面向质量目标的统计过程控制方法与应用研究
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摘要
制造过程质量是实现设计意图、保证产品质量的重要基础,过程质量控制已成为企业质量改进的先行技术。企业为了提高质量、降低成本就需要最大限度地控制和减少围绕设计目标产生的波动,尽可能的实现预期的质量目标。如何建立质量目标与过程质量控制之间的联系,从而确保质量目标的实现逐渐成为国内外质量控制研究者和实践者关注的焦点。
本文提出的面向质量目标的统计过程控制方法的研究和应用,在预期的质量目标与现场的过程质量控制之间建立了一座桥梁,实现面向质量目标的制造过程质量集成控制,在生产过程中确保预期的质量目标实现。其应用价值在于可以用和传统方法相同的工艺成本和设备条件实现机械产品更高的质量和精度,为有效地定量控制关键工序的废品率提供了一种可操作性强且规范化的新方法,对提升我国机械制造业的产品质量和制造精度水平有重大现实意义。论文的主要工作及创新成果如下:
1、根据确立质量目标的需求,研究了满足不同质量控制要求的质量指标及评价体系,主要包括以反映过程不合格率为特征的指标和以反映过程质量损失率和对中性为特征的指标,同时建立这个质量指标体系对应于一定的过程能力可实现性的合理分级。
2、研究了面向质量目标的统计公差及公差带的表达方式,总结了满足控制功能和三个层次的统计公差的定量要求,为质量指标的选择、统计过程控制图及其参数设计、给定置信度的抽样方案设计提供了所需要的标准化的方法。实现了这种统计公差技术功能的拓展、内涵的深化和创新,使其成为了指导统计过程控制、保证预期质量目标的不可缺少的界面。
3、基于上述面向质量目标的统计公差技术研究,提出了面向质量目标的统计过程控制方法,解决了生产过程中预期质量指标的实现问题。分别研究了面向质量目标的计量型常规控制图的设计及应用流程,以及针对过程小偏移情况的面向质量目标的累积和控制图(CUSUM)和面向质量目标的指数加权滑动平均控制图(EWMA)的参数优化设计及应用流程。
4、实现了面向质量目标的统计过程控制方法的初步应用研究,以系统研发的形式实现了对理论方法的进一步拓展和深化,结合具体企业的车间集成质量系统项目的开发实施,对该方法的推广应用进行了初步探索。通过系统运行分析,实现了对生产过程的实时监控和趋势分析,确保了过程在受控和有能力的状态下运行时质量目标的合理改进和实现。
Manufacture process quality is the important foundation to realize designing intention and assure product quality, the process quality control has become precession technique of enterprise's quality improving. In order to improve quality and reduce cost, the fluctuation produced around the design target is farthest controlled and reduced, a predetermined quality target is realized to the best of our abilities. How to establish the connection between quality target and process quality control, thus insure the realization of the quality target, it gradually becomes the focus that is cared by international quality control researcher and practitioner.
A quality-oriented statistical process control approach is put forward by this dissertation, therefore a bridge is set up between predetermined quality target and scene process quality control by researching of this method. The manufacture process quality control based quality target is realized. The predetermined quality target is realized in production process. Its using value lies in realizing mechanical product higher quality and precision with craft cost and apparatus condition the same as traditional method, the operable and standardized new method is offered for effectively and quantificationally controlling nonconforming rate of pivotal working procedure, there are great realistic meanings to improve the level of product quality and manufacture precision in mechanical manufacturing industry of our country. The main work and innovative achievement of this dissertation are as follows:
1、According to the requirements of establishing quality target, the quality target and quality evaluation system that could fill the request of different quality control. A set of standardized process quality indices for variables is introduced for meeting the measurement and evaluation to process yield, process centering and quality loss, the standardized process quality indices value system is presented based on raisonne grading by using the geometrical series of preferred numbers and arithmetical series.
2、The expression of quality-oriented statistical tolerance and quality-oriented statistical tolerance zones are studied, the quantitative requirement of three levels statistical tolerance and quality control are summarized. Standardized method is offered for choosing process quality target, designing statistical process control chart parameter, designing sampling plan based on a required confidence probability. Function development and connotation promotion of this statistical tolerance is realized, to develop a quality-oriented statistical process control approach, a standardized interface between process quality indices system and the parameter design of control charts is needed.
3、On the basis of the research of quality-oriented statistical tolerance, a quality-oriented statistical process control approach is put forward. The design and application flow of quality-oriented conventional control chart is studied. For more efficient detecting small in the process mean, the Cumulative Sum (CUSUM) Control Chart and the exponentially weighted moving average (EWMA) control chart is studied, an optimization design parameters and application flow of CUSUM control chart and EWMA control chart are designed to make the chart have the best average run length performance. This kind of method is improvement of the traditional statistical process quality control.
4、The preliminary application study of the quality-oriented statistical process control approach is realized. The further expansion and deepen of this theory method is realized by the form of software system. Combining the development of the workshop integrated quality system project, the popularization and application of this method is explored tentatively. By analyzing system run, make the manufacture process is in real-time monitored, make sure that the rational improvement of the quality target could be realized in controlled process condition.
本文提出的面向质量目标的统计过程控制方法的研究和应用,在预期的质量目标与现场的过程质量控制之间建立了一座桥梁,实现面向质量目标的制造过程质量集成控制,在生产过程中确保预期的质量目标实现。其应用价值在于可以用和传统方法相同的工艺成本和设备条件实现机械产品更高的质量和精度,为有效地定量控制关键工序的废品率提供了一种可操作性强且规范化的新方法,对提升我国机械制造业的产品质量和制造精度水平有重大现实意义。论文的主要工作及创新成果如下:
1、根据确立质量目标的需求,研究了满足不同质量控制要求的质量指标及评价体系,主要包括以反映过程不合格率为特征的指标和以反映过程质量损失率和对中性为特征的指标,同时建立这个质量指标体系对应于一定的过程能力可实现性的合理分级。
2、研究了面向质量目标的统计公差及公差带的表达方式,总结了满足控制功能和三个层次的统计公差的定量要求,为质量指标的选择、统计过程控制图及其参数设计、给定置信度的抽样方案设计提供了所需要的标准化的方法。实现了这种统计公差技术功能的拓展、内涵的深化和创新,使其成为了指导统计过程控制、保证预期质量目标的不可缺少的界面。
3、基于上述面向质量目标的统计公差技术研究,提出了面向质量目标的统计过程控制方法,解决了生产过程中预期质量指标的实现问题。分别研究了面向质量目标的计量型常规控制图的设计及应用流程,以及针对过程小偏移情况的面向质量目标的累积和控制图(CUSUM)和面向质量目标的指数加权滑动平均控制图(EWMA)的参数优化设计及应用流程。
4、实现了面向质量目标的统计过程控制方法的初步应用研究,以系统研发的形式实现了对理论方法的进一步拓展和深化,结合具体企业的车间集成质量系统项目的开发实施,对该方法的推广应用进行了初步探索。通过系统运行分析,实现了对生产过程的实时监控和趋势分析,确保了过程在受控和有能力的状态下运行时质量目标的合理改进和实现。
Manufacture process quality is the important foundation to realize designing intention and assure product quality, the process quality control has become precession technique of enterprise's quality improving. In order to improve quality and reduce cost, the fluctuation produced around the design target is farthest controlled and reduced, a predetermined quality target is realized to the best of our abilities. How to establish the connection between quality target and process quality control, thus insure the realization of the quality target, it gradually becomes the focus that is cared by international quality control researcher and practitioner.
A quality-oriented statistical process control approach is put forward by this dissertation, therefore a bridge is set up between predetermined quality target and scene process quality control by researching of this method. The manufacture process quality control based quality target is realized. The predetermined quality target is realized in production process. Its using value lies in realizing mechanical product higher quality and precision with craft cost and apparatus condition the same as traditional method, the operable and standardized new method is offered for effectively and quantificationally controlling nonconforming rate of pivotal working procedure, there are great realistic meanings to improve the level of product quality and manufacture precision in mechanical manufacturing industry of our country. The main work and innovative achievement of this dissertation are as follows:
1、According to the requirements of establishing quality target, the quality target and quality evaluation system that could fill the request of different quality control. A set of standardized process quality indices for variables is introduced for meeting the measurement and evaluation to process yield, process centering and quality loss, the standardized process quality indices value system is presented based on raisonne grading by using the geometrical series of preferred numbers and arithmetical series.
2、The expression of quality-oriented statistical tolerance and quality-oriented statistical tolerance zones are studied, the quantitative requirement of three levels statistical tolerance and quality control are summarized. Standardized method is offered for choosing process quality target, designing statistical process control chart parameter, designing sampling plan based on a required confidence probability. Function development and connotation promotion of this statistical tolerance is realized, to develop a quality-oriented statistical process control approach, a standardized interface between process quality indices system and the parameter design of control charts is needed.
3、On the basis of the research of quality-oriented statistical tolerance, a quality-oriented statistical process control approach is put forward. The design and application flow of quality-oriented conventional control chart is studied. For more efficient detecting small in the process mean, the Cumulative Sum (CUSUM) Control Chart and the exponentially weighted moving average (EWMA) control chart is studied, an optimization design parameters and application flow of CUSUM control chart and EWMA control chart are designed to make the chart have the best average run length performance. This kind of method is improvement of the traditional statistical process quality control.
4、The preliminary application study of the quality-oriented statistical process control approach is realized. The further expansion and deepen of this theory method is realized by the form of software system. Combining the development of the workshop integrated quality system project, the popularization and application of this method is explored tentatively. By analyzing system run, make the manufacture process is in real-time monitored, make sure that the rational improvement of the quality target could be realized in controlled process condition.
引文
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