多品种小批量生产模式下基于相似元的工序能力分析
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摘要
随着社会的发展和科技的进步,消费者对于产品的需求呈现多样化,因此多品种小批量生产模式成为制造业的一大主流趋势,但由此带来的加工数据量少的问题给企业生产过程的质量控制及工序能力分析带来了困难。为了解决这个问题,利用相似元理论,根据影响工序的各种因素,将与目标工序相似的其他工序合并成组,通过数据转换扩大样本容量,进而利用大样本加工数据对目标工序进行质量控制和工序能力分析。以某生产车间车削工序为例,计算出该工序的工序能力指数,所得结果与实际情况相符。结果表明,该方法可以给多品种小批量生产模式下企业的质量控制和工序能力分析工作带来许多便捷。
With the development of society and the progress of science and technology,consumers prefer to choose personalized products.Therefore,multiple-variety and small-batch production mode becomes the mainstream of manufacturing.However,under the multiple-variety and smallbatch production mode,it is difficult for companies to control quality and analyse process capability because of the lack of process data.To solve this problem,processes which were similar to target process were sorted out using the principle of similarity cell based on factors which influenced the processes,and then the target process and the similar processes were made into one group.After data from different processes was transformed to the standard,the sample space of target process was expanded.Then quality control and analysis of process capability were carried out on target process using the expanded process data.At last,a turning process in a workshop was taken as an example,its process capability index was obtained by using the proposed method.The result showed that the capability of target process was satisfactory,and the result agreed with the reality.The results show that much convenience can be brought to enterprises to control quality and analysis process capability under the multiple-variety and small-batch production mode.
With the development of society and the progress of science and technology,consumers prefer to choose personalized products.Therefore,multiple-variety and small-batch production mode becomes the mainstream of manufacturing.However,under the multiple-variety and smallbatch production mode,it is difficult for companies to control quality and analyse process capability because of the lack of process data.To solve this problem,processes which were similar to target process were sorted out using the principle of similarity cell based on factors which influenced the processes,and then the target process and the similar processes were made into one group.After data from different processes was transformed to the standard,the sample space of target process was expanded.Then quality control and analysis of process capability were carried out on target process using the expanded process data.At last,a turning process in a workshop was taken as an example,its process capability index was obtained by using the proposed method.The result showed that the capability of target process was satisfactory,and the result agreed with the reality.The results show that much convenience can be brought to enterprises to control quality and analysis process capability under the multiple-variety and small-batch production mode.
引文
[1]王丽颖.小批量工序质量控制方法及其若干关键技术的研究[D].大连:大连交通大学机械工程学院,2007:42-45.WANG Li-ying.Research on small batch procedure quality control method and their key techniques[D].Dalian:Dalian Jiaotong University,School of Mechanical Engineering,2007:42-45.
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[14]陈博,孙薇.SPC技术在多品种小批量数控车削中的应用[J].价值工程,2014(28):56-57.CHEN Bo,SUN Wei.Application of SPC technology in multi-type&small batch CNC turning[J].Value Engineering,2014(28):56-57.
[15]郎茂涛.多品种小批量制造模式下工序质量控制研究[D].西安:西安电子科技大学经济与管理学院,2012:24-25.LANG Mao-tao.Study on the quality control of working procedure in multi-specification&small-batch manufacturing[D].Xi’an:Xidian University,School of Economics and Management,2012:24-25.
[16]黄朝志,伍建军,刘飞飞,等.基于相似性原理的轴类零件小批量多品种生产的统计质量控制[J].组合机床与自动化加工技术,2008(2):110-112.HUANG Chao-zhi,WU Jian-jun,LIU Fei-fei,et al.SQC of axis parts under multi-type and small batch condition based on analogical theory[J].Modular Machine Tool&Automatic Manufacturing Technique,2008(2):110-112.
[17]张根保.现代质量工程[M].北京:机械工业出版社,2015:54-82.ZHANG Gen-bao.Advanced quality engineering[M].Beijing:China Machine Press,2015:54-82.
[18]余进,陈维进,王弘,等.层次分析法在确定评估体系指标权重中的应用[J].中国医疗设备,2013,28(12):44-47.YU Jin,CHEN Wei-jin,WANG Hong,et al.Application of analytic hierarchy process in establishing the weight values of PACS score system[J].China Medical Devices,2013,28(12):44-47.
[19]汤淑明,王飞跃.过程能力指数综述[J].应用概率统计,2004,20(2):207-216.TANG Shu-ming,WANG Fei-yue.Recent development in process capability indices[J].Chinese Journal of Applied Probability and Statistics,2004,20(2):207-216.
[2]张越迪.面向轴承制造过程的工序质量控制研究[D].重庆:重庆大学机械工程学院,2012:16-17.ZHANG Yue-di.Study on process quality control for manufacturing process of bearing[D].Chongqing:Chongqing University,School of Mechanical Engineering,2012:16-17.
[3]贾学增,吴小勇.基于多变异分析的成组工序过程质量控制与分析[J].机械制造,2012,50(4):73-76.JIA Xue-zeng,WU Xiao-yong.Quality control and analysis of process group based on MVA[J].Machinery,2012,50(4):73-76.
[4]吴小勇.多品种小批量环境下成组工序质量控制方法的研究及应用[D].重庆:重庆大学机械工程学院,2011:14-15.WU Xiao-yong.The study and application of quality control method for grouping of procedures in multi-varieties&small batch production[D].Chongqing:Chongqing University,School of Mechanical Engineering,2011:14-15.
[5]DOVICH R A.Statistics for the small-lot job shop[J].Machine and Tool Blue Book,1998,83(1):10-12.
[6]STATHAM A,Al-SALTI M.The application of group technology concept for implementing SPC in small batch manufacture[J].International Journal of Quality&Reliability Management,1994,11(4):64-76.
[7]STEINER S H,GEYER P L,WESOLOWSKY G O,et al.Shewhart control charts to detect mean and standard deviation shifts based on grouped data[J].Quality and Reliability Engineering International,1996,12(5):345-353.
[8]PAGE E S.Continuous inspection schemes[J].Biometrika,1954,41(1/2):100-115.
[9]HILLIER F S.Chart control limits based on a small number of subgroups[J].Journal of Quality Technology,1969,1(1):17-26.
[10]QUESENBERRY C P.SPC q-charts for start-up and short or long runs[J].Journal of Quality Technology,1991,23(3):213-224.
[11]QUESENBERRY C P.The effect of sample size on estimated limits for X control charts[J].Journal of Quality Technology,1993,25(4):237-247.
[12]VARGAS V D C C D,LOPES L F D,SOUZA A M.Comparative study of the performance of the CuSum and EWMA control charts[J].Computers&Industrial Engineering,2004,46(4):707-724.
[13]牟永善,赵文波.成组加工质量控制中工序诊断调节法与公差百分数控制图的应用[J].工业工程与管理,2005,10(2):81-85.MOU Yong-shan,ZHAO Wen-bo.On control of process quality in group production cell with diagnosis and regulation method of operation and control diagram of tolerance percentage[J].Industrial Engineering and Management,2005,10(2):81-85.
[14]陈博,孙薇.SPC技术在多品种小批量数控车削中的应用[J].价值工程,2014(28):56-57.CHEN Bo,SUN Wei.Application of SPC technology in multi-type&small batch CNC turning[J].Value Engineering,2014(28):56-57.
[15]郎茂涛.多品种小批量制造模式下工序质量控制研究[D].西安:西安电子科技大学经济与管理学院,2012:24-25.LANG Mao-tao.Study on the quality control of working procedure in multi-specification&small-batch manufacturing[D].Xi’an:Xidian University,School of Economics and Management,2012:24-25.
[16]黄朝志,伍建军,刘飞飞,等.基于相似性原理的轴类零件小批量多品种生产的统计质量控制[J].组合机床与自动化加工技术,2008(2):110-112.HUANG Chao-zhi,WU Jian-jun,LIU Fei-fei,et al.SQC of axis parts under multi-type and small batch condition based on analogical theory[J].Modular Machine Tool&Automatic Manufacturing Technique,2008(2):110-112.
[17]张根保.现代质量工程[M].北京:机械工业出版社,2015:54-82.ZHANG Gen-bao.Advanced quality engineering[M].Beijing:China Machine Press,2015:54-82.
[18]余进,陈维进,王弘,等.层次分析法在确定评估体系指标权重中的应用[J].中国医疗设备,2013,28(12):44-47.YU Jin,CHEN Wei-jin,WANG Hong,et al.Application of analytic hierarchy process in establishing the weight values of PACS score system[J].China Medical Devices,2013,28(12):44-47.
[19]汤淑明,王飞跃.过程能力指数综述[J].应用概率统计,2004,20(2):207-216.TANG Shu-ming,WANG Fei-yue.Recent development in process capability indices[J].Chinese Journal of Applied Probability and Statistics,2004,20(2):207-216.