多级生产过程中关键质量特性识别研究
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摘要
产品质量是是一个企业得以生存的根本,在市场竞争中发挥着重要的作用。随着人们对于产品质量的要求越来越高,企业作为产品的生产者对于产品质量的标准制定也在不断的提高。产品质量依赖于构成产品的原材料和零部件的各级生产过程。现今企业的生产过程越来越复杂,自动化的连续生产模式成为了制造业的发展方向。自动化的连续生产模式强调不同生产环节和阶段的整合和协同,各个节点间存在相互作用和影响的关系。传统的质量控制技术都只关注单级生产过程的质量控制和评价,而没有考虑到前一级生产过程的质量波动对后续生产过程的影响和监控的有效性。在实际应用中,传统的质量控制图发出了警告,但是生产过程的操作者无法及时的判断多级生产过程的哪一部分出现了错误,这就会使得过程错误无法及时消除,过程错误在生产过程之间不断的传递,导致过程错误扩大、质量控制成本的增加。特别是自动化程度高的行业,可能出现控制图频繁报警,使得多级生产过程中的质量控制难以进行。因此,传统质量控制需要从单一生产过程拓展为整个生产过程的控制和优化。但是要是对整个生产过程进行全局的质量控制,由于多级生产过程质量特性众多,如果对每一个质量特性都进行监控,这样会造成的控制成本高昂、生产效率低下等一系列问题。在这种情况下,只有识别出多级生产过程的关键质量特性,然后对于关键质量特性进行质量控制。
本文提出产品的生产过程是一个系统的过程,每个生产过程不是单独存在的,在进行质量控制的时候要考虑生产过程之间的传递关系,以便更快和更准确的找出过程错误的出现的位置。以往对于产品的质量特性的识别研究,并没有对产品的不同生产过程进行区分,没有具体的分析多级生产过程中上下游生产过程之间质量特性的传递关系。本文首次提出了多级生产过程应分为串联、并联和网状三种结构形式,并对三种不同结构形式的多级生产过程的传递关系进行了阐述,然后使用结构方程模型建立多级生产过程质量特性的关系模型,通过质量特性关系模型阐述不同生产过程质量特性的传递关系,最终可识别出多级生产过程中的关键质量特性。
The product quality is fundamental to an enterprise, and plays an important role in the market competition. With the increasingly high demand for product quality, the product quality standards are constantly improving. Product quality depends on the raw materials and components constituting the product. Nowadays the product needs increasingly complex production process, so automated continuous production mode becomes the direction of the development of the manufacturing sector. Automated continuous production model emphasizes the integration and synergy of different production processes, interaction and impact of the relationship between the various processes. The traditional quality control techniques are only concerned about the quality control and evaluation of the single-stage production process, without taking into account fluctuations in the quality of the upstream production process downstream production process. The traditional quality control charts issue a warning, but the operator of the production process cannot be timely determine which part of the multi-stage production process error has occurred. This will make the process error unable to eliminate, and the process errors constantly passed between the production processes, resulting in process error expansion, the increase in the cost of quality control. In particular, the high degree of automation industry, control charts may appear frequent alarms. This will lead to a multi-stage production process quality control is difficult to play a role. Therefore, the traditional quality control needs to expand from a single production process for the entire production process. The quality characteristics of multi-stage production process are too many. If the enterprise controls every quality characteristic, this will cause the control of the high cost and low production efficiency. In this case, the enterprises only identify key quality characteristics of multi-stage production process in order to conduct quality control. Previous studies for the identification of the key quality characteristics, They do not have a specific analysis of the transfer relationship between multi-stage production process quality characteristics. This paper described the transitive relation of the three different structures multi-stage production process, and then establishing a relational model of the multi-stage production process quality characteristic.Though this model describes the different production process quality characteristics transitive relation, and ultimately this method can identify the key quality characteristics of the multi-stage production process.
本文提出产品的生产过程是一个系统的过程,每个生产过程不是单独存在的,在进行质量控制的时候要考虑生产过程之间的传递关系,以便更快和更准确的找出过程错误的出现的位置。以往对于产品的质量特性的识别研究,并没有对产品的不同生产过程进行区分,没有具体的分析多级生产过程中上下游生产过程之间质量特性的传递关系。本文首次提出了多级生产过程应分为串联、并联和网状三种结构形式,并对三种不同结构形式的多级生产过程的传递关系进行了阐述,然后使用结构方程模型建立多级生产过程质量特性的关系模型,通过质量特性关系模型阐述不同生产过程质量特性的传递关系,最终可识别出多级生产过程中的关键质量特性。
The product quality is fundamental to an enterprise, and plays an important role in the market competition. With the increasingly high demand for product quality, the product quality standards are constantly improving. Product quality depends on the raw materials and components constituting the product. Nowadays the product needs increasingly complex production process, so automated continuous production mode becomes the direction of the development of the manufacturing sector. Automated continuous production model emphasizes the integration and synergy of different production processes, interaction and impact of the relationship between the various processes. The traditional quality control techniques are only concerned about the quality control and evaluation of the single-stage production process, without taking into account fluctuations in the quality of the upstream production process downstream production process. The traditional quality control charts issue a warning, but the operator of the production process cannot be timely determine which part of the multi-stage production process error has occurred. This will make the process error unable to eliminate, and the process errors constantly passed between the production processes, resulting in process error expansion, the increase in the cost of quality control. In particular, the high degree of automation industry, control charts may appear frequent alarms. This will lead to a multi-stage production process quality control is difficult to play a role. Therefore, the traditional quality control needs to expand from a single production process for the entire production process. The quality characteristics of multi-stage production process are too many. If the enterprise controls every quality characteristic, this will cause the control of the high cost and low production efficiency. In this case, the enterprises only identify key quality characteristics of multi-stage production process in order to conduct quality control. Previous studies for the identification of the key quality characteristics, They do not have a specific analysis of the transfer relationship between multi-stage production process quality characteristics. This paper described the transitive relation of the three different structures multi-stage production process, and then establishing a relational model of the multi-stage production process quality characteristic.Though this model describes the different production process quality characteristics transitive relation, and ultimately this method can identify the key quality characteristics of the multi-stage production process.
引文
[1]苏秦.现代质量管理学[M].北京：清华大学出版社,2005.
[2]张公绪.多元统计过程诊断理论[J].质量与可靠性,2003,(1)：23-27.
[3]余忠华,殷建军,吴昭同.工序相似性分析及其在SPC方法中运用研究[J].系统工程理论与实践,200211(11)15-19.
[4]Ding, Y., Ceglarek, D. and Shi, J. Fault diagnosis of multistage manufacturing processes by using state space approach [J]. Journal of Manufacturing Science and Engineering,2002, 124(2):313-322.
[5]Jin, J. and Shi, J. State space modeling of sheet metal assembly for dimensional control [J]. Journal of Manufacturing Science and Engineering,1999,121(4):756-762.
[6]Agrawal, R., Lawless, J.F., Mackay, R.J. Analysis of Variation Transmission in Manufacturing Process-Part Ⅱ [J]. Journal of Quality Technology,1999,31(2):143-154
[7]Yang J., Liu Y. Process Variation Transmission in Process Capability Analysis[J], Proceeding of the 14th IE&EM. China Machine Press, Oct.2007:180-183.
[8]Thornton A.C.Using key characteristics to balance cost and quality during product development[A].Design Theory and Methodology Conference,ASME Design Technical Conferences[C],Sacramento,CA,1997.
[9]Yao, Y. and Gao, F. A survey on multistage/multiphase statistical modeling methods for batch processes [J]. Annual reviews in control,2009,33:172-283.
[10]Loose, J. Zhou, S. and Ceglarek, D. Variation source identification in manufacturing processes based on relation measurements of key product characteristics [J]. Journal of Manufacturing Science and Engineering,2008,130(3):1-11.
[11]Guo,Huixin;Ren,Pishun;Zhang,Guoping. Decoupling of multi-quality characteristics and robust design optimization[J]. Chinese Society of Agricultural Machinery,2009.1,40(1):203-205.
[12]Woodall, W.H., et al. Controversies and Contradictions in Statistical Process Control [J]. Journal of Quality Technology,2000,32(4):341-378.
[13]Lawless, J.F., Mackay, R.J. Analysis of Variation Transmission in Manufacturing Process-Part I [J]. Journal of Quality Technology,1999,31(2):131-142.
[14]Xiang, L. and Tsung, F. Statistical monitoring of multistage processes based on engineering models [J]. IIE transactions,2008,40(10):957-970.
[15]Zou, C. and Tsung, F. Directional MEWMA schemes for multistage, process monitoring and diagnosis. Journal of Quality Technology,2008,40(4):407-427.
[16]何桢,刘豹,齐二.基于多变异分析的工序控制方法研究[J].管理工程学报,2002,16(2)：1-4.
[17]Pearn, W.L., Chang, C.S. Precision measures for processes with multiple manufacturing lines [J]. International Journal of Advanced Manufacturing Technology,2006,30:1202-1210.
[18]Tapiero, C.S. Consumers risk and quality control in a collaborative supply chain [J]. European Journal of Operational Research,2007,182(2):683-694.
[19]Linn, R.J., Au, E., Tsung, F. Process Capability Improvement for Multistage Processes [J]. Quality Engineering,2002/3,15(2):281-292.
[20]Forker, L.B., Mendez, D., Hershauer, J.C. Total quality management in the supply chain: what is its impact on performance [J]. International Journal of Production Research,1997,35(6): 1681-701.
[21]张根保.现代质量工程[M].北京：机械工业出版社,2004.
[22]张根保,何桢等.质量管理与可靠性[M].北京：中国科学技术出版社2005.3.
[23]郑联语,汪叔淳.产品全生命周期的工艺质量模型与并行制造方法研究[J].中国机械工程,2001,12(5)：535-539.
[24]杨剑锋.自相关特性对过程能力分析的影响[J].制造技术与机床,2008,(11)：116-120.
[25]何益海,唐晓青.基于关键质量特性的产品保质设计[J].航空学报,2007(6)：1468-1481.
[26]蔡宪杰,王信民,尹启生.烤烟外观质量指标量化分析初探[J].烟草科技,2004,203(6)：7-12.
[27]马义中.减小和控制多元质量特性波动的理论和方法[D].西安：西北工业大学博士论文,2002.
[28]王宗君.机械零件最佳选定质量特性重要度是实行质量重点控制的重要举措[J].机械工业标准化与质量,1999,1：28-29.
[29]王成柱.制造过程质量管理探讨[J].工业工程与管理,1998(5)：41-44.
[30]戴敏.多工序制造过程质量分析方法与信息集成技术研究[D].南京：东南大学博士学位论文,2006.
[31]商建东,陈康宁.质量驱动的产品设计质量模糊评价及方案决策方法研究[J].中国机械工程,2000,11(12)：1394-1398.
[32]张根保,纪富义,任显林,等.复杂机电产品关键质量特性提取模型[J].重庆大学学报(自然科学版)2010,33(2)：8-14.
[33]陈文多,苗瑞,赵言正.基于路径图的多元统计过程诊断方法[J].上海交通大学大学学报,2010,44(12)：1758-1762.
[34]候杰泰,成子娟.结构方程模型的应用及分析策略[J].心理学探新,1999,19(1)：54-59.
[35]侯杰泰,温忠麟,成子娟.结构方程模型及其应用[M].教育科学出版社.2004,32-77.
[36]周涛,卢耀斌.结构方程模型及其在实证分析中的应用[J].工业工程与管理,2006(05),45-49.
[37]孟鸿伟,模型构建方法与结构方程建模[J].心理学报.1994,26(4).
[38]宇传华.SPSS与统计分析[M].北京：电子工业出版社,2007.
[39]赵富强.基于PLS路径模型的顾客满意度测评研究[D].天津：天津大学博士论文,2010.
[40]赵嵩正,殷茗,梁工谦,赵远志.大型复杂航空产品质量评估模型研究[J].航空学报,2006,27(4)：588-593.
[41]李延来,唐加福.质量功能配置中工程特性最终重要度的确定方法[J].机械工程学报,2007,43(4)：178-186
[42]岳朝生.机载设备制造过程的质量控制[J].航空精密制造技术,1995,31(4)：39-41.
[43]杨剑锋,徐济超,王海宇.机械加工过程的输出分布和性能分析[J].机械科学与技术,2006, 25(5)：612-615.
[44]闫克玉,王建民,屈剑波,等.河南烤烟评吸质量与主要理化指标的相关分析[J].烟草科技,2001,(10)：5-9.
[45]阎克玉,袁志永,吴殿信.烤烟质量评价指标体系研究[J].郑州轻工业学院学报(自然科学版)2001,16(4)：57-61.
[46]于建军主编.卷烟工艺学[M].北京：中国农业出版社,2003.
[47]吉书文,滕兆波.烟草物理检测[M].郑州：河南科学技术出版社,1997.
[48]方平,熊端琴姜媛.结构方程模式及其成功应用的判断标准[J].首都师范大学学报(社会科学版),2000,134.61-64.
[49]孙静.接近零不合格过程的质量控制[M].北京：清华大学出版社,2001.
[50]魏丽,郑联语.概要工艺规划中关键特性的识别过程与方法[J].计算机集成制造系统,200713(1)：147-152.
[51]杨剑锋.面向连续质量改进的过程能力分析与评价研究[D].西安：西北工业大学博士论文,2006
[2]张公绪.多元统计过程诊断理论[J].质量与可靠性,2003,(1)：23-27.
[3]余忠华,殷建军,吴昭同.工序相似性分析及其在SPC方法中运用研究[J].系统工程理论与实践,200211(11)15-19.
[4]Ding, Y., Ceglarek, D. and Shi, J. Fault diagnosis of multistage manufacturing processes by using state space approach [J]. Journal of Manufacturing Science and Engineering,2002, 124(2):313-322.
[5]Jin, J. and Shi, J. State space modeling of sheet metal assembly for dimensional control [J]. Journal of Manufacturing Science and Engineering,1999,121(4):756-762.
[6]Agrawal, R., Lawless, J.F., Mackay, R.J. Analysis of Variation Transmission in Manufacturing Process-Part Ⅱ [J]. Journal of Quality Technology,1999,31(2):143-154
[7]Yang J., Liu Y. Process Variation Transmission in Process Capability Analysis[J], Proceeding of the 14th IE&EM. China Machine Press, Oct.2007:180-183.
[8]Thornton A.C.Using key characteristics to balance cost and quality during product development[A].Design Theory and Methodology Conference,ASME Design Technical Conferences[C],Sacramento,CA,1997.
[9]Yao, Y. and Gao, F. A survey on multistage/multiphase statistical modeling methods for batch processes [J]. Annual reviews in control,2009,33:172-283.
[10]Loose, J. Zhou, S. and Ceglarek, D. Variation source identification in manufacturing processes based on relation measurements of key product characteristics [J]. Journal of Manufacturing Science and Engineering,2008,130(3):1-11.
[11]Guo,Huixin;Ren,Pishun;Zhang,Guoping. Decoupling of multi-quality characteristics and robust design optimization[J]. Chinese Society of Agricultural Machinery,2009.1,40(1):203-205.
[12]Woodall, W.H., et al. Controversies and Contradictions in Statistical Process Control [J]. Journal of Quality Technology,2000,32(4):341-378.
[13]Lawless, J.F., Mackay, R.J. Analysis of Variation Transmission in Manufacturing Process-Part I [J]. Journal of Quality Technology,1999,31(2):131-142.
[14]Xiang, L. and Tsung, F. Statistical monitoring of multistage processes based on engineering models [J]. IIE transactions,2008,40(10):957-970.
[15]Zou, C. and Tsung, F. Directional MEWMA schemes for multistage, process monitoring and diagnosis. Journal of Quality Technology,2008,40(4):407-427.
[16]何桢,刘豹,齐二.基于多变异分析的工序控制方法研究[J].管理工程学报,2002,16(2)：1-4.
[17]Pearn, W.L., Chang, C.S. Precision measures for processes with multiple manufacturing lines [J]. International Journal of Advanced Manufacturing Technology,2006,30:1202-1210.
[18]Tapiero, C.S. Consumers risk and quality control in a collaborative supply chain [J]. European Journal of Operational Research,2007,182(2):683-694.
[19]Linn, R.J., Au, E., Tsung, F. Process Capability Improvement for Multistage Processes [J]. Quality Engineering,2002/3,15(2):281-292.
[20]Forker, L.B., Mendez, D., Hershauer, J.C. Total quality management in the supply chain: what is its impact on performance [J]. International Journal of Production Research,1997,35(6): 1681-701.
[21]张根保.现代质量工程[M].北京：机械工业出版社,2004.
[22]张根保,何桢等.质量管理与可靠性[M].北京：中国科学技术出版社2005.3.
[23]郑联语,汪叔淳.产品全生命周期的工艺质量模型与并行制造方法研究[J].中国机械工程,2001,12(5)：535-539.
[24]杨剑锋.自相关特性对过程能力分析的影响[J].制造技术与机床,2008,(11)：116-120.
[25]何益海,唐晓青.基于关键质量特性的产品保质设计[J].航空学报,2007(6)：1468-1481.
[26]蔡宪杰,王信民,尹启生.烤烟外观质量指标量化分析初探[J].烟草科技,2004,203(6)：7-12.
[27]马义中.减小和控制多元质量特性波动的理论和方法[D].西安：西北工业大学博士论文,2002.
[28]王宗君.机械零件最佳选定质量特性重要度是实行质量重点控制的重要举措[J].机械工业标准化与质量,1999,1：28-29.
[29]王成柱.制造过程质量管理探讨[J].工业工程与管理,1998(5)：41-44.
[30]戴敏.多工序制造过程质量分析方法与信息集成技术研究[D].南京：东南大学博士学位论文,2006.
[31]商建东,陈康宁.质量驱动的产品设计质量模糊评价及方案决策方法研究[J].中国机械工程,2000,11(12)：1394-1398.
[32]张根保,纪富义,任显林,等.复杂机电产品关键质量特性提取模型[J].重庆大学学报(自然科学版)2010,33(2)：8-14.
[33]陈文多,苗瑞,赵言正.基于路径图的多元统计过程诊断方法[J].上海交通大学大学学报,2010,44(12)：1758-1762.
[34]候杰泰,成子娟.结构方程模型的应用及分析策略[J].心理学探新,1999,19(1)：54-59.
[35]侯杰泰,温忠麟,成子娟.结构方程模型及其应用[M].教育科学出版社.2004,32-77.
[36]周涛,卢耀斌.结构方程模型及其在实证分析中的应用[J].工业工程与管理,2006(05),45-49.
[37]孟鸿伟,模型构建方法与结构方程建模[J].心理学报.1994,26(4).
[38]宇传华.SPSS与统计分析[M].北京：电子工业出版社,2007.
[39]赵富强.基于PLS路径模型的顾客满意度测评研究[D].天津：天津大学博士论文,2010.
[40]赵嵩正,殷茗,梁工谦,赵远志.大型复杂航空产品质量评估模型研究[J].航空学报,2006,27(4)：588-593.
[41]李延来,唐加福.质量功能配置中工程特性最终重要度的确定方法[J].机械工程学报,2007,43(4)：178-186
[42]岳朝生.机载设备制造过程的质量控制[J].航空精密制造技术,1995,31(4)：39-41.
[43]杨剑锋,徐济超,王海宇.机械加工过程的输出分布和性能分析[J].机械科学与技术,2006, 25(5)：612-615.
[44]闫克玉,王建民,屈剑波,等.河南烤烟评吸质量与主要理化指标的相关分析[J].烟草科技,2001,(10)：5-9.
[45]阎克玉,袁志永,吴殿信.烤烟质量评价指标体系研究[J].郑州轻工业学院学报(自然科学版)2001,16(4)：57-61.
[46]于建军主编.卷烟工艺学[M].北京：中国农业出版社,2003.
[47]吉书文,滕兆波.烟草物理检测[M].郑州：河南科学技术出版社,1997.
[48]方平,熊端琴姜媛.结构方程模式及其成功应用的判断标准[J].首都师范大学学报(社会科学版),2000,134.61-64.
[49]孙静.接近零不合格过程的质量控制[M].北京：清华大学出版社,2001.
[50]魏丽,郑联语.概要工艺规划中关键特性的识别过程与方法[J].计算机集成制造系统,200713(1)：147-152.
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