基于提高产品质量的质量屋需求优化

以质量屋为研究对象,基于产品广义质量将用户需求划分为产品质量需求、时间需求、成本需求、环境需求、售后服务需求5类,建立用户需求结构;应用层次分析法确定用户需求重要度;基于产品设计质量,将设计需求展开为24个子项;分析5类用户需求与24个设计需求间的相互对应关系,应用Swing方法定量确定用户需求与设计需求关系值。以直线振动筛为例验证基于上述研究结果所构成质量屋的有效性。     

Evaluation of design alternatives in collaborative development and production of modular products

In the globally competitive business environment, collaborative product development has become an important strategy for enterprises to reduce risks and enhance their competitiveness. The planning phase becomes more significant and complicated when utilizing external resources to determine a product solution to achieve customer satisfaction and business goals. The decision process for assessing design alternatives depends on the tradeoffs between quality, time, and cost. In this research, we propose a framework for collaborative product development and production of modular products. It aims at linking customer requirements, generating design alternatives, and then evaluating and selecting these choices to determine the optimum solution. They are considered from both design aspects and manufacturing concerns. Product strategy is discussed as the most important factor in the evaluation process. Further, a practical application of a system-on-a-chip product planning process was carried out to demonstrate the completeness and benefit of our proposed framework.     

以顾客满意为中心的大规模定制质量改进

以顾客满意为中心的大规模定制质量改进研究是为解决大规模定制生产模式下保证稳定的、不断改进的产品质量,以持续提升顾客满意度问题而提出的系统性方法。在对大规模定制质量改进过程中顾客满意、产品平台、质量保证、改进过程和相互关系等关键要素分析的基础上,构建质量改进体系,实现产品平台质量的稳定和持续改进,继而推动最终产品的质量改进,增强企业满足顾客个体与群体质量要求的能力,最终达到持续提升顾客满意的目的。     

Concurrent process/inspection planning for a customized manufacturing system based on genetic algorithm

Producing products with multiple quality characteristics is always one of the concerns for an advanced manufacturing system. To assure product quality, finite manufacturing resources (i.e., process workstations and inspection stations) could be available and employed. The manufacturing resource allocation problem then occurs, therefore, process planning and inspection planning should be performed. Both of these are traditionally regarded as individual tasks and conducted separately. Actually, these two tasks are related. Greater performance of an advanced manufacturing system can be achieved if process planning and inspection planning can be performed concurrently to manage the limited manufacturing resources. Since the product variety in batch production or job-shop production will be increased for satisfying the changing requirements of various customers, the specified tolerance of each quality characteristic will vary from time to time. Except for finite manufacturing resource constraints, the manufacturing capability, inspection capability, and tolerance specified by customer requirement are also considered for a customized manufacturing system in this research. Then, the unit cost model is constructed to represent the overall performance of an advanced manufacturing system by considering both internal and external costs. Process planning and inspection planning can then be concurrently solved by practically reflecting the customer requirements. Since determining the optimal manufacturing resource allocation plan seems to be impractical as the problem size becomes quite large, in this research, genetic algorithm is successfully applied with the realistic unit cost embedded. The performance of genetic algorithm is measured in comparison with the enumeration method that generates the optimal solution. The result shows that a near-optimal manufacturing resource allocation plan can be determined efficiently for meeting the changing requirement of customers as the problem size becomes quite large.     

Automotive special report - A holistic approach to quality - Quality control in automotive manufacturing has certainly evolved dramatically over recent years. One of the best examples is the Renault facility in Palencia, Spain

The evolution of quality control in automative manufacturing is exemplified by the Renault facility in Palencia, Spain, where quality improvement is part of its three-pronged Renault Commitment 2009 strategy. New standard processes and methods have been set up under the Renault Production Way (SPR), placing a strong emphasis on personnel responsibility at Renault production plants. A number of concrete measures have been taken to enthrone deep-rooted quality as the centrepiece of the Renault manufacturing system: attentive supplier management, fine-tuned operator training, responsive quality leadership at production plants, and systematic application of certain static and dynamic tests on completion of the production process. Then final vehicle quality is validated by a rigorous Alliance-wide scoring system (known as AVES, for Alliance Vehicle Evaluation Standard), examining over 500 criteria. At the same time, quality improvement actions at production plants are driven by customer feedback, input via the dealer network in real time. Operator training is an essential prerequisite, both for the implementation of standards and for any successful quality drive     

基于RFID技术的汽车混流装配生产监控系统的设计与实现

汽车混流装配生产是一种面向客户订单的、小批量的装配生产模式,能够在同一条汽车装配生产线上按照客户的要求生产不同型号的产品。在汽车混流装配的生产过程中,容易发生错装和漏装问题,或出现等料、送错料和缺料等情况,影响产品质量和生产效率。因此,应用RFID和电子看板等信息技术研究汽车混流装配线的实时生产监控系统,实现车间现场数据的实时采集、在制品的跟踪、产品的质量监测、工艺信息的传递与及时反馈等,引导工人正确完成装配工作,减少错误的发生,提高生产率。     

Pro/E5.0骨架模型在装配设计中应用

在使用Pro/E软件进行外形及结构设计过程中,因客户需要或其它方面的原因,产品的外形、尺寸和结构有时需要改变或调整,如果是采用零件设计继而装配成产品的方式进行产品设计,在设计更改时,工作量较大,有时会因再生失败而必须重新设计,本人通过多年工作经验,总结了一套行之有效的方法,能较好的适应设计更改引起的外形,尺寸、结构的变化,能快速的完成设计更改。     

Quick decision-making support for inspection allocation planning with rapidly changing customer requirements

Manufacturing products with multiple quality characteristics is always one of the main concerns for an advanced manufacturing system. To assure product quality, finite automatic inspection systems should be available and employed. Inspection planning to allocate inspection stations should then be performed to manage limited inspection resources. Since product variety in batch production or job shop production is increased to satisfy the changing requirements of various customers, the specified tolerance of each quality characteristic varies from time to time. Except for a finite inspection resource constraint, therefore, manufacturing capability, inspection capability, and tolerance specified by customer requirement are considered concurrently in this research. A unit cost model is constructed to represent the overall performance of an advanced manufacturing system. Both the internal and external costs of a multiple quality characteristic product are considered. The inspection allocation problem can then be solved to reflect customer requirements. Since determining the optimal inspection allocation plan seems to be impractical as the problem size gets larger, in this research, two decision criteria (i.e., sequence order of workstation and tolerance interval) are employed concurrently to develop a heuristic method. The performance of the heuristic method is measured in comparison with an enumeration method that generates the optimal solution. The result shows that a feasible inspection allocation plan to meet changing customer requirements can be determined efficiently.     

面向需求增溢的客户满意度模型研究

提出一种面向需求增溢现象的产品综合客户满意度计算方法,该方法首先对需求质量特征类型和客户满意度区间进行划分;然后采用分段式指数型函数建立不同类型的客户需求特征满意度模型;最后采用层次分析法确定各个需求特征的相关权重,从而得到不同产品对应的客户综合满意度。以工程自卸车产品客户选择为例,对该客户满意度模型应用的有效性和实用性进行了说明。     

产品设计中泡沫塑料模型的制作探讨

模型制作是产品设计的重要阶段,是设计师直观表达设计思维的有效途径,笔者通过实践,探讨硬质聚氨酯泡沫塑料模型制作中比较适用的技巧和方法,灵活的运用"少量多次"原则,实现产品模型制作快(加工时间少)、好(模型质量高)、省(经济成本低)。     

Rapid Sheet Metal Manufacturing. Part 1: Indirect Rapid Tooling

Rapid sheet metal manufacturing (RSMM) is a closed loop process for making sheet metal products which uses advanced computer-aided techniques and computer-controlled machines to produce non-ferrous tooling directly or indirectly. The tooling would be suitable for short-run production or design evaluation of sheet metal products for which prototyping cost and lead time are greatly reduced. The key aspect of this closed-loop process is the method used to fabricate and modify the sheet metal forming tool. Various approaches are adopted in the preparation of the tooling for onward embossing on a sheet metal. The three indirect approaches use selective laser sintering (SLS), stereolithography (SLA), and high-speed computer numerical controlled (CNC) milling to build the masters from computer data models. The masters are used in the vacuum casting process to generate the non-ferrous tooling. Comparisons on quality, lead time and cost are presented.     

Product Hardware Complexity and Its Impact on Inventory and Customer On-Time Delivery

This paper studies the impact of a reduction in hardware complexity on the supply-chain inventory against various customer on-time delivery alternatives and manufacturing environments. Different methods of reducing hardware complexity are proposed, and their impact on total supply-chain inventory and customer serviceability quantified. An analytical inventory optimization scheme taking into account multistage supply networks, product structure, forecast accuracy, lead-time variability, and supplier reliability is used to determine optimal inventory levels in a stochastic modeling environment. The analysis is based on a business case for an IBM midrange computer family consisting of more than 200 models and upgrades with hundreds of features. We investigate different hardware complexity reduction strategies, including low-usage feature reduction, low-volume feature reduction, and feature substitution, as well as quick response and postponement mechanisms. Our computational results show that, in a fabrication-fulfillment center environment, reducing hardware complexity results in significantly higher inventory savings than in an integrated manufacturing environment. The results presented in this paper were used to reduce hardware complexity in IBM's midrange computer division.     

A decision support system for analysis of effects of timely fulfillment of customer demand in supply chain management practices

This paper is based on the data collected from a survey of 66 Indian textile-related organizations carried out to ascertain issues related to effects of timely fulfillment of customer demand in supply chain management (SCM) practices. Using the data collected, fuzzy set theory has been applied to reach a decision regarding effects of timely fulfillment of customer demand on an organization. Four multi-input single-output (MISO) Mamdani fuzzy inference systems have been proposed as an alternative approach to handle the various variables that are normally considered in such cases in Indian textile organizations. First three MISO systems consist of four inputs (decrease in production lead time, reduction in overall cycle time, improvement in quality, betterment in process integration), three inputs (decrease in production cost, increase in profits, increase in market share), and three inputs (decrease in internal conflicts, increase in customer satisfaction, betterment in buyer–supplier relations), respectively, and give out single output each, namely production effect, monetary effect, and relation effect, respectively. These three outputs are used as inputs to the fourth MISO system to give out single output, termed as final effect.     

Measurement system escape and overkill rate analysis

In 100% inspection, measurement errors are unavoidable. Due to these errors, acceptable products are sometimes rejected (overkill) and defective products are accepted (escape). Overkill increases production costs, while escape is a source of customer dissatisfaction. This study presents a model for calculating overkill and escape rates using process and measurement system performance data. A practical example of applying the model is also presented to calculate gage reproducibility and repeatability requirements for different production settings. Industrial managers and quality engineers can utilize the results of this study to calculate escape and overkill rates of their production systems, and to assess and improve their processes.     

特种制造业准时制用户驱动生产系统研究

通过对特种制造业基于准时制的用户驱动型制造系统的研究，提出了适应于客户驱动的以模块化设计、另部件标准化、系列化为基础；以合作供应为主要管理要素的准时生产运行管理模型，给出基于准时制的用户驱动型制造系统在特种制造行业——电梯制造业中的应用。     

SMT装联工艺过程及其环境的控制

主要论述了表面组装技术（SMT）的装联工艺实施过程,并对其实施环境进行工艺控制,使产品采用最佳的生产工艺,并在最佳的环境下进行生产,以提高SMT产品的生产质量,从而保证电子产品的最终质量与使用可靠性.     

推荐一种可追溯零件生产全过程信息的质量控制工具

基于零组件生产实行全员、全过程、精细化管理、零缺陷和可追踪等全面质量管理理念,推荐一种可追踪零组件生产全过程质量信息的质量控制工具,经过2年多的应用,达到了预期效果,在提高产品和服务质量及管理水平的同时,也给企业带来经济效益和文化建设等多方面的收获.本文包括企业通用的零组件生产流程和批次质量管理记录,希望该记录能对其他企业产品质量的改进和完善有所帮助,使其利益相关者可以借鉴.     

网络环境下客户信息主动获取研究

通过分析企业中客户参与和客户信息获取的重要性，指出客户行为是区分客户信息获取模式的决定性因素，由此提出客户信息主动获取的概念，并阐述了其主要特征。构建了多用户参与的客户信息主动获取模型（MUPIA）以支持集成的客户参与和客户信息获取，并对该模型的层次结构和其中的关键元素进行了研究。在此基础上，还构建了多用户交互集成框架来实现客户信息主动获取的应用，重点研究了多用户交互过程的实现。实例表明，客户信息主动获取模式提高了客户信息获取质量，有利于产品制造的客户参与，是一个多方互动的客户信息获取模式。     

An ontology learning system for customer needs representation in product development

The intense competition and high failure rate of product introduction necessitate a deeper understanding of customer needs for product design. The conventional process of interpreting customer statements relies on imprecise information, making it highly unlikely, if not impossible, to acquire accurate need statements for the front-end process of product development. To deal with this problem, an ontology-learning customer needs representation (OCNR) system is proposed in this paper. The system uses natural language processing tools to preprocess customer statements. The customer needs ontology is then established based on the key concepts and their relations that are extracted from the customer statements. A set of need statements are then generated using the established customer needs ontology. A word property-based method is proposed to extract more nontaxonomic relations. A case study was conducted to illustrate the proposed approach. Results of this study suggest that the customer needs ontology derived from the proposed OCNR system contains more semantics than those obtained from the existing ontology learning systems, and, therefore, might be able to generate more accurate need statements.