板式薄木贴面柜类家具返修率研究
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摘要
中国家具制造业已经成为了世界家具制造中心,但是生产过程管理与先进管理还存在着相当的差距。返修率高影响了家具生产效率,提高了其制造成本,影响了家具品牌,因此本论文系统地研究了返修的种类、形成原因、影响因素、具体数值等。
本论文运用工业工程方法,以某家具企业在某年一月生产的薄木贴面柜类家具返修为研究对象,通过现场实地数据测量与统计,采用数理统计的方法,分析了机械加工工序、薄木种类等因素对于返修率的影响。具体结论如下:
(1)在所调研的企业中,开料、定厚砂光、贴皮、封边、钻孔工序中,贴皮工序返修率最高,为19.91%;开料工序的返修率最低,为4.55%,五个工序的平均返修率为12.32%。
(2)经过实地调研,造成返修的原因众多,其中封边脱胶是主要原因,由于其造成的返修件占所有返修件的比例到达了21.09%。
(3)在所调研的楸木、桦木、柞木、橡木、胡桃木五种薄木中,胡桃木饰面的零部件返修率最高,达19.84%;橡木饰面的零部件返修率最低,为8.97%。胡桃木饰面零部件最大的缺陷为离缝,木皮离缝在胡桃木饰面零部件返修中所占比例达到了95.24%。
(4)在所调研的封边工序中,重新封边的单位返修成本大约是不需重新封边的10倍左右。返修措施为重新封边时,单位材料成本在单位返修成本中所占比例最高。
本课题只分析了返修成本中的直接人工成本、材料成本、设备折旧成本、能源耗用成本,对于其他成本的影响未有涉及。
Chinese furniture manufacturing industry has become the world's furniture manufacturing center, but the production process management is far away from the advanced management. High rate of repairing impacts furniture production efficiency, improves its manufacturing costs, and impacts the furniture brands. This thesis systematically studied the repairing’s types, causes, influencing factors, such as specific data.
In this thesis, using industrial engineering methods to a furniture factory in one year’s January of the production veneer Cabinet’s rework as the research object. The use of data-processing are methods of mathematical statistics, and analysis of machining processes, such factors as the type of veneer for the impact of the rate of repairing. Specific conclusions are as follows:
(1) in the investigation of Cutting, Set thickness sanding, Veneering, Edging, Drilling, the rate of repairing for veneering process is the highest, 19.91 percent; the rate of repairing for cutting process is the lowest, 4.55 percent; the average rate of repairing for the five processes is 12.32 percent.
(2) there are many reasons for rework, the main reason is Degumming Edge. Because its resulting rework of all the rework is 21.09 percent.
(3) in the investigation of Catalpa wood, birch, oak wood, oak, walnut veneer, the rate of repairing for the walnut veneer parts is the highest at 19.84 percent; the rate of repairing for oak veneer is the lowest at 8.97 percent. Walnut veneer’s biggest reason is joints, from the slit in the proportion of rework parts and components reached 95.24%.
(4) Edging processes, the re-Edge Repair cost is about not re-Edge of about 10 times. Repair measures for the re-Edge, material costs in repairing the highest proportion of the cost.
This issue only in the cost of repairing the direct labor costs, materials costs, equipment depreciation costs, energy consumption costs and other costs not related to the impact.
本论文运用工业工程方法,以某家具企业在某年一月生产的薄木贴面柜类家具返修为研究对象,通过现场实地数据测量与统计,采用数理统计的方法,分析了机械加工工序、薄木种类等因素对于返修率的影响。具体结论如下:
(1)在所调研的企业中,开料、定厚砂光、贴皮、封边、钻孔工序中,贴皮工序返修率最高,为19.91%;开料工序的返修率最低,为4.55%,五个工序的平均返修率为12.32%。
(2)经过实地调研,造成返修的原因众多,其中封边脱胶是主要原因,由于其造成的返修件占所有返修件的比例到达了21.09%。
(3)在所调研的楸木、桦木、柞木、橡木、胡桃木五种薄木中,胡桃木饰面的零部件返修率最高,达19.84%;橡木饰面的零部件返修率最低,为8.97%。胡桃木饰面零部件最大的缺陷为离缝,木皮离缝在胡桃木饰面零部件返修中所占比例达到了95.24%。
(4)在所调研的封边工序中,重新封边的单位返修成本大约是不需重新封边的10倍左右。返修措施为重新封边时,单位材料成本在单位返修成本中所占比例最高。
本课题只分析了返修成本中的直接人工成本、材料成本、设备折旧成本、能源耗用成本,对于其他成本的影响未有涉及。
Chinese furniture manufacturing industry has become the world's furniture manufacturing center, but the production process management is far away from the advanced management. High rate of repairing impacts furniture production efficiency, improves its manufacturing costs, and impacts the furniture brands. This thesis systematically studied the repairing’s types, causes, influencing factors, such as specific data.
In this thesis, using industrial engineering methods to a furniture factory in one year’s January of the production veneer Cabinet’s rework as the research object. The use of data-processing are methods of mathematical statistics, and analysis of machining processes, such factors as the type of veneer for the impact of the rate of repairing. Specific conclusions are as follows:
(1) in the investigation of Cutting, Set thickness sanding, Veneering, Edging, Drilling, the rate of repairing for veneering process is the highest, 19.91 percent; the rate of repairing for cutting process is the lowest, 4.55 percent; the average rate of repairing for the five processes is 12.32 percent.
(2) there are many reasons for rework, the main reason is Degumming Edge. Because its resulting rework of all the rework is 21.09 percent.
(3) in the investigation of Catalpa wood, birch, oak wood, oak, walnut veneer, the rate of repairing for the walnut veneer parts is the highest at 19.84 percent; the rate of repairing for oak veneer is the lowest at 8.97 percent. Walnut veneer’s biggest reason is joints, from the slit in the proportion of rework parts and components reached 95.24%.
(4) Edging processes, the re-Edge Repair cost is about not re-Edge of about 10 times. Repair measures for the re-Edge, material costs in repairing the highest proportion of the cost.
This issue only in the cost of repairing the direct labor costs, materials costs, equipment depreciation costs, energy consumption costs and other costs not related to the impact.
引文
[1]胡景初.经济全球化与中国家具工业发展趋势[J].林产工业,2005,32(5):12～15.
[2]贾清文.经济全球化进程中的中国家具业[J].家具室内与装饰,2007,(10):11～15.
[3]金晶.中国家具制造业国际竞争力分析[J].中国林业产业,2007,(5):38～43.
[4]闫玉秀,季晓芬.服装厂降低返修率的系统研究[J].纺织学报,2004,25(3):66～67.
[5]郭克莎.质量经济学概论[M].北京:机械工业出版社,1987.
[6]尤建新,陈宝胜.不合格产品返修经济分析[J].同济大学学报,2002,30(9):1125～1128.
[7]易树平,郭伏.基础工业工程[M].北京:机械工业出版社,2006.
[8]张根保,何桢,刘英.质量管理与可靠性(修订本)[M].北京:中国科学技术出版社,2005.
[9]宋明顺.质量管理学[M].北京:科学出版社,2005.
[10]李爱华,曹霞.企业的作业成本法研究[J].沈阳大学学报,2003,15(3):44～46.
[11]道格拉斯·希克斯.作业成本会计:在中小企业中的实施方案(第2版)[M].上海:上海人民出版社,2002.
[12]肖序,王颖梅,邓永勤.成本会计学[M].中南大学出版社,2004,46～48.
[13]丁启叶.浅析作业成本动因[J].财会月刊,2001,(12):44.
[14]GB3330-82,家具工业常用名词术语[S].
[15]穆亚平,黄河润,沈凤明.微薄木饰面工艺技术研究[J].家具,2003,(3):23～27.
[16]申利明,路则光,黄河浪,吴新凤,陈秀兰,薛丽丹.工艺参数对硬枫薄木贴面杨木多层板表面[J].
[17]质量的影响[J].木材加工机械,2006,(4):19～23.
[18]闫玉秀,季晓芬.服装厂降低返修率的系统研究[J].纺织学报,2004,25(3):66～67.
[19]刘艳红.批量与设备影响板式家具成本分析[D].南京林业大学,2006.
[20]郝景新.板式家具典型作业岗位工时与产能研究[D].南京林业大学,2006.
[21]关星.质量成本的计量及其控制方法研究[D].天津大学,2005.
[22]赵新革.外向型家具企业产品成本策划[D].东北林业大学,2006.
[23]祁忆青.板式家具工序质量的研究[D].南京林业大学,2005.
[24]杨丽萍.作业成本法在H家具厂的应用[D].西南交通大学,2006.
[25]李云雁,胡传荣.试验设计与数据处理[M].北京:化学工业出版社,2005.
[26]吴智慧.木家具制造工艺学[M].北京:中国林业出版社,2004.
[27]王剀.木材工业实用大全[M].北京:中国林业出版社,2002.
[2]贾清文.经济全球化进程中的中国家具业[J].家具室内与装饰,2007,(10):11～15.
[3]金晶.中国家具制造业国际竞争力分析[J].中国林业产业,2007,(5):38～43.
[4]闫玉秀,季晓芬.服装厂降低返修率的系统研究[J].纺织学报,2004,25(3):66～67.
[5]郭克莎.质量经济学概论[M].北京:机械工业出版社,1987.
[6]尤建新,陈宝胜.不合格产品返修经济分析[J].同济大学学报,2002,30(9):1125～1128.
[7]易树平,郭伏.基础工业工程[M].北京:机械工业出版社,2006.
[8]张根保,何桢,刘英.质量管理与可靠性(修订本)[M].北京:中国科学技术出版社,2005.
[9]宋明顺.质量管理学[M].北京:科学出版社,2005.
[10]李爱华,曹霞.企业的作业成本法研究[J].沈阳大学学报,2003,15(3):44～46.
[11]道格拉斯·希克斯.作业成本会计:在中小企业中的实施方案(第2版)[M].上海:上海人民出版社,2002.
[12]肖序,王颖梅,邓永勤.成本会计学[M].中南大学出版社,2004,46～48.
[13]丁启叶.浅析作业成本动因[J].财会月刊,2001,(12):44.
[14]GB3330-82,家具工业常用名词术语[S].
[15]穆亚平,黄河润,沈凤明.微薄木饰面工艺技术研究[J].家具,2003,(3):23～27.
[16]申利明,路则光,黄河浪,吴新凤,陈秀兰,薛丽丹.工艺参数对硬枫薄木贴面杨木多层板表面[J].
[17]质量的影响[J].木材加工机械,2006,(4):19～23.
[18]闫玉秀,季晓芬.服装厂降低返修率的系统研究[J].纺织学报,2004,25(3):66～67.
[19]刘艳红.批量与设备影响板式家具成本分析[D].南京林业大学,2006.
[20]郝景新.板式家具典型作业岗位工时与产能研究[D].南京林业大学,2006.
[21]关星.质量成本的计量及其控制方法研究[D].天津大学,2005.
[22]赵新革.外向型家具企业产品成本策划[D].东北林业大学,2006.
[23]祁忆青.板式家具工序质量的研究[D].南京林业大学,2005.
[24]杨丽萍.作业成本法在H家具厂的应用[D].西南交通大学,2006.
[25]李云雁,胡传荣.试验设计与数据处理[M].北京:化学工业出版社,2005.
[26]吴智慧.木家具制造工艺学[M].北京:中国林业出版社,2004.
[27]王剀.木材工业实用大全[M].北京:中国林业出版社,2002.