相关理论及控制系统研究。在回顾质量管理、工序质量和过程能力指数等基本理论与发展历程的基础上,对工序质量分析方法进行了探讨,建立了工序质量控制系统体系结构。
②基于过程能力指数的工序质量控制研究。在归纳分析几种基本过程能力指数的基础上,提出动态过程能力指数和动态修正过程能力指数、多工序过程能力指数等的概念,分析了动态过程能力指数与制造质量(合格率及废品率)之间的关系,并从质量损失的角度探讨了基于多工序过程能力指数的质量控制方法。分析了基于5M1E的过程能力指数改进关键因素,为从源头探究将过程能力指数持续维持在经济、合理范围奠定了基础。
③基于过程能力指数的抽样检验方案研究。考虑到过程能力指数在工序质量评价时使用的有效性和广泛性,建立了基于过程能力指数的抽样方案,研究了过程能力指数与抽样样本容量和不合格品率之间的关系,提出了在某一批量下,抽样样本容量和合格判定数的确定方法,并通过实例研究表明,该检验方法能够有效剔除不合格品、实现样本容量和合格判定数的正确确定。
Quality management and control are important means to realize the preventive principle and keep the stable production for enterprise. Only the process quality satisfies the manufacture demands, the quality aims of enactment during the products development and design can be realized and the high quality products satisfied the user desired can be produced. So, in Advanced Manufacturing condition, how to improve efficiently process quality has been the research focus in the current product quality control field.
In this paper, based on the correlation theories of the process quality control and the process capability indices induction and summarization, the process quality control and the sampling inspection plan are further studied based on the process capability indices. The mainly study is concerned about the following aspects:
①The correlation theories of the process quality control and control system are investigated. Biased on review the theories of quality control, the process quality control and the process capability indiceses and their development course, the methods of process quality analysis are discussed and the frame system of process quality control is founded.
②The process quality control based on the process capability indiceses is studied. Based on the basic process capability indiceses induction, the concepts of dynamic process capability indices, dynamic modify process capability indices and the multistage process capability indices are proposed. The relationship between dynamic process capability indices and manufacturing quality is analyzed. The method of quality control based on multistage process capability indices from quality loss is discussed.
③The products sampling inspection plan based on the process capability indiceses is researched. In view of prevent function of the process quality from the process capability indiceses, the products sampling inspection plan is established. The connections of the process capability indiceses with the sampling samples content and reject rate are studied. The in one batch is calculated. With the example investigate, the result shows that the inspection method can eliminate the reject and realize the sampling samples content and the number of eligibility products confirmation correctly.
引文
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[2]张根保,何帧等.质量管理与可靠性[M].北京:中国科学技术出版社,2005.
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[5]林志航.计算机辅助质量系统[M].北京:机械工业出版社,1997.
[6]A.V.Feigenboum.全面质量管理[M].北京:机械工业出版社,1991.
[7]Werner A.J.Schippers.An Integrated Approach to Process Control[J].Int.J.Production Economics,2001,69:93-105.
[8]Kevin Linderman,Kathleen E.McKone-Sweet.An Integrated Systems Approach to Process Control and Maintenance[J].European Journal of Operational Research,2005,164:324-340.
[9]Winco K.C.Yung.An Integrated Model for Manufacturing Process Improvement.Journal of Materials Processing Technology 61(1996):39-45.
[10]吴少雄,黄恩洲.基于支持向量机的控制图模式识别[J].计算机应用,2007,9(1):61-63.
[11]龙震宇.计算机辅助工序质量统计分析系统的研究[D].大连:大连交通大学.2004.
[12]郑立伟.基于成组技术的质量控制方法与工具研究[D].天津:天津大学,2004.
[13]王丽颖,孙丽,王秀伦.基于虚拟工序的小批量工序质量控制方法研究[J].计算机集成制造系统,2006,12(08):1263-1266.
[14]翟敬梅,纪生,蒋梁中.制造过程质量超前控制方法的研究[J].机床与液压,2003,31(4):117-120.
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[16]王建稳.多品种小批量生产情形下的工序质量控制图[J].数理统计与管理,2002,7:34-37.
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[21]Boyles R.A.The Taguchi Capability Index[J].Journal of Quality Technology.1991,23(1):17-26.
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[24]Parlar M.,Wesolowsky G.O.Specification Limits,Capability Indices and Centering in Assembly Manufacture[J].Quality Engineering,1999,31(2):317-325.
[25]龙震宇.杨志刚.王秀伦.过程能力指数应用分析[J].现代制造工程 2004(2):10-11.
[26]赵妙霞,贾九红,郑玉巧.工序控制方法中工序能力的分析[J].甘肃工业大学学报,2003,29(4):49-51.
[27]黄平捷,杨将新.基于工序能力指标的工序公差优化设计研究[J].工程设计,2000(3):45-47.
[28]李奔波.基于成本控制的小批量生产过程能力指数研究[J].工业工程与管理,2005,(2):18-21.
[29]陈涛.基于因子分析的多元工序能力指数[J].机床与液压,2003,31(1):284-286.
[30]魏世振,韩玉启,郭建华.基于差异系数的多元过程能力指数[J].运筹与管理,2003,12(1):83-86.
[31]马义中.多元质量特性的过程能力指数[J].工业工程,2001,4(4):22-25.
[32]王启平.械制造工艺学[M].哈尔滨:哈尔滨工业大学出版社.1990.
[33]王毓芳,郝凤.过程控制与统计技术[M].北京:中国计量出版社.2001.
[34]Michael Stuart,Eamonn Mullins,Eileen Drew.Statistical Quality Control and Improvement[J].European Journal of Operational Research,1996,88:203-214
[35]宋友成.统计过程控制(SPC)的应用研究[D].天津:天津大学,2002.
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