CN110163538A - Movable core quality inspection improved method based on DMAIC - Google Patents
Movable core quality inspection improved method based on DMAIC Download PDFInfo
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Abstract
The invention discloses the movable core quality inspection improved methods based on DMAIC, it is related to valve body assembling quality field, its step includes: A, defines the stage: testing whithin a period of time to movable core, lists the inspection project of movable core, and obtains the fraction defective of each inspection project；B, measuring phases: the analysis of movable core poor prognostic cause is assessed the data and processes result of output, the principal element for influencing quality is found out using arrangement figure, is carried out on-site investigation to existing issue and is collected data；C, the underlying causes of cause-and-effect diagram problem analysis the analysis phase: are utilized；D, it improves the stage: proposing effective improvement project, optimization process output reduces or even eliminates the factor for influencing quality, minimizes defect；E, it controls the stage: standardizing improved achievement and pass through control figure production process is monitored and is maintained.The advantages of present invention has the underlying causes of analysis quality problems, proposes improvement plan and is implemented.
Description
Technical field
The present invention relates to electromagnet assembling quality fields, and in particular to the movable core quality inspection based on DMAIC improves
Method.
Background technique
With the past in enterprise's " measure victory " epoch, " quality first " has become the grand strategy of enterprise's profit.It can
For dynamic iron core as one of most important components of electromagnet, quality problems are the key components in production process.Due to movable
The demand of iron core is excessive, and before carrying out production line Assembling Production, quality department needs using CCD optical evaluation facility to it
Carry out quality inspection.
For the quality problems occurred in production process, most of corporate boss will be recycled by total quality control, PDCA
Etc. management methods product quality is controlled and is improved, however these methods are more suitable for the quality management of whole system, but
It is difficult to thoroughly solve the problems, such as some tiny, such as the quality inspection of Incoming Quality Control components.Under normal circumstances, supplied materials quality controls
(Incoming Quality Control, IQC) (the bulk bad lot number being transported on production line and arrives leak rate
Expect total lot number ratio) excessively high problem, it will usually reason of both considering: first is that inspection specification and gimmick go wrong, two
It is supplier's deficient purchase.However, either more positive test gimmick still replaces supplier again, do not simply fail to find out basic original
Cause simultaneously thoroughly solves the problems, such as, it is also possible to unnecessary loss can be caused to enterprise.Therefore, traditional method for quality control is very much
In the case of can not some tiny link occurs suitable for enterprise quality problems.
Summary of the invention
In order to overcome the shortcomings of that background technique, the present invention provide a kind of underlying causes for analyzing quality problems, propose to improve
Scheme and the movable core quality inspection improved method based on DMAIC being implemented.
The technical solution adopted in the present invention: the movable core quality inspection improved method based on DMAIC, step packet
It includes:
A, it defines the stage: a specific understanding and planning being carried out to movable core quality detection project, in a period of time
It is interior to test to movable core, the inspection project of movable core is listed, and obtain the fraction defective of each inspection project, is subsequent
Each stage lay the foundation；
B, measuring phases: the analysis of movable core poor prognostic cause assesses the data and processes result of output, utilizes row
Column figure finds out the principal element for influencing quality, carries out on-site investigation to existing issue and collects data, makes problem sharpening；
C, the analysis phase: using the underlying causes of cause-and-effect diagram problem analysis, find out measuring phases the output of process it is crucial because
Son；
D, it improves the stage: being directed to key factor, propose effective improvement project, and confirm that the program needs ideal to be achieved
Target, the target in this stage are optimization process output, reduce or even eliminate the factor for influencing quality, minimize defect；
E, it controls the stage: standardizing improved achievement and pass through control figure production process is monitored and is tieed up
It holds, while constantly seeking better improved method.
Inspection project in the step A includes:
Appearance test: it mainly checks whether damage of colliding with, whether has scratch, whether has that dirty and whether there is or not chamferings；
Dimension control: it mainly checks the right height dimension of movable core neck, left height dimension and outer diameter.
In the step B to existing issue carry out on-site investigation the following steps are included:
B1, several sampling observation quantity are determined, determines product qualification determination standard, enterprise and client's provisions for negotiations, is subjected to
The quality level upper limit is P0, acceptable limit rejected product percentage is P1, P1/P0；
B2, it determines risk indicator, determines producer risk α, user's risk β after enterprise and supplier's negotiation；
B3, it determines Plan of Double Sampling Inspection, inquires xx table, determine c, np0And n=np0/p0；
B4, implement Plan of Double Sampling Inspection, several movable cores are numbered and are put in sequence, with computer generate with
Machine number table extracts product to be checked according to the random number of generation；Respectively using CCD optical evaluation facility and projector to extraction can
Left height, right height and the outer diameter of dynamic iron core measure.
In the step C further include:
C1, use cause-and-effect diagram profound analysis is carried out to quality problems, come respectively from " man-machine material method ring " five broad aspects
The big reason of searching problem:
" people ": training is insufficient, be lacking in responsibility, self-test consciousness is insufficient；
" machine ": the maintenance of CCD optical evaluation facility is not in place, surface is dirty, numerical value setting is improper；
" material ": deficient purchase, mixing are excessive；
" method ": detection gimmick is inconsistent, detection method is improper；
" ring ": uneven illumination, temperature humidity are unsuitable, dust is excessive；
C2, the reason in step C1 is sorted out, respectively machine detection process goes wrong, production line detection process occurs
Problem and supplier's selection are improper, and establish movable core poor prognostic cause dendrogram.
The step D further include:
D1, using DOE experimental design method, establish 5 factor, 4 horizontal quadrature table L16(45) tested；Wherein 5 because of attached bag
It includes: right altitude range, left altitude range, external diametrical extent, intensity of illumination, temperature；
D2, DOE-field mouthful analysis is carried out to orthogonal experiments using Minitab, obtains the importance row of each factor
The combination of the optimum level of sequence and each factor.
Include: in the step F
F1, formulation simultaneously implement improvement plan, to the dimensional values adjustment of CCD optical evaluation facility and the tune of ambient enviroment
It is whole, machinery equipment is safeguarded using TPM management thought, reinforce employee's post training, per half a month replacement is primary on production line
Cubing；
F2, it is monitored using quality management tool (control figure), identifies the fluctuation situation occurred at present and takes reduction
The measure of fluctuation；
Overall equipment efficiency.comprehensive efficiency of equipment and movable core fraction defective, formula before and after F3, computed improved is as follows:
OEE=T*P*G；
T=S/L；
L=W-PS；
S=L-H-D；
P=N*V；
N=(Q*AC)/S；
V=T/AT；
G=q/p；
In formula, T is the time to start rate, and P is Performance Rate, and G is yields, and S is running time, and L is duration of load application, W
For the working time, PS is Scheduled Down Time, and H is the downtime, and D is adjusting machine time, and N is to start rate only, and V opens for speed
Dynamic rate, Q are processing quantity, and AC is the actual processing period, and T is theoretical process time, and AT is the actual processing time, and q is qualified product
Number, p is processing quantity.
The beneficial effects of the present invention are: the technical program, which passes through, understands the problem status in production assembling process,
And related data is collected for using the underlying causes of cause and effect map analysis quality problems, proposing improvement plan where defining issue
And be implemented, finally the achievement of implementation is analyzed and controlled；DMAIC can use in small batch production process a small amount of
Data, and then the main reason for leading to movable core quality problems is accurately analyzed, propose accurate corrective measure, and being formed can
The movable core quality control process leaned on, finally establish complete set, advantageously improve small lot production movable core plus
The method system of work technical process quality, facilitating enterprise reduces product defect rate, improves overall equipment efficiency.comprehensive efficiency of equipment.
Detailed description of the invention
Fig. 1 is the structural schematic diagram of movable core of the embodiment of the present invention.
Fig. 2 is the bad arrangement figure of movable core.
Fig. 3 is single sampling plan table.
Fig. 4 is the difference value histogram of the right height of movable core neck.
Fig. 5 is the difference value histogram of the left height of movable core neck.
Fig. 6 is the difference value histogram of movable core outer diameter.
Fig. 7 is the bad causal analysis diagram of movable core size.
Fig. 8 is movable core size poor prognostic cause classification dendrogram.
Fig. 9 is DOE-field mouthful analysis chart.
Figure 10 is TPM management method figure.
Figure 11 is the movable core fraction defective line chart for observing one month.
Figure 12 is movable core fraction defective control figure.
Specific embodiment
Embodiments of the present invention is further illustrated with reference to the accompanying drawing:
(1) stage is defined
1, understand Enterprises Quality Management status: firstly, purchasing department is responsible for periodically ordering a batch movably from supplier weekly
Then iron core transports movable core to CCD optical evaluation facility inspection from warehouse by IQC and carries out quality inspection, finally machine
The non-defective unit that platform filters out is sent to production line assembly electromagnet, and is configured in the final stage of production line for electromagnet
The process of " full inspection ", wherein mainly testing to movable core.Specific inspection of the CCD optical evaluation facility to movable core
Project is referring to table 1:
1 movable core of table examines project
Wherein in dimension control project, the specific inspection content of the left height of movable core, right height and outer diameter referring to
Attached drawing 1:
CCD optical evaluation facility is respectively as follows: the numerical value setting of each size at this time
Right height 3.780-3.850mm, offset: -0.09；Left height 3.780-3.850mm, offset: -0.09；Outside
Diameter 2.960-3.030mm, offset: 0.03.
2, clear quality problems status: observation and record by one month, during assembling electromagnet, " full inspection "
There are more serious quality problems in this process, and main cause is movable core size, bad order rate is excessively high, sends out after calculating
Existing, average fraction defective is up to 5.28%.
3, must solve the problems, such as and purpose: reduce movable core fraction defective on production line, raising product quality.
Two, measuring phases:
1, movable core poor prognostic cause is analyzed: the factor for the influence movable core quality that the stage of defining is recorded being arranged and is divided
Analysis, and principal element is found out from numerous factors for influencing quality using arrangement figure, referring to attached drawing 2:
By attached drawing 2 it is found that the undesirable principal element of movable core is that size is bad, i.e., outer diameter is bad and height is bad,
Cumulative percentage is respectively 40.5% and 68.5%, and bad order is then secondary cause and general factor, below for movable iron
The data collection and analysis of the bad progress of the size of core more further.
2, on-site investigation: since the movable core on production line derives from the non-defective unit of CCD optical evaluation facility screening, however
There are still a large amount of defective products for discovery in " full inspection " this process, so carrying out to the non-defective unit of CCD optical evaluation facility screening
Simple random sampling.To ensure that each unit product can be extracted into equal probability in be checked batch, selection is raw using computer
Random sampling is carried out to movable core at table of random numbers method, detailed process is as follows:
(1) determine sampling observation quantity: 200 non-defective units that CCD optical evaluation facility is filtered out are as inspection lot；Determine product
Qualification determination standard: enterprise and client's provisions for negotiations, the acceptable quality level upper limit are p0=1.5%, acceptable limit does not conform to
Lattice product percentage is p1=8%, in addition, p1/p0=5.33；
(2) it determines risk indicator: being determined after enterprise and supplier's negotiation, producer risk α=0.05, user's risk β
=0.05；
(3) Plan of Double Sampling Inspection is determined: it is found that c=3, np after inquiry single sampling plan table0=1.366, n=1.366 ÷
1.5%=91, single sampling plan table is referring to attached drawing 3, so Plan of Double Sampling Inspection is (91,3), i.e., sampling observation product sample quantity is 91
It is a, and rejected product number is necessarily less than and just can determine that be checked batch of qualification equal to 3；
(4) implement Plan of Double Sampling Inspection: 200 movable cores number is put in order, generate machine number table with computer, totally 91
It is a, product to be checked is extracted according to the random number of generation.It respectively can to 91 of extraction using CCD optical evaluation facility and projector
Left height, right height and the outer diameter of dynamic iron core measure, and this two groups of data are compared, and difference is referring to attached drawing 4,5
With 6；Wherein, the difference mean value of right height dimension is -0.01277mm, standard deviation 0.006687mm；The difference of left height dimension
Mean value is -0.01320mm, standard deviation 0.007198mm；The difference mean value of outer diameter is 0.01295mm, and standard deviation is
0.03067mm.That is the difference of outer diameter is maximum, illustrates that the setting of CCD optical evaluation facility numerical value needs to adjust, will be directed to CCD below
The excessively high problem of optical evaluation facility False Rate (defective products misjudgement is non-defective unit) is made a concrete analysis of.
Three, the analysis phase:
1, size poor prognostic cause is analyzed: profound analysis is carried out to quality problems using cause-and-effect diagram, respectively from " man-machine material method
Five broad aspect of ring " finds the big reason of problem, and brainstorming is recycled to seek the possible middle reason of each aspect or even small
Reason does the bad causal analysis diagram of movable core size until finding out all possible reason for causing quality to go wrong, and has
Body result is referring to attached drawing 7:
Each reason is arranged and is analyzed:
" people ": switching on and shutting down and batch turning need to be carried out to it since the operation of CCD optical evaluation facility is only responsible for by a people, and only
Work, be under normal circumstances not in mistake.And " full inspection " this process is grasped using the cubing of customization on production line
Make, the problems such as employee's operating method on production line is improper, attitude is careless and sloppy may be related to, so training is insufficient, lacks
Sense of responsibility, self-test consciousness deficiency etc. belong to production line detection process and go wrong；
" machine ": the maintenance of CCD optical evaluation facility is not in place, surface is dirty, numerical value is arranged the machine that belongs to such as improper and detects work
Sequence goes wrong；
" material ": deficient purchase, mixing are excessive etc. to belong to supplier's problem, that is, needs purchasing department negotiated therewith；
" method ": detection gimmick is inconsistent, detection method is improper etc. when being primarily referred to as employee on production line using cubing
Operating method is improper, belongs to production line detection process and goes wrong；
" ring ": the problems such as uneven illumination, temperature humidity are unsuitable, dust is excessive is mainly normal with CCD optical evaluation facility
It runs related, related personnel is needed to be adjusted in time, belong to machine detection process and go wrong.
Find after analysis and arrangement, it is a little bigger that all reasons can finally be attributed to three: (1) machine detection process goes wrong；(2)
Production line detection process goes wrong；(3) supplier's selection is improper.
2, reason, which arranges, sorts out: since the selection of supplier is responsible for by purchasing department, below only for preceding two a little bigger problems
The reason of analyzed and arranged classification, do movable core poor prognostic cause classification dendrogram, concrete outcome is referring to attached drawing 8:
Four, the stage is improved:
(1) machine detection process improves
Firstly, improving machine adjustment and its environmental problem using DOE experimental design method.DOE is according to mathematical statistics side
Method scientifically selects several groups of most representational experiment conditions from a large amount of experimental point comprehensively, and the specification of marshalling is made
Change table-orthogonal arrage.The expression symbol of orthogonal arrage can be expressed from the next:
Ln(tq)-it is known as t horizontal quadrature table；
In formula, L is orthogonal arrage symbol, and n is experiment number (orthogonal arrage line number), and t is that the number of levels of factor (occurs in 1 column
The number of different digital), q is most multipotency arrangement because of prime number (orthogonal arrage columns), it is meant that the q factor is shared in experiment, often
The state (level) that one factor has t kind different.
Wherein, common orthogonal arrage includes L4(23), L8(27), L12(211), L9(34), L16(45), L25(56), next
It need to determine the specific value of n, t, q.
The quality inspection of movable core is mainly responsible for by CCD optical evaluation facility, and CCD optical evaluation facility is being examined
Occur higher False Rate in the process, illustrates that the machine needs that go wrong are adjusted.CCD optical evaluation facility is influenced to examine
Factor be mainly that numerical value adjusts improper and environment influence, particular content includes: that right height number setting, left height number are set
It sets, the setting of outer diameter numerical value, intensity of illumination and temperature, i.e., there are five the factors altogether for machine and its environment adjustment, therefore t is 5, below
Its number of levels is determined to each factor according to the actual situation.
(1) dimensional values are arranged:
Hereinbefore it was mentioned that the invention that the dimensional values of CCD optical evaluation facility are arranged are as follows: right height 3.780-3.850, compensation
Value: -0.09；Left height 3.780-3.850, offset: -0.09；Outer diameter 2.960-3.030, offset: 0.03.And CCD optics
Equipment and the dimension difference of projector measurement is examined to be respectively as follows: right height dimension difference mean value: -0.01277；Left height dimension is poor
Value mean value: -0.01320；Outer diameter difference mean value: 0.01295.It is arranged below according to raw value setting and dimension difference
The number of levels of each dimensional values:
Right height: dimension difference takes -0.012 and -0.013 (3.780-0.012=3.768,3.780-0.013=respectively
3.767,3.850-0.012=3.838,3.850-0.013=3.837), four number of levels are determined after calculating, are respectively as follows:
3.768-3.838,3.768-3.837,3.767-3.838,3.767-3.837；
Left height: dimension difference takes -0.012 and -0.013 (3.780-0.012=3.768,3.780-0.013=respectively
3.767,3.850-0.012=3.838,3.850-0.013=3.837), four number of levels are determined after calculating, are respectively as follows:
3.768-3.838,3.768-3.837,3.767-3.838,3.767-3.837；
Outer diameter: dimension difference takes 0.012 and 0.013 (2.960+0.013=2.973,2.960+0.012=respectively
2.972,3.030+0.013=3.043,3.030+0.012=3.042), four number of levels are determined after calculating, are respectively as follows:
2.973-3.043,2.972-3.043,2.973-3.042,2.972-3.042；
Intensity of illumination setting:
Due to lacking the professional measurer such as illumination photometer, so can only be according to visual range estimation.CCD optical evaluation facility is located at quality
Department side near the window, and window is installed with curtain, and sunlight irradiation can be adjusted by curtain is pulled, has determined therefrom that four
Number of levels, intensity of illumination when being respectively as follows: sunlight irradiation near the window and standard-sized sheet lamp, illumination is strong when half lamp is only opened in sunlight irradiation near the window
Degree, intensity of illumination when sunlight irradiation near the window is not turned on light, intensity of illumination when without sunlight near the window is irradiated and do not turned on light.
Temperature setting:
The room as locating for CCD optical evaluation facility be equipped with air-conditioning and temperature monitoring, can by adjust air-conditioner temperature and
Temperature levels are arranged in observation temperature monitoring, are respectively as follows: 5 DEG C~10 DEG C, and 10 DEG C~15 DEG C, 15 DEG C~20 DEG C, 20 DEG C~25
℃。
From the analysis above, we can see that sharing 5 factors, each factor respectively has 4 levels, i.e. t is 5, q 4, settable horizontal quadrature
Table L16(45), referring specifically to table 2:
2 horizontal quadrature table of table
For the optimal combination for finding out the setting of machine numerical value and environment, 16 tests are carried out for 5 factor 4 is horizontal, just
Hand over table and experimental result referring to table 3
3 orthogonal experiments of table
DOE-field mouthful analysis is carried out using Mini tab, and obtains DOE-field mouthful analysis chart, result is referring to attached drawing
9:
Field mouthful analysis mean value response results are referring to table 4:
4 mean value of table responds table
In table, Delta is the difference of minimum and maximum feature average, for the size of measuring effect.
The field comprehensive analysis DOE- mouthful analysis chart and mean value response table are it is found that since the higher the better for yields, so 5 factors
Importance ranking are as follows: B > C > D > A > E, each factor optimum level combination are as follows: B1, C3, D3, A1, E3 can obtain machine accordingly
With the optimal setting of environment adjustment, i.e., right height: 3.768-3.838；Left height: 3.768-3.838；Outer diameter: 2.973-
3.042；Intensity of illumination: sunlight irradiation near the window is not turned on light；Temperature: 15 DEG C -20 DEG C, CCD light is finally adjusted according to this optimal setting
It learns and examines equipment dimensional values to be measured and ambient light intensity and temperature.
Five, the stage is controlled:
Around the components quality inspection corrective measure of DMAIC, total retainer system (Total Productive is used
Management, TPM) management method improvement corrective maintenance problem.TPM management object is all machinery equipments of production scene,
It is guiding theory and the production for needing total involvement (including leader, all employees in scene and technical staff) that it, which is with " prevention ",
System is repaired and saves from damage, final goal is to accomplish " 40 ": zero shutdown, zero waste product, zero accident and zero velocity loss, TPM pipe
Reason method concrete meaning is referring to attached drawing 10:
TPM management method implement main contents include:
(1) 6S activity.6S is the basis of total retainer system management thought, specifically includes arrangement (Seiri), rectifies
(Seiton), (Seiso), cleaning (Seiketsu), attainment (Shitsuke), safety (Security) are cleaned, is lived wherein cleaning
Dynamic is the emphasis place of TPM, it not only includes the cleaning to production scene ambient enviroment, it is often more important that the cleaning to equipment,
The problem of discovery, is handled in time in cleaning process, such as the loose-parts of equipment, surface oxidisation, operating position mill
Damage, leak oil leak etc.；The implementation of 6S will be with " eight big main points " for pillar: 1, independent save from damage；2, plan is saved from damage；3, improve item by item；
4, quality is saved from damage；5, better business；6, initial management；7, security context；8, education improves.
(2) equipment Classifications.Spot inspection system, which refers to, regularly provides equipment according to certain standard, using reasonable means
Position carries out early detection, and so as to timely discovering device potential faults and maintenance as early as possible adjusts, and equipment is made to keep original function
A set of management system.The way of the inspection of " Trinity " point and " five layers of guard wire " is applicable for each enterprise." three one
The inspection of body " point refers to the accurate point of the daily point inspection of post operation employee, regular the point inspection and professional technician of profession point inspection person
Inspection." five layers of guard wire " is respectively as follows: the daily point inspection that first layer is post operation employee, and the second layer is the regular of profession point inspection person
Point inspection, third layer are the accurate point inspections of professional technician, and the 4th layer is to verify reason to the problem by diagnosis of technique
And countermeasure is made, layer 5 is every half a year or complete detection annually.
(3) maintenance of equipment.Maintenance of equipment is for holding, a kind of activity of recovery and improvement technology state, its base
This content includes equipment maintenance, equipment inspection and equipment repair.Overall equipment efficiency.comprehensive efficiency of equipment (Overall Equipment
Effectiveness, OEE) be effective evaluation total retainer system implementation result one of important indicator, it can be used to show reality
The ratio of border production capacity and theoretical production capacity, directly reflects the quality of equipment started rate and produce product, and OEE numerical value is bigger
The effect for illustrating that equipment plays is more abundant, and the effect that TPM management method is implemented is better.The calculation formula of overall equipment efficiency.comprehensive efficiency of equipment is such as
Under:
OEE=T*P*G (1)
T=S/L (2)
L=W-PS (3)
S=L-H-D (4)
P=N*V (5)
N=(Q*AC)/S (6)
V=T/AT (7)
G=q/p (8)
In formula, T is the time to start rate, and P is Performance Rate, and G is yields, and S is running time, and L is duration of load application, W
For the working time, PS is Scheduled Down Time, and H is the downtime, and D is adjusting machine time, and N is to start rate only, and V opens for speed
Dynamic rate, Q are processing quantity, and AC is the actual processing period, and T is theoretical process time, and AT is the actual processing time, and q is qualified product
Number, p is processing quantity.
According to these calculation formula, when can obtain the average movable core of detection daily in CCD optical evaluation facility one month
Overall equipment efficiency.comprehensive efficiency of equipment；In one month stage, the CCD optical evaluation facility daily working time is 11h, Scheduled Down Time
60min, average daily disorderly closedown 20min, averagely daily adjusting machine time 10min, the theoretical process-cycle of product are
0.01min/ part, actual processing period are 0.02min/ part, average daily converted products 20000, and average yields is
94.72%.It is available by these data formula (1)-(8):
It is calculated according to formula (1):
OEE=95% × 36% × 94.72%=32.4%.
It is calculated by formula (2):
It is calculated by formula (3):
L=(11 × 60-60) min=600min.
It is calculated by formula (4):
S=(600-20-10) min=570min.
It is calculated by formula (5):
P=50% × 70.2%=36%.
It is calculated by formula (6):
It is calculated by formula (7):
Putting maintenance into practice is finally carried out to CCD optical evaluation facility according to the management method of the above TPM and content, after one month
The implementation result after improving can be evaluated by comparing the size of OEE numerical value.
(2) production line detection process improves
The cubing that employee on production line is customized using enterprise detects the height and outer diameter of movable core neck, makes
The neck of movable core need to be only inserted in respectively height detection process and outer diameter detection process by the used time, when movable core neck is in
It can determine that it when the position of middle section then as qualified product, the problem has following two aspect at present:
(1) detection determines that qualified method is inconsistent.Correct determination method is that product to be checked is in cubing middle position
Shi Caiwei non-defective unit, can not be by port or leading to port bottom is determined as defective products, and certain employees on production line miss
Think also to can determine that when product leads to bottom for non-defective unit, causes some defective products to be mistaken for non-defective unit shipment, influence the production of enterprise
Quality.
(2) cubing abrasion excessively causes to judge by accident.The defective products detected by CCD optical evaluation facility is sent on production line
It is found after being examined with cubing, having 5 unexpectedly in average every 10 defective products is non-defective unit.To find out basic reason, to cubing and not
Non-defective unit is tested using suitable tool.
Since cubing belongs to contact type measurement, selection examines its two sides using feeler gauge, as a result as follows:
Examine outer diameter side: 2.98,3.02 feeler gauges can pass through, 3.04 feeler gauges also by, illustrate examine outer diameter side have
Problem；
Detect height side: 3.80,3.82,3.84 feeler gauges are stuck, and 3.86 feeler gauges can pass through, and illustrate to detect height side
No problem.
For the correctness for verifying defective products, finds, be not mixed in defective products good after being detected using projector to it
Product, explanation are that cubing there is a problem.
It learns after related personnel by inquiring production line, is up to daily using the quantity of cubing detection movable core on line
Up to ten thousand, and the time for replacing cubing is monthly.Since excessive detection is prone to wear cubing, easily make to detect the logical of both ends
Mouth becomes larger and False Rate is caused to rise, to influence goodwill.
According to this two o'clock problem, it is proposed that preliminary improvement plan:
(1) related management personnel should consult the determination method of inspection and inform employee, and reinforcing staffs training keeps it known
Action, employee is pre-job need to conscientiously to join good berth.
(2) original cubing of monthly replacement is changed to cubing of per two weeks replacement.
According to improvement plan set forth above, implemented:
1, implement improvement plan: tentatively being implemented according to the improvement plan that the improvement stage proposes, scheme includes: to CCD
The dimensional values of optical evaluation facility adjust and the adjustment of ambient enviroment, are tieed up using TPM management thought to machinery equipment
Shield reinforces employee's post training, and per half a month replaces a cubing on production line.It is observed continuously one month and records movable core not
Yield data, as a result referring to attached drawing 11；
2, it is monitored using quality management tool (control figure), identifies the fluctuation situation occurred at present and takes reduction wave
Dynamic measure obtains movable core fraction defective control figure, as a result referring to attached drawing 12；
Improve front and back comparison:
The CCD optical evaluation facility daily disorderly closedown that is averaged is reduced to 15min after improvement, and the actual processing period is reduced to
0.0125min/ part, it is 26000 that average daily converted products, which increases, and average yields rises to 98.28%, and remainder data is equal
It is constant, these data are brought into and are calculated:
It is obtained according to formula (1), OEE=95.8% × 45.2% × 98.28%=42.56%.Formula (2),Formula (3), L=(11 × 60-60) min=600min.Formula (4), S=(600-15-10) min
=575min.Formula (5), P=0% × 56.52%=45.2%.Formula (6),
Formula (7),
Effect is finally improved referring to table 5:
Table 5 improves front and back contrast table
By above table it can be seen that movable core fraction defective reduces 3.56%, CCD optics after implementing improvement project
Equipment OEE is examined to improve 10.16%.
The technical program collects related data by understanding the problem status in production assembling process for boundary
Where determining problem, using the underlying causes of cause and effect map analysis quality problems, proposes improvement plan and be implemented, finally to implementation
Achievement analyzed and controlled；DMAIC can use data a small amount of in small batch production process, and then accurately analyzes and lead
The main reason for causing movable core quality problems, proposes accurate corrective measure, and forms reliable movable core quality control
Process, method finally establishing complete set, advantageously improving the machining process quality of small lot production movable core
System, facilitating enterprise reduces product defect rate, improves overall equipment efficiency.comprehensive efficiency of equipment.
Every technical staff's notice: of the invention although the present invention is described according to above-mentioned specific embodiment
Invention thought be not limited in the invention, any repacking with inventive concept will all be included in this patent protection of the patent right
In range.
Claims (6)
1. the movable core quality inspection improved method based on DMAIC, which is characterized in that its step includes:
A, it defines the stage: a specific understanding and planning is carried out to movable core quality detection project, it is right whithin a period of time
Movable core is tested, and the inspection project of movable core is listed, and obtains the fraction defective of each inspection project, is subsequent each
Stage lays the foundation；
B, measuring phases: the analysis of movable core poor prognostic cause is assessed the data and processes result of output, is schemed using arrangement
The principal element for influencing quality is found out, on-site investigation is carried out to existing issue and collects data, makes problem sharpening；
C, the analysis phase: using the underlying causes of cause-and-effect diagram problem analysis, the key factor of measuring phases the output of process is found out；
D, it improves the stage: being directed to key factor, propose effective improvement project, and confirm that the program needs ideal mesh to be achieved
Mark, the target in this stage are optimization process output, reduce or even eliminate the factor for influencing quality, minimize defect；
E, it controls the stage: standardizing improved achievement and pass through control figure production process is monitored and is maintained,
Constantly seek better improved method simultaneously.
2. the movable core quality inspection improved method according to claim 1 based on DMAIC, which is characterized in that described
Inspection project in step A includes:
Appearance test: it mainly checks whether damage of colliding with, whether has scratch, whether has that dirty and whether there is or not chamferings；
Dimension control: it mainly checks the right height dimension of movable core neck, left height dimension and outer diameter.
3. the movable core quality inspection improved method according to claim 2 based on DMAIC, which is characterized in that described
In step B to existing issue carry out on-site investigation the following steps are included:
B1, several sampling observation quantity are determined, determines product qualification determination standard, enterprise and client's provisions for negotiations, acceptable quality
Upper level is P0, acceptable limit rejected product percentage is P1, P1/P0；
B2, it determines risk indicator, determines producer risk α, user's risk β after enterprise and supplier's negotiation；
B3, it determines Plan of Double Sampling Inspection, inquires xx table, determine c, np0And n=np0/p0；
B4, implement Plan of Double Sampling Inspection, several movable cores are numbered and are put in sequence, generate random number with computer
Table extracts product to be checked according to the random number of generation；Use CCD optical evaluation facility and projector to the movable iron of extraction respectively
Left height, right height and the outer diameter of the heart measure.
4. the movable core quality inspection improved method according to claim 3 based on DMAIC, which is characterized in that described
In step C further include:
C1, use cause-and-effect diagram profound analysis is carried out to quality problems, found respectively from " man-machine material method ring " five broad aspects
The big reason of problem:
" people ": training is insufficient, be lacking in responsibility, self-test consciousness is insufficient；
" machine ": the maintenance of CCD optical evaluation facility is not in place, surface is dirty, numerical value setting is improper；
" material ": deficient purchase, mixing are excessive；
" method ": detection gimmick is inconsistent, detection method is improper；
" ring ": uneven illumination, temperature humidity are unsuitable, dust is excessive；
C2, the reason in step C1 is sorted out, respectively machine detection process goes wrong, production line detection process goes wrong
And supplier's selection is improper, and establishes movable core poor prognostic cause dendrogram.
5. the movable core quality inspection improved method according to claim 4 based on DMAIC, which is characterized in that described
Step D further include:
D1, using DOE experimental design method, establish 5 factor, 4 horizontal quadrature table L16(45) tested；Wherein 5 factors include:
Right altitude range, left altitude range, external diametrical extent, intensity of illumination, temperature；
D2, DOE-field mouthfuls of analyses are carried out to orthogonal experiments using Minitab, obtain the importance ranking of each factor with
And the optimum level combination of each factor.
6. the movable core quality inspection improved method according to claim 5 based on DMAIC, it is characterised in that: described
Include: in step F
F1, formulation simultaneously implement improvement plan, the dimensional values adjustment and the adjustment of ambient enviroment to CCD optical evaluation facility,
Machinery equipment is safeguarded using TPM management thought, reinforces employee's post training, per primary inspection of half a month replacement on production line
Tool；
F2, it is monitored using quality management tool (control figure), identifies the fluctuation situation occurred at present and reduction is taken to fluctuate
Measure；
Overall equipment efficiency.comprehensive efficiency of equipment and movable core fraction defective, formula before and after F3, computed improved is as follows:
OEE=T*P*G；
T=S/L；
L=W-PS；
S=L-H-D；
P=N*V；
N=(Q*AC)/S；
V=T/AT；
G=q/p；
In formula, T is the time to start rate, and P is Performance Rate, and G is yields, and S is running time, and L is duration of load application, and W is work
Make the time, PS is Scheduled Down Time, and H is the downtime, and D is adjusting machine time, and N is to start rate only, and V starts for speed
Rate, Q are processing quantity, and AC is the actual processing period, and T is theoretical process time, and AT is the actual processing time, and q is qualified product number,
P is processing quantity.
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Application publication date: 20190823 |