大重集团减速机厂质量控制模式研究与实现
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摘要
本课题来源于大重集团减速机厂风电产品全生命周期质量监控与管理的研发。结合企业自身的生产特点,遵循全面质量管理理论、统计过程控制等先进的思想,对企业的质量管理活动深入调研,确定了产品生命周期质量信息流。全面分析企业质量生产相关数据的采集、反馈、汇总统计以及决策信息的分析处理等方面的问题后,确定了系统要实现的功能目标。进而提出了基于信息闭环反馈控制管理模式的信息中枢系统框架模型,相应设计并开发了企业实际迫切需求的质量管理信息系统。
此系统分为三大子系统:信息管理数字化、执行管理标准化和反馈管理可视化。信息管理数字化子系统是在对增速器生产技术标准深入分析的基础上,构建了面向企业生产过程中所有质量活动的质量BOM体系。该体系以产品结构和配置为引导,作为产品质量数据流合理有效的载体和组织形式,最大程度地解决了质量数据的分散性问题,并在此基础上,提出了故障代码模型;执行管理标准化子系统是把工艺信息、加工信息和标准信息综合起来为生产过程监控服务,将控制图分为分析用和控制用两个阶段,通过与直方图和因果图的有效结合,实现系统自动判定当前工序加工能力,并予于调整;反馈管理可视化实现了实时接收各阶段中的分析结果数据,按照产品、零件和工序的细化顺序和深度,把各个监控点上零散的质量特征信息与所在合同、产品以及相关各种信息挂钩,使管理层可以从全局角度监控产品质量,同时能够根据企业各级相关部门的信息需求对反馈数据进行汇总统计分析,形成有用的质量信息,直观地显示给企业各级负责人进行决策,从而实现质量信息流的闭环反馈控制。
在系统的软件设计过程中,采用面向对象的程序设计语言Visual Studio 2008和企业级关系数据库SQL Server 2000作为系统的开发平台和数据库平台。
最后采用理论与实践相结合的研究方法,阐述了系统的实施应用过程。系统在企业初步实现了质量生产过程的数据集成、信息分析和决策支持,证明了本文工作的有效性和实用性。
This paper is derived from the research and development of life-cycle quality control and management on the wind power products for DHI Gear Reducer. With its own production features, made an in-depth research on the quality management of the company follows ideas such as the theory of TQM, Statistical Process Control and so on, product's life-cycle quality information flow is ascertained. So the function aim of system is according to the study of the collection, feedback, statistic and analysis of data and the consideration of the characteristics during the process of the formation of product's quality. The frame model of information center based on the closed-loop feedback control management mode is brought forward then and the information system of quality management is developed and implemented.
The system is divided into three subsystems: digital-information management, standard-execution management and visual-feedback management. Upon thorough in-depth analysis of the technique standards of gearbox production, digital-information management subsystems respectively build quality BOM facing all quality activities during the process production. The quality BOM is product structure and configuration oriented and maximally solves the dispersion problem of quality data, which is a reasonable and effective carrier and organization of product quality data flow. And on this basis, the fault code model is proposed. Standard-execution management subsystems integrate craft information, manufacturing process information and standard information for service process monitoring. And the control charts are divided into two stages as analyze-control chart and control-control chart. With the effective integration of histogram and causality diagrams the processing capacity of the current process could be determined by this system automatically on which the adjustment could be done; Visual-feedback management receives the analysis results from all stages of the control initiatively. According to the order and depth of the products, parts and process, the scattered quality characteristics information from all control points are linked to the contract, products and related information. By this way, all perspective supervising and control to product's quality are provided to leaders. Meanwhile, according to the requirements from the relevant departments of the different ranks in enterprise, the subsystem feedbacks and analyses these data to form useful as well as intuitive management information to support managers' decision. Therefore the quality information flow's close-loop feedback control is realized.
The system is developed using Visual Studio 2008 and Microsoft SQL Server 2000 platforms.
In the end the author illustrates the implementation of the system, which realizes data collection, information analysis and decision support during the process of producing quality. The practice of software shows that the approaches in this dissertation are effective and practicable.
此系统分为三大子系统:信息管理数字化、执行管理标准化和反馈管理可视化。信息管理数字化子系统是在对增速器生产技术标准深入分析的基础上,构建了面向企业生产过程中所有质量活动的质量BOM体系。该体系以产品结构和配置为引导,作为产品质量数据流合理有效的载体和组织形式,最大程度地解决了质量数据的分散性问题,并在此基础上,提出了故障代码模型;执行管理标准化子系统是把工艺信息、加工信息和标准信息综合起来为生产过程监控服务,将控制图分为分析用和控制用两个阶段,通过与直方图和因果图的有效结合,实现系统自动判定当前工序加工能力,并予于调整;反馈管理可视化实现了实时接收各阶段中的分析结果数据,按照产品、零件和工序的细化顺序和深度,把各个监控点上零散的质量特征信息与所在合同、产品以及相关各种信息挂钩,使管理层可以从全局角度监控产品质量,同时能够根据企业各级相关部门的信息需求对反馈数据进行汇总统计分析,形成有用的质量信息,直观地显示给企业各级负责人进行决策,从而实现质量信息流的闭环反馈控制。
在系统的软件设计过程中,采用面向对象的程序设计语言Visual Studio 2008和企业级关系数据库SQL Server 2000作为系统的开发平台和数据库平台。
最后采用理论与实践相结合的研究方法,阐述了系统的实施应用过程。系统在企业初步实现了质量生产过程的数据集成、信息分析和决策支持,证明了本文工作的有效性和实用性。
This paper is derived from the research and development of life-cycle quality control and management on the wind power products for DHI Gear Reducer. With its own production features, made an in-depth research on the quality management of the company follows ideas such as the theory of TQM, Statistical Process Control and so on, product's life-cycle quality information flow is ascertained. So the function aim of system is according to the study of the collection, feedback, statistic and analysis of data and the consideration of the characteristics during the process of the formation of product's quality. The frame model of information center based on the closed-loop feedback control management mode is brought forward then and the information system of quality management is developed and implemented.
The system is divided into three subsystems: digital-information management, standard-execution management and visual-feedback management. Upon thorough in-depth analysis of the technique standards of gearbox production, digital-information management subsystems respectively build quality BOM facing all quality activities during the process production. The quality BOM is product structure and configuration oriented and maximally solves the dispersion problem of quality data, which is a reasonable and effective carrier and organization of product quality data flow. And on this basis, the fault code model is proposed. Standard-execution management subsystems integrate craft information, manufacturing process information and standard information for service process monitoring. And the control charts are divided into two stages as analyze-control chart and control-control chart. With the effective integration of histogram and causality diagrams the processing capacity of the current process could be determined by this system automatically on which the adjustment could be done; Visual-feedback management receives the analysis results from all stages of the control initiatively. According to the order and depth of the products, parts and process, the scattered quality characteristics information from all control points are linked to the contract, products and related information. By this way, all perspective supervising and control to product's quality are provided to leaders. Meanwhile, according to the requirements from the relevant departments of the different ranks in enterprise, the subsystem feedbacks and analyses these data to form useful as well as intuitive management information to support managers' decision. Therefore the quality information flow's close-loop feedback control is realized.
The system is developed using Visual Studio 2008 and Microsoft SQL Server 2000 platforms.
In the end the author illustrates the implementation of the system, which realizes data collection, information analysis and decision support during the process of producing quality. The practice of software shows that the approaches in this dissertation are effective and practicable.
引文
[1]Juran J M.China's ancient history of managing for quality[J].Quality Progress,1990,22(7):31-35.
[2]周纪芗,茆诗松.质量管理统计方法[M].北京:高等教育出版社,1999.
[3]王海宇.过程质量控制的性能评价与改进方法研究[D].西安:西北工业大学,2006.
[4]李家锋,刘智华.质量管理综述[J].华南农业大学学报,1994,15(1):133-138.
[5]Harrison M W.Generic quality standards-standards activities of the American society for quality control[J].ASTM Standardization News,1990,18(1):50-52.
[6]Nell J D,Sterett.W K.History of the Mallcolm Baldrige National of the American Society for quality control[J].ASTM Standardization News,1990,18(10):50-52.
[7]贾放.当前我国产品质量的状况和问题[J].世界标准化与质量管理,1992(6):4-7.
[8]刘文卿.六西格玛过程改进技术[M].北京:中国人民大学出版社,2003.
[9]周奎,朗志正.质量管理信息系统的开发与应用研究[J].质量管理,1991(6):35-38.
[10]张善诲.质量管理方法及应用[M].北京:中国计量出版社,2007.
[11]石川馨.质量管理入门[M].北京:机械工业出版,1979.
[12]董华.基于质量信息集成的“全质量”管理系统实现技术研究[D].安徽:合肥工业大学,2006.
[13]张莉莉.用友ERP生产管理系统实验教程[M].北京:清华大学出版社,2007.
[14]甘烽,宋光贵.技术与质量管理[M].广州:华南理工大学出版社,1992.
[15]尤建新,张建同,杜学美等.质量管理学[M].北京:科学出版社,2003.
[16]张玉生,刘增德.工序质量控制点的设置与控制[J].河北工程技术高等专科学校学报,2001(3):46-48.
[17]Haiyu Wang,Jichao Xu,Young H.Park.Analysis and Compare for Control Charts under the Changed Alarm Rule[J].The Asian Journal on Quality,2003,4(2):65-72.
[18]郎志正.质量控制方法与管理[M].北京:国防工业出版社,1982.
[19]彭泽军,陈辉,周定果.质量控制图及其工序质量控制[J].机械设计与制造,2008(8):139-141.
[20]辛琳琳.大重集团减速机厂信息中枢系统的研究与实现[D].辽宁:大连理工大学,2005.
[21]秦现生.质量管理学[M].北京:中国科学技术出版社,2008.
[22]程培培.面向全寿命周期BOM的航空武器装备质量管理模式研究[D].西安:西北工业大学,2006.
[23]王灿,张根保,黄忠全等.基于质量BOM和整合条码的质量信息系统的开发和实施[J].工业工程与管理,2001(5):22-25.
[24]谭爱红,周胜,张友宏,等.车间级产品加工质量控制的研究[J].机械设计与制造,2006(4):175-176.
[25]于涛,张树生.工序质量控制系统研究[J].世界标准化与质量管理,1999(8):7-10.
[26]Xiaoqing Tang,Guijiang Duan,Kwai-Sang Chin.Development and implementation of an integrated quality information system—a China experience[J].The International Journal of Advanced Manufacturing Technology,2007,32(5-6):608-616.
[27]陈国铭.统计质量控制——数据收集和整理[M].北京:中国计量出版社,1995.
[28]王邦国.加工工序质量控制系统[D].辽宁:大连交通大学,2006
[29]戴维M.莱文.六西格玛绿带统计分析[M].北京:机械工业出版社,2007.
[30]于涛.工序质量控制理论与应用[M].北京:经济管理出版社,2008.
[31]陈晋美.国内外企业常用抽样检验与测量技术[M].北京:中国计量出版社,2006.
[32]李汉昭.帕累托80/20效率法则[M].北京:海潮出版礼,2001.
[33]曹烨,郑双双.基于分类管理的汽车制造业供应商评价与选择方法[J].天津汽车,2007(1):18-21.
[34]王会良,朱德荣,桂斌,杨进濮.MINITAB软件在工序质量控制中的应用[J].煤矿机械,2006,27(10):115-116.
[35]刘钦.基于生命周期的制造企业供应商选择研究[D].广东:广东外语外贸大学,2008.
[36]Luitzen De Boer,Eva Labro,Pierangela Morlacchi.A review of methods supporting supplier selection[J].European Journal of Purchasing & Supply Management,2001,2(7):75-89.
[37]郝海,踪家峰.系统分析与评价方法[M].北京:经济科学出版社,2007.
[38]Robert Handfield,Steven V.Walton,Robert Sroufe,Steven,A.Melnyk.Applying environmental criteria to supplier assessment:A study in the application of the Analytical Hierarchy Process[J].Journal of Operational Research,2002,141(1):70-87.
[39]黄绍服,赵韩.供应商选择的AHP/随机DEA方法[J].重庆大大学学报,2004.27(2):28-31.
[40]李开鹏,吴新敏.制造企业不合格品的管理[J].电子质量,2005(5):46-48.
[41]王善武.谈不合格品的让步尺度[J].国防技术基础,2002(1):37-38.
[42]刘天仁.大重集团减速机厂库存管理模式研究与软件实现[D].辽宁:大连理工大学,2005.
[2]周纪芗,茆诗松.质量管理统计方法[M].北京:高等教育出版社,1999.
[3]王海宇.过程质量控制的性能评价与改进方法研究[D].西安:西北工业大学,2006.
[4]李家锋,刘智华.质量管理综述[J].华南农业大学学报,1994,15(1):133-138.
[5]Harrison M W.Generic quality standards-standards activities of the American society for quality control[J].ASTM Standardization News,1990,18(1):50-52.
[6]Nell J D,Sterett.W K.History of the Mallcolm Baldrige National of the American Society for quality control[J].ASTM Standardization News,1990,18(10):50-52.
[7]贾放.当前我国产品质量的状况和问题[J].世界标准化与质量管理,1992(6):4-7.
[8]刘文卿.六西格玛过程改进技术[M].北京:中国人民大学出版社,2003.
[9]周奎,朗志正.质量管理信息系统的开发与应用研究[J].质量管理,1991(6):35-38.
[10]张善诲.质量管理方法及应用[M].北京:中国计量出版社,2007.
[11]石川馨.质量管理入门[M].北京:机械工业出版,1979.
[12]董华.基于质量信息集成的“全质量”管理系统实现技术研究[D].安徽:合肥工业大学,2006.
[13]张莉莉.用友ERP生产管理系统实验教程[M].北京:清华大学出版社,2007.
[14]甘烽,宋光贵.技术与质量管理[M].广州:华南理工大学出版社,1992.
[15]尤建新,张建同,杜学美等.质量管理学[M].北京:科学出版社,2003.
[16]张玉生,刘增德.工序质量控制点的设置与控制[J].河北工程技术高等专科学校学报,2001(3):46-48.
[17]Haiyu Wang,Jichao Xu,Young H.Park.Analysis and Compare for Control Charts under the Changed Alarm Rule[J].The Asian Journal on Quality,2003,4(2):65-72.
[18]郎志正.质量控制方法与管理[M].北京:国防工业出版社,1982.
[19]彭泽军,陈辉,周定果.质量控制图及其工序质量控制[J].机械设计与制造,2008(8):139-141.
[20]辛琳琳.大重集团减速机厂信息中枢系统的研究与实现[D].辽宁:大连理工大学,2005.
[21]秦现生.质量管理学[M].北京:中国科学技术出版社,2008.
[22]程培培.面向全寿命周期BOM的航空武器装备质量管理模式研究[D].西安:西北工业大学,2006.
[23]王灿,张根保,黄忠全等.基于质量BOM和整合条码的质量信息系统的开发和实施[J].工业工程与管理,2001(5):22-25.
[24]谭爱红,周胜,张友宏,等.车间级产品加工质量控制的研究[J].机械设计与制造,2006(4):175-176.
[25]于涛,张树生.工序质量控制系统研究[J].世界标准化与质量管理,1999(8):7-10.
[26]Xiaoqing Tang,Guijiang Duan,Kwai-Sang Chin.Development and implementation of an integrated quality information system—a China experience[J].The International Journal of Advanced Manufacturing Technology,2007,32(5-6):608-616.
[27]陈国铭.统计质量控制——数据收集和整理[M].北京:中国计量出版社,1995.
[28]王邦国.加工工序质量控制系统[D].辽宁:大连交通大学,2006
[29]戴维M.莱文.六西格玛绿带统计分析[M].北京:机械工业出版社,2007.
[30]于涛.工序质量控制理论与应用[M].北京:经济管理出版社,2008.
[31]陈晋美.国内外企业常用抽样检验与测量技术[M].北京:中国计量出版社,2006.
[32]李汉昭.帕累托80/20效率法则[M].北京:海潮出版礼,2001.
[33]曹烨,郑双双.基于分类管理的汽车制造业供应商评价与选择方法[J].天津汽车,2007(1):18-21.
[34]王会良,朱德荣,桂斌,杨进濮.MINITAB软件在工序质量控制中的应用[J].煤矿机械,2006,27(10):115-116.
[35]刘钦.基于生命周期的制造企业供应商选择研究[D].广东:广东外语外贸大学,2008.
[36]Luitzen De Boer,Eva Labro,Pierangela Morlacchi.A review of methods supporting supplier selection[J].European Journal of Purchasing & Supply Management,2001,2(7):75-89.
[37]郝海,踪家峰.系统分析与评价方法[M].北京:经济科学出版社,2007.
[38]Robert Handfield,Steven V.Walton,Robert Sroufe,Steven,A.Melnyk.Applying environmental criteria to supplier assessment:A study in the application of the Analytical Hierarchy Process[J].Journal of Operational Research,2002,141(1):70-87.
[39]黄绍服,赵韩.供应商选择的AHP/随机DEA方法[J].重庆大大学学报,2004.27(2):28-31.
[40]李开鹏,吴新敏.制造企业不合格品的管理[J].电子质量,2005(5):46-48.
[41]王善武.谈不合格品的让步尺度[J].国防技术基础,2002(1):37-38.
[42]刘天仁.大重集团减速机厂库存管理模式研究与软件实现[D].辽宁:大连理工大学,2005.