制造质量零废品控制理论与技术的研究
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摘要
产品质量的优劣，是衡量一个国家生产力发展水平以及技术、经济发展水平
的重要标志。随着社会的进步和科学技术的发展，人们对产品制造质量提出了越来
越高的要求。为此，本文基于国家自然科学基金重点资助项目“现代制造质量控制、
溯源若干基础问题的研究”（项目编号：59375254），重点对其中的子课题——零废
品控制理论和技术进行了深入的研究。论文的主要工作和取得的成果如下：
1．在介绍了常用质量控制方法的基础上，对统计质量控制的几个关键问题进
行了详尽的讨论，提出了质量控制界限的确定方法，建立了基于产品质量多变异的
抽样方案的数学模型，利用模糊识别理论对质量控制图工序加工状况进行了判别。
2．分析了机械加工系统的加工误差和测量误差分布的动态时变特性，建立了
零件测量尺寸分布的数学模型；在分析了加工误差和测量误差动态时变特性及测量
对零件尺寸分布影响的基础上，首次提出了零件加工尺寸分布的动态模型——棚状
模型。
3．分析了传统的统计质量控制中3σ质量水平存在的不足，引入了现代质量
控制中的6σ原则的概念，定义了意义更广的加工能力及加工能力指数的含义。另
外，根据加工误差动态时变的特性，首次提出了动态加工能力指数的概念，在此基
础上，依据数理统计和质量控制的原理，分别研究了几种加工尺寸动态误差分布与
制造质量的关系，建立了相应的数学模型，提出了废品开始出现的临界值判据。
4．以尺寸精度为例，分别应用时间序列分析、灰色系统理论及人工神经网络
原理等现代数学手段建立了加工精度动态损失的数学模型，通过实例进行了各种模
型精度的比较。
5．基于加工误差和测量误差分布的动态时受特性，给出了实现零废品加工对
加工能力和测量能力的要求。根据产品质量要求和公差规定，建立了单元制造质量
控制理论的模型。
6．分析了加工过程尺寸基准与零件加工合格率的关系，在考虑加工成本及效
率的情况下，给出了过程尺寸基准的优化模型。
7．利用两种质量诊断理论，分析了零件多工位加工时的质量控制原理。首次
提出了多工位加工精度等效损失的概念，建立了多工位生产系统加工精度的等效损
11 合吧工业大学博士学位论文
夫模型，同时提出了保证实现多工位加工精度等效损失应遵循的基本原则。
8．以大批量生产的油泵油咀柱塞精密偶件和轴承件为对象，对上述理论研究
结果进行了实际应用与验证。
The quality of products is an important flag to symbolize the developing level of the productivity, the technology and the economics in a country. With the advancement of the society and the development of science and technology, the requirements to the manufacturing quality of products become higher and higher. Therefore, based on the key project 慠esearch on Some Basic Problems on Quality Control and Source Tracing in Modern Manufacture?(No.59735120) sponsored by National Natural Science Foundation, a deep research is made in this dissertation its branch subject?the theory and technology of zero-waste control.The main work and achievements are as follows:
1. On the basis of the introduction of common quality control methods, some key problems about statistical quality control are elaborately discussed; a method to decide the quality control line is developed; a mathematical model based on the sampling plan of multi-variation of product quality is set up; the process manufacturing condition of quality control chart is discriminated using the theory of fuzzy diagnosis.
2. The dynamic time-variant characteristics of manufacturing errors and measuring errors of mechanical manufacturing system are analyzed; the mathematical model of the distribution of measured dimension of the work-pieces is established. Moreover, on the basis of analyzing the dynamic time-variant characteristics of manufacturing errors and measuring errors and the influence of the measurement to the dimensional
Iv
distribution of the work-pieces, a dynamic model ?shedlike model for the first time is initiated of the manufacturing dimension distribution of the work-pieces.
3. The limitation is analyzed of 30-criterion in traditional statistical quality control, the concept of 6 a criterion in modern quality control is introduced, and the definitions are developed of more comprehensive manufacturing ability and manufacturing ability index. Furthermore, according to the dynamic time-variant characteristics of manufacturing errors, a concept of dynamic manufacturing ability index is initiated for the first time. And on this basis, according to the principles of mathematical statistics and quality control, The relations between the dynamic-error distribution of some different manufacturing dimensions and corresponding manufacturing quality are individually analyzed, the relevant mathematical model is set up, and a critical value criterion for waste appearance is advanced.
4. Taking example for dimension accuracy, and applying modem mathematical methods such as time series analysis, grey system theory and artificial neural network theory, the mathematical models of dynamic loss of manufacturing accuracy are established. The comparison of the accuracy of each model is made by illustrations.
5. Based on the dynamic time-variant characteristics of manufacturing errors and measuring errors, the requirement is given of manufacturing ability and measuring ability in order to realize the zero-waste manufacturing. According to product quality requirements and tolerance regulations, a model of the theory of unit manufacturing quality control is obtained.
6. The relation between the dimensional reference of manufacturing process and the percent of pass of the work-pieces is analyzed. Regarding to manufacturing costs and efficiency, an optimized model of process dimension reference is given.
7. Applying two kinds of quality diagnosis theories, the quality control principle of multi-process manufacturing of the work-piece is analyzed. A new concept for an equivalent loss of machining accuracy of multi-
V
position producing system is firstly proposed and an equivalent loss model of machining accuracy of multi-position producing system is set up.
8. Taking precise plungers of oil pump mouth and bearings produced in a large scale as the objects, practical application and verification of above theoretically research results were made.
的重要标志。随着社会的进步和科学技术的发展，人们对产品制造质量提出了越来
越高的要求。为此，本文基于国家自然科学基金重点资助项目“现代制造质量控制、
溯源若干基础问题的研究”（项目编号：59375254），重点对其中的子课题——零废
品控制理论和技术进行了深入的研究。论文的主要工作和取得的成果如下：
1．在介绍了常用质量控制方法的基础上，对统计质量控制的几个关键问题进
行了详尽的讨论，提出了质量控制界限的确定方法，建立了基于产品质量多变异的
抽样方案的数学模型，利用模糊识别理论对质量控制图工序加工状况进行了判别。
2．分析了机械加工系统的加工误差和测量误差分布的动态时变特性，建立了
零件测量尺寸分布的数学模型；在分析了加工误差和测量误差动态时变特性及测量
对零件尺寸分布影响的基础上，首次提出了零件加工尺寸分布的动态模型——棚状
模型。
3．分析了传统的统计质量控制中3σ质量水平存在的不足，引入了现代质量
控制中的6σ原则的概念，定义了意义更广的加工能力及加工能力指数的含义。另
外，根据加工误差动态时变的特性，首次提出了动态加工能力指数的概念，在此基
础上，依据数理统计和质量控制的原理，分别研究了几种加工尺寸动态误差分布与
制造质量的关系，建立了相应的数学模型，提出了废品开始出现的临界值判据。
4．以尺寸精度为例，分别应用时间序列分析、灰色系统理论及人工神经网络
原理等现代数学手段建立了加工精度动态损失的数学模型，通过实例进行了各种模
型精度的比较。
5．基于加工误差和测量误差分布的动态时受特性，给出了实现零废品加工对
加工能力和测量能力的要求。根据产品质量要求和公差规定，建立了单元制造质量
控制理论的模型。
6．分析了加工过程尺寸基准与零件加工合格率的关系，在考虑加工成本及效
率的情况下，给出了过程尺寸基准的优化模型。
7．利用两种质量诊断理论，分析了零件多工位加工时的质量控制原理。首次
提出了多工位加工精度等效损失的概念，建立了多工位生产系统加工精度的等效损
11 合吧工业大学博士学位论文
夫模型，同时提出了保证实现多工位加工精度等效损失应遵循的基本原则。
8．以大批量生产的油泵油咀柱塞精密偶件和轴承件为对象，对上述理论研究
结果进行了实际应用与验证。
The quality of products is an important flag to symbolize the developing level of the productivity, the technology and the economics in a country. With the advancement of the society and the development of science and technology, the requirements to the manufacturing quality of products become higher and higher. Therefore, based on the key project 慠esearch on Some Basic Problems on Quality Control and Source Tracing in Modern Manufacture?(No.59735120) sponsored by National Natural Science Foundation, a deep research is made in this dissertation its branch subject?the theory and technology of zero-waste control.The main work and achievements are as follows:
1. On the basis of the introduction of common quality control methods, some key problems about statistical quality control are elaborately discussed; a method to decide the quality control line is developed; a mathematical model based on the sampling plan of multi-variation of product quality is set up; the process manufacturing condition of quality control chart is discriminated using the theory of fuzzy diagnosis.
2. The dynamic time-variant characteristics of manufacturing errors and measuring errors of mechanical manufacturing system are analyzed; the mathematical model of the distribution of measured dimension of the work-pieces is established. Moreover, on the basis of analyzing the dynamic time-variant characteristics of manufacturing errors and measuring errors and the influence of the measurement to the dimensional
Iv
distribution of the work-pieces, a dynamic model ?shedlike model for the first time is initiated of the manufacturing dimension distribution of the work-pieces.
3. The limitation is analyzed of 30-criterion in traditional statistical quality control, the concept of 6 a criterion in modern quality control is introduced, and the definitions are developed of more comprehensive manufacturing ability and manufacturing ability index. Furthermore, according to the dynamic time-variant characteristics of manufacturing errors, a concept of dynamic manufacturing ability index is initiated for the first time. And on this basis, according to the principles of mathematical statistics and quality control, The relations between the dynamic-error distribution of some different manufacturing dimensions and corresponding manufacturing quality are individually analyzed, the relevant mathematical model is set up, and a critical value criterion for waste appearance is advanced.
4. Taking example for dimension accuracy, and applying modem mathematical methods such as time series analysis, grey system theory and artificial neural network theory, the mathematical models of dynamic loss of manufacturing accuracy are established. The comparison of the accuracy of each model is made by illustrations.
5. Based on the dynamic time-variant characteristics of manufacturing errors and measuring errors, the requirement is given of manufacturing ability and measuring ability in order to realize the zero-waste manufacturing. According to product quality requirements and tolerance regulations, a model of the theory of unit manufacturing quality control is obtained.
6. The relation between the dimensional reference of manufacturing process and the percent of pass of the work-pieces is analyzed. Regarding to manufacturing costs and efficiency, an optimized model of process dimension reference is given.
7. Applying two kinds of quality diagnosis theories, the quality control principle of multi-process manufacturing of the work-piece is analyzed. A new concept for an equivalent loss of machining accuracy of multi-
V
position producing system is firstly proposed and an equivalent loss model of machining accuracy of multi-position producing system is set up.
8. Taking precise plungers of oil pump mouth and bearings produced in a large scale as the objects, practical application and verification of above theoretically research results were made.
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