公理化六西格玛设计方法的研究
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摘要
由于在实施六西格玛设计(DFSS)的过程中,两个主要的设计缺陷会影响到产品的质量,即,由于违背设计原则而引起的概念缺陷、以及由于在应用环境中缺少稳健性而引起的操作缺陷。其中,操作缺陷可以通过减少变异来减少或避免,因而在设计过程中,应用稳健性设计(RD)以通过减少变异效应带动产品的功能性来提高产品质量;而在产品开发过程中,由于缺乏一种找到理想方案的系统化设计方法,概念缺陷通常被忽略。为此,本文将公理化设计(AD)的理论方法引入到六西格玛设计中来,提出了公理化六西格玛设计(ADFSS)方法,并对其进行了深入的研究与探讨:
首先,阐述了DFSS、AD、TRIZ、QFD以及稳健性设计等设计方法和理念,提出了ADFSS的方法,并以AD的过程为主线,集成TRIZ、QFD、VA/VE、RD、FMEA、DFA、DFM等设计工具与方法并将其融入到六西格玛的哲理之中;
随后,开展了ADFSS的主要关键技术---公理化六西格玛设计的解耦合设计、基于TRIZ理论的公理化六西格玛设计、基于QFD的公理化六西格玛设计以及基于稳健性的公理化六西格玛设计的研究与应用。即,提出了公理化六西格玛设计解耦合的一般方法,并开发了一种融合分离算法、AHP法和最短路径法去改善复杂系统设计的耦合;通过分析TRIZ与AD的内在联系,提出了基于TRIZ理论的公理化六西格玛设计方法,对现有产品进行理想解分析、S曲线分析,预测产品的演化路线,并采用发明原理和分离原理解决设计过程的冲突和约束问题,实现产品的无耦合设计;针对QFD实施过程中存在的问题,建立了基于QFD的公理化六西格玛设计模型,缩短了产品开发周期,避免了顾客需求信息的损失;为减少或避免设计过程中的操作缺陷,稳健性的思想被应用到公理化六格玛设计中,运用DOE和田口方法对设计参数进行优化,并将功能要求的质量损失和设计参数的控制成本考虑进来,建立基于成本-质量的非线性公差优化数学模型,消除偏差,减小方差,合理分配设计参数的公差,使产品的功能要求从设计一开始就真正满足顾客需求,达到六西格玛质量水平;
最后,应用公理化六西格玛设计方法设计了应变测量系统的无源滤波器,结果表明:应用公理化六西格玛设计方法,可简化设计结构,使功能要求从设计一开始就真正达到六西格玛质量水平,同时优化了设计参数、减少了过程波动、节约了成本、避免了设计过程中的概念缺陷和操作缺陷。
During the implementation of Design for Six Sigma (DFSS), the quality of products is influenced by two major design weaknesses, i.e., conceptual weakness due to violating design principles and operational weakness due to lack of robustness in the use environment. The operational weaknesses can be lessened or avoided by reducing variation. Robust Design is thus employed to improve product quality through reducing variation to bring along product functionality during design. However, conceptual weaknesses are usually overlooked during product development as a result of lack of a systematic design approach for seeking ideal solutions.
Therefore, the theory of Axiomatic Design is incorporated herein into DFSS, and Axiomatic Design for Six Sigma is put forward and researched deeply as follows: Firstly, some design methods and theories are described such as DFSS, Axiomatic Design, TRIZ, QFD and Robust Design, etc. Moreover, Axiomatic Design for Six Sigma (ADFSS) is put forward. The ADFSS approach is based on Axiomatic Design which is integrated with design and quality methods such as TRIZ, QFD, VA/VE, Robust Design, FMEA, DFA, DFM and the like, and merged into the philosophy of Six Sigma.
Thereafter, the key techniques are studied and applied including decoupling of Axiomatic Design for Six Sigma, Axiomatic Design for Six Sigma based on TRIZ, QFD and Robustness. That is, a common method for decoupling of Axiomatic Design for Six Sigma is put forward and a method incorporating separation algorithm, AHP and shortest path is developed to improve coupling of design of a complicated system. Axiomatic Design for Six Sigma based on TRIZ is provided through analyzing the internal relationship between TRIZ and AD. Analyses of ideal solution and S curve are conducted and the evolution route of products is predicted. At the meantime, inventive principle and separation principle are utilized to solve the problems of conflict and constrains during design to realize uncoupled design of products. With regard to the problems occurred in the application of QFD, a model of Axiomatic Design for Six Sigma based on QFD is established to shorten the cycle of product development and avoid loss of information on customers needs. To reduce or avoid operational weaknesses during design, the concept of robustness is utilized in Axiomatic Design of Six Sigma. Design parameters are optimized with DOE and Taguchi methods, and with the quality loss of function requirements and control cost of design parameters considered, a nonlinear mathematic model for optimizing tolerance is established based on cost-to-quality to eliminate deviation, reduce variance and distribute tolerance of design parameters appropriately, which make the function requirements of products really meet the needs of customers from the beginning of design and reach the level of Six Sigma.
Finally, a passive filter of a strain measurement system is designed with the approach of Axiomatic Design for Six Sigma. The result shows that the design structure is simplified and the level of Six Sigma is reached just at the beginning of the design of function requirements with optimized design parameters, less process variation, lower cost, and conceptual and operational weakness during design being avoided.
首先,阐述了DFSS、AD、TRIZ、QFD以及稳健性设计等设计方法和理念,提出了ADFSS的方法,并以AD的过程为主线,集成TRIZ、QFD、VA/VE、RD、FMEA、DFA、DFM等设计工具与方法并将其融入到六西格玛的哲理之中;
随后,开展了ADFSS的主要关键技术---公理化六西格玛设计的解耦合设计、基于TRIZ理论的公理化六西格玛设计、基于QFD的公理化六西格玛设计以及基于稳健性的公理化六西格玛设计的研究与应用。即,提出了公理化六西格玛设计解耦合的一般方法,并开发了一种融合分离算法、AHP法和最短路径法去改善复杂系统设计的耦合;通过分析TRIZ与AD的内在联系,提出了基于TRIZ理论的公理化六西格玛设计方法,对现有产品进行理想解分析、S曲线分析,预测产品的演化路线,并采用发明原理和分离原理解决设计过程的冲突和约束问题,实现产品的无耦合设计;针对QFD实施过程中存在的问题,建立了基于QFD的公理化六西格玛设计模型,缩短了产品开发周期,避免了顾客需求信息的损失;为减少或避免设计过程中的操作缺陷,稳健性的思想被应用到公理化六格玛设计中,运用DOE和田口方法对设计参数进行优化,并将功能要求的质量损失和设计参数的控制成本考虑进来,建立基于成本-质量的非线性公差优化数学模型,消除偏差,减小方差,合理分配设计参数的公差,使产品的功能要求从设计一开始就真正满足顾客需求,达到六西格玛质量水平;
最后,应用公理化六西格玛设计方法设计了应变测量系统的无源滤波器,结果表明:应用公理化六西格玛设计方法,可简化设计结构,使功能要求从设计一开始就真正达到六西格玛质量水平,同时优化了设计参数、减少了过程波动、节约了成本、避免了设计过程中的概念缺陷和操作缺陷。
During the implementation of Design for Six Sigma (DFSS), the quality of products is influenced by two major design weaknesses, i.e., conceptual weakness due to violating design principles and operational weakness due to lack of robustness in the use environment. The operational weaknesses can be lessened or avoided by reducing variation. Robust Design is thus employed to improve product quality through reducing variation to bring along product functionality during design. However, conceptual weaknesses are usually overlooked during product development as a result of lack of a systematic design approach for seeking ideal solutions.
Therefore, the theory of Axiomatic Design is incorporated herein into DFSS, and Axiomatic Design for Six Sigma is put forward and researched deeply as follows: Firstly, some design methods and theories are described such as DFSS, Axiomatic Design, TRIZ, QFD and Robust Design, etc. Moreover, Axiomatic Design for Six Sigma (ADFSS) is put forward. The ADFSS approach is based on Axiomatic Design which is integrated with design and quality methods such as TRIZ, QFD, VA/VE, Robust Design, FMEA, DFA, DFM and the like, and merged into the philosophy of Six Sigma.
Thereafter, the key techniques are studied and applied including decoupling of Axiomatic Design for Six Sigma, Axiomatic Design for Six Sigma based on TRIZ, QFD and Robustness. That is, a common method for decoupling of Axiomatic Design for Six Sigma is put forward and a method incorporating separation algorithm, AHP and shortest path is developed to improve coupling of design of a complicated system. Axiomatic Design for Six Sigma based on TRIZ is provided through analyzing the internal relationship between TRIZ and AD. Analyses of ideal solution and S curve are conducted and the evolution route of products is predicted. At the meantime, inventive principle and separation principle are utilized to solve the problems of conflict and constrains during design to realize uncoupled design of products. With regard to the problems occurred in the application of QFD, a model of Axiomatic Design for Six Sigma based on QFD is established to shorten the cycle of product development and avoid loss of information on customers needs. To reduce or avoid operational weaknesses during design, the concept of robustness is utilized in Axiomatic Design of Six Sigma. Design parameters are optimized with DOE and Taguchi methods, and with the quality loss of function requirements and control cost of design parameters considered, a nonlinear mathematic model for optimizing tolerance is established based on cost-to-quality to eliminate deviation, reduce variance and distribute tolerance of design parameters appropriately, which make the function requirements of products really meet the needs of customers from the beginning of design and reach the level of Six Sigma.
Finally, a passive filter of a strain measurement system is designed with the approach of Axiomatic Design for Six Sigma. The result shows that the design structure is simplified and the level of Six Sigma is reached just at the beginning of the design of function requirements with optimized design parameters, less process variation, lower cost, and conceptual and operational weakness during design being avoided.
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