光电半导体封装测量系统能力分析方法研究

为了提高半导体封装分箱工序的质量水平,有必要对测量系统进行：分析与研究。在深入分析光电半导体封装过程中的测量系统特征的基础上,建立了基于属性GR＆R的测量系统能力分析模型和方法,并通过实例进行了验证。     

基于DMAIC的转向轴生产质量改进

转向轴是循环球式转向器中重要的传导部件,利用六西格玛DMAIC模式对XinH公司Z转向轴生产的高废品率问题进行了质量改进。通过SIPOC流程图和帕累托图分析找出需要改进的质量点为磨削外圆圆度超差;针对分析明确的改进质量点,在利用MSA(measurement system analysis, 测量系统分析)以及过程能力分析等方法对测量系统和工序过程能力进行判定基础上,重点结合FTA(fault tree analysis, 故障树分析)和一般线性模型方法分析,确定其关键影响因素为中心孔跳动大,并通过根源分析法找出导致中心孔跳动大的原因为液压夹紧装置夹紧压力较大;利用回归分析确定出压力值的最优区间,同时制定实施全面改进方案并对改进结果进行监控。改进结果显示,改进后的Z转向轴不合格率从改进前的8%降到了1.6%,不合格率得到有效的控制,实现了质量改进的既定目标。     

Winning customer loyalty in an automotive company through Six Sigma: a case study

Six Sigma is a disciplined approach to improving product, process and service quality. Since its inception at Motorola in the mid 1980s Six Sigma has evolved significantly and continues to expand to improve process performance, enhance business profitability and increase customer satisfaction. This paper presents an extensive literature review based on the experiences of both academics and practitioners on Six Sigma, followed by the application of the Define, Measure, Analyse, Improve, Control (DMAIC) problem‐solving methodology to identify the parameters causing casting defects and to control these parameters. The results of the study are based on the application of tools and techniques in the DMAIC methodology, i.e. Pareto Analysis, Measurement System Analysis, Regression Analysis and Design of Experiment. The results of the study show that the application of the Six Sigma methodology reduced casting defects and increased the process capability of the process from 0.49 to 1.28. The application of DMAIC has resulted in a significant financial impact (over U.S. $110 000 per annum) on the bottom‐line of the company. Copyright © 2006 John Wiley & Sons, Ltd.     

On the Effect of Measurement Error with Linearly Increasing‐Type Variance on Simultaneous Monitoring of Process Mean and Variability

In most quality control applications, the errors generated from measurement system can adversely affect the ability of control charts in detecting out‐of‐control conditions. In this paper, the effect of measurement error with linearly increasing‐type variance on the performance of maximum exponentially weighted moving average and mean‐squared deviation (MAX‐EWMAMS) control chart is studied. For this purpose, different out‐of‐control scenarios including mean shifts, variance shifts, and simultaneous shifts in both are considered, and the detecting performance of the proposed approach is investigated through simulation study. The results of simulation study in terms of three criteria including average run length, standard deviation of run lengths, and the empirical distribution of run lengths prove that the measurement error with linearly increasing‐type variance can adversely affect the performance of MAX‐EWMAMS control. Copyright © 2015 John Wiley & Sons, Ltd.     

An improved run‐to‐run process control scheme for categorical observations with misclassification errors

When product quality characteristics are evaluated and assigned to exclusive categories, measurement errors (misclassification of products) always exist unless a perfect measurement system is used to identify the categories. In run‐to‐run (R2R) process control, a categorical controller has been developed for process adjustments with categorical variables. However, if process outputs are misclassified, an adjustment bias will be introduced by the controller. In this study, an improved categorical R2R controller that utilizes the misclassification probabilities to decrease process deviation is proposed. Simulation results show that the proposed controller exhibits better performance when misclassification exists. Copyright © 2008 John Wiley & Sons, Ltd.     

DMAIC流程在AC-pin铆接质量改进中的应用

通过对C企业AC-pin铆接过程系统实施六西格玛DMAIC流程来提高AC-pin铆接质量。首先,对问题进行定义,明确项目的改进范围和改进目标。接着,分析AC-pin铆接过程的主要缺陷类型,并对相关测量系统进行评价与改进。在此基础上,进一步分析导致AC-pin铆接缺陷的根本原因,并确定相应的改进方案,使AC-pin铆接缺陷由先前的7000ppm降到500ppm以下,同时产量得到显著提高。最后,对关键质量特性建立相应的控制方案和纠偏措施,以使改进成果得以保持。DMAIC流程在AC-pin铆接质量改进中的成功应用有助于促进六西格玛管理在我国企业的有效实施,提升企业的质量管理水平。     

Die Kalibrierung von Vakuummessgeräten in Industrie und Forschung

The increasing economic demand for higher measurement accuracy and the demands of modern quality assurance systems require regular calibration of the measuring and testing gauges. Vacuum gauges are more and more utilized as measuring and testing gauges in manufacturing processes and research in order to get reliable and correct product specifications. Systematic and statistical measuring deviations can only be determined through calibration. The reliability of test results is not only dependent on the accuracy, precision, repeatability and reproducibility but also depends on the competence of the tester and correctness of the testing method. Therefore, the confidence in the validity of the measurement results and in the competence of the calibration laboratory is a decisive factor. The calibration of vacuum gauges and the traceability to national standard is done through a series of comparison measurements. The calibration laboratories of the German calibration service (DKD), which are accredited by the Physikalische‐Technische Bundesanstalt (PTB), are distinguished by their technical expertise and high quality standard. The DKD‐calibration certificates offer reliable measurement results including the measuring uncertainty and are accepted by the accreditation bodies of the member states of the European co‐operation for Accreditation (EA). The typical requirements on a calibration laboratory for vacuum gauges are explained exemplarily for the DKD‐calibration laboratory of VACUUBRAND GMBH + CO KG company.     

Application of six sigma methodology to reduce defects of a grinding process

Six Sigma is a data‐driven leadership approach using specific tools and methodologies that lead to fact‐based decision making. This paper deals with the application of the Six Sigma methodology in reducing defects in a fine grinding process of an automotive company in India. The DMAIC (Define–Measure–Analyse–Improve–Control) approach has been followed here to solve the underlying problem of reducing process variation and improving the process yield. This paper explores how a manufacturing process can use a systematic methodology to move towards world‐class quality level. The application of the Six Sigma methodology resulted in reduction of defects in the fine grinding process from 16.6 to 1.19%. The DMAIC methodology has had a significant financial impact on the profitability of the company in terms of reduction in scrap cost, man‐hour saving on rework and increased output. A saving of approximately US$2.4 million per annum was reported from this project. Copyright © 2011 John Wiley & Sons, Ltd.     

A low‐cost and reliable optical inspection system for rapid surface roughness measurements of polycrystalline thin films

Excimer laser crystallization is a well‐known industrially used technique to produce high‐performance polycrystalline silicon thin films on the commercially available inexpensive glass substrates for the development of high‐performance low temperature polycrystalline silicon thin‐film transistors in active matrix flat panel displays. A rapid optical measurement system for rapid surface roughness measurement of polycrystalline silicon thin films was developed in this study. Two kinds of thicknesses of polycrystalline silicon thin films were used to study rapid surface roughness measurements. Six different incident angles were employed for measuring surface roughness of polycrystalline silicon thin films. The results reveal that the incident angle of 20° was found to be a good candidate for measuring surface roughness of polycrystalline silicon thin films. Surface roughness (y) of polycrystalline silicon thin films can be determined rapidly from the average value of reflected direct current voltage (x) measured by the optical system developed using the trend equation of y = –8.9854x + 91.496. The maximum measurement error rate of the optical measurement system developed was less than 5.72%. The savings in measurement time was up to 83%.     

Slope of the Out‐of‐Plane Deflection Measurement of Composite Sandwich Plate With a Fully Potted Insert by Using Digital Phase‐Shifting Shearography

Abstract: A digital shearographic (DS) technique is a tool well‐suited for precision strain measurement and is a non‐destructive testing technology. But the fringe patterns of DS have not so high sensitivity due to the limitation of CCD camera resolution. Therefore a phase‐shifting technique is incorporated into DS and demonstrated to yield fringe patterns with good quality. The main purpose of this study is to set‐up a measuring system of digital phase‐shifting shearography (DPSS) to measure slope of the out‐of‐plane deflection of sandwich plate with a fully potted insert. The present system includes piezoelectric transducer, servo controller, Michelson shearing mechanism, image processing system and loading system. The four‐step phase shifting method is used to obtain phase map and then the phase expansion is proceeded by Macy algorithm to obtain the slope of the out‐of‐plane deflection of honeycomb sandwich plate with insert/potting material. Finally, comparing the slope of the out‐of‐plane deflection of DPSS with that of DS shows 2 to 7% difference of slope of deflection exhibiting.     

测力刀柄系统标定技术研究

测力刀柄系统可实时监测切削过程的轴向力和扭矩的变化,为测试自主设计的测力刀柄系统的使用性能,设计并研制了一套标定辅助工装,搭建了标定实验平台,完成了静、动态标定实验.采用逐级加、卸载法,确定了测力刀柄系统的线性度、重复性和滞后性等静态特性指标;通过脉冲激励法获得了测力刀柄系统的固有频率、阻尼比和最大工作频率等动态特性指...     

基于最小PDOP的跟踪仪顺次多站测量站位优化

工业机器人进行大型构件加工时，精确测量机器人与大型构件的相对位置关系是保证加工质量的关键。采用单台激光跟踪仪顺次多站法进行测量时，为了提高测量精度，充分考虑了激光跟踪仪的位置误差，对激光跟踪仪站位优化进行了研究。首先，探讨了激光跟踪仪测量误差主要来源，分析了顺次多站法测量原理；然后，基于最小位置精度衰减因子(PDOP)的方法进行了激光跟踪仪站位的优化，并给出了各站位位置测量精度最优的求解算法。最后，进行了站位优化前后的验证实验，结果表明：优化站位后测量系统的测量精度可提高50%以上，验证了站位优化方法的有效性。     

Evaluation of Measurement Systems with a Small Number of Observers

The standard R&R study for evaluation of measurement systems assumes that participating observers constitute a random sample. Often there are only a few observers, all of them included in the study. An alternative measure for the gauge R&R is proposed for this situation, and it is shown that this may improve the perception of the quality of the measurement system markedly, especially with only a few observers. Finally it is shown that a simple estimator can be used, with a bias limited to just a few percent.     

民用航空发动机全生命周期全链路测量管理体系建设研究

为打破传统计量保障仅关注测量设备准确性而非测量结果可靠性的局限,构建了适用于民用航空 发动机全链路的测量过程控制管理体系。该体系以提升测量数据质量为目的,覆盖从部件设计到整机试验,从 适航取证到客户交付所涉及的全部产品测量过程。在测量过程设计阶段,根据测量需求及过程的关重程度,分 析测量能力,导出测量质量要求。在测量过程控制阶段,根据不确定度分析结果,锁定不确定度来源,利用测 量系统分析、控制图、测量能力审核等手段监控测量过程。在测量有效性验证阶段,结合科研阶段航空发动机 测量过程特点,建立同族测量过程归集,通过测量不确定度评定实现质量验证。该体系初期应用于厂内装配执 行过程“高压压气机转子装配”项目的测量分级、能力分析、过程监控、结果验证等,对实现包括试验验证、 生产制造等过程的全部相关方测量过程管理具有借鉴意义。     

Gauge capability studies for attribute data

A gauge repeatability and reproducibility (R&R) method is developed to assess the capability of a measurement system. Although gauge capability studies have received substantial attention, few studies have investigated attribute data despite their wide application in industry. The primary aim of this research is to develop a procedure, based on the generalized linear model, to evaluate the R&R of a measurement system for attribute data. To calculate repeatability of a system, the procedure integrates the iterative weighted least squares (IWLS) method and deviance analysis. The proposed procedure is applied to an inclusion measurement system to verify its adequacy to model the process capability. Copyright © 2007 John Wiley & Sons, Ltd.     

HIOKI3280-10型钳形数字万用表电阻测量系统测量不确定度的评定及动态预测

本文首先阐述了对测量系统进行测量不确定度评定的重要意义，通过对HIOKI3289-10型钳形数字万用表电阻的测量不确定度的评定和动态分析，提出并利用了灰色理论的GM(1，1)模型对该测量系统进行动态预测，建立了该测量系统测量不确定度的动态预测模型，并对该预测模型的预测准确度进行了检验，检验结果表明该预测模型能比较准确地预测该测量系统的测量不确定度的变化趋势，为了持续保证测量结果的质量，本文最后给出了几点结论和建议。     

Carbon‐MEMS‐Based Alternating Stacked MoS2@rGO‐CNT Micro‐Supercapacitor with High Capacitance and Energy Density

A novel process to fabricate a carbon‐microelectromechanical‐system‐based alternating stacked MoS₂@rGO–carbon‐nanotube (CNT) micro‐supercapacitor (MSC) is reported. The MSC is fabricated by successively repeated spin‐coating of MoS₂@rGO/photoresist and CNT/photoresist composites twice, followed by photoetching, developing, and pyrolysis. MoS₂@rGO and CNTs are embedded in the carbon microelectrodes, which cooperatively enhance the performance of the MSC. The fabricated MSC exhibits a high areal capacitance of 13.7 mF cm^?2 and an energy density of 1.9 µWh cm^?2 (5.6 mWh cm^?3), which exceed many reported carbon‐ and MoS₂‐based MSCs. The MSC also retains 68% of capacitance at a current density of 2 mA cm^?2 (5.9 A cm^?3) and an outstanding cycling performance (96.6% after 10 000 cycles, at a scan rate of 1 V s^?1). Compared with other MSCs, the MSC in this study is fabricated by a low‐cost and facile process, and it achieves an excellent and stable electrochemical performance. This approach could be highly promising for applications in integration of micro/nanostructures into microdevices/systems.     

碳纤维增强复合材料螺旋铣孔切削力及加工质量研究

针对传统钻孔方法加工复合材料时易导致分层、撕裂等缺陷的问题,采用螺旋铣作为新的制孔技术,根据飞机装配现场的实际加工条件,构建以机器人为移动载体、螺旋铣孔终端执行器为加工单元、螺旋铣孔专用刀具为切削工具的加工系统,采用该加工系统对碳纤维增强复合材料(CFRP)螺旋铣孔关键工艺参数进行正交试验,并讨论了刀具主轴转速、每齿进给量和轴向切削深度等工艺参数对切削力的影响规律;通过对加工缺陷的监测,探讨了切削力与CFRP分层、撕裂等缺陷之间的关系;最后对工艺参数进行优化,经试验验证,优化后轴向切削力较优化前降低26%以上,孔入口及出口处均无撕裂、毛刺,加工质量最优。     

测量视觉系统MTF的一种客观方法

视觉系统的光学调制传递函数( MTF ),通常采用以大脑知觉为基准,对客观物理刺激进行主观评价的心理物理方法来测量。利用哈特曼-夏克波前传感器测量视觉系统的波像差,再由波像差和瞳函数的自相关,即可得出视觉系统的MTF。与心理物理方法相比,该方法不受被测试者情绪和心理状态的影响,并克服了测量过程繁琐的缺陷,具有客观、简便、快捷的特点,测量的全过程仅需3分钟。     

Intermittent process hybrid measurement system on the machining centre

This study introduces the development of a hybrid measurement system integrated on a machining centre to carry out the possible intermittent measurement of a workpiece. The developed hybrid measurement system principally consists of a MP10 touch trigger probe system, a circular triangulation laser probe system, and the measurement software. The touch trigger probe system was primarily used to measure the regular geometric features, whereas the circular triangulation laser probe system was adopted to inspect the freeform surface part of a test carrier with the help of the developed measurement software. An adjustment device consisting mainly of an adjustment unit, a joint unit, and an assembly unit, was designed and manufactured to minimize the cosine error caused by the assembly inaccuracy for the laser probe. The measuring uncertainty analysis experiments for both the touch trigger probe system and the non-contact laser probe system were investigated by using a calibrated standard sphere and the HP5529A laser interferometer system, respectively. The information in the whole measuring system – which comprised a personal computer, a CNC machining centre controller, a Renishaw MP10 touch probe system, and the controller of a Wolf & Back OTM3A20 circular triangulation laser probe system – was integrated technically. The measurement software was also developed to simulate the measuring path, prevent collision, and generate the corresponding measuring NC codes. The developed system can also be used to digitize the data points of a 3D small complex workpiece, such as a tooth model and an IC part. A carrier, combined with free form surface and regular geometric feature referred to in the ISO 10791-7 cutting test standard, was designed, manufactured and inspected in order to evaluate the performance of the developed hybrid measuring system. The measurement results of this carrier were verified through a CNC coordinate measuring machine, with satisfactory consistency. According to the measuring results, the developed hybrid measuring system was successfully and effectively used to carry out the intermittent measurement.