精益6Sigma在A公司印制线路板自动涨缩系统中的应用研究

发布时间：2019-03-17 20:06

【摘要】：随着科技日新月异地发展,用于各种电子电器设备起电气连接作用的印制线路板,也随之被要求更复杂更精密的线路设计。随着印制线路板的线路设计更复杂越精准,导致原本一直被行业忽略的涨缩问题也被越来越多客户提上日程要求印制线路板制造商进行管控。长期处于印制线路板制造行业技术和质量领跑者的A公司,面对众多客户突然提出的对于印制线路板涨缩管控的要求,虽然有着行业最领先的设备,最领先的技术和经验丰富的工程师。但对于影响因素复杂,影响制程跨度大的涨缩问题却无法进行良好的控制,且要在满足客户要求的同时,又让自己企业的成本降到最低。六西格玛管理是现行最有效的质量管理方法。在六西格玛六大主题的指引下,运用六西格玛特有的“DMAIC”步骤,从剖析客户的需求出发,分析现有A公司涨缩问题的现状,以及和客户需求的差距。寻找公司内部影响涨缩的因子,指定改善方案。并加入精益生产的理念,剔除非增值活动,规范步骤,简化步骤,并引入防呆防错理念,控制并维护改善的效果。六西格玛项目小组,在集合各部门各工序的工程师,从“零”开始重新研究A公司涨缩的现状、多次运用头脑风暴和鱼骨头系统的查找可能的影响因素。层层把关,收集数据,缩小有影响的工序的范围。对最终经过分析判定为有影响的工序,进行再一次的数据收集,实验安排和实验结果验证,在不影响其他印制线路板重要特性的前提下,制定最佳制程参数和最佳流程。在原有模糊地凭“经验”制定的涨缩控制流程上,改善参数,重新制定规则,改善流程。并对有关联的工程系统也采取改善行动,避免任何的由手动操作带来的错误,导致大批量产品的报废。同时,根据A公司现有的各生产系统,工程系统和监控系统,开发一套独有的自动涨缩系统。该自动涨缩系统不单具有警告功能,还有反馈预警功能和自动计算并建议补偿值功能。该系统不单弥补了操作员可能会漏放涨缩超规范的产品流入下工序,当产品涨缩的趋势有所不对,还能及时得发预警给相关工程师,同时还会经过后台的计算,建议具体的修改值。且在后台进行计算之前,系统还会自动检查该批次的相关生产信息和工程信息,自动过滤非计算范围内的产品数据。大大降低了工程师面对庞大的、多个数据库的信息处理时的工作量,提高了效率又提高了准确性。对于部分特殊产品,虽然还未能用自动涨缩系统进行控制,但为了避免不合格品流入客户手中,也加入了适当的监控方法和全面的预防涨缩超规范的流程。并在监控方法中加入自动化元素,及时有效的监控涨缩,以最大限度达到客户满意。
[Abstract]:With the rapid development of science and technology, printed circuit boards (PCB), which are used for electrical connection of various electronic and electrical equipment, are also required to be more complex and more precise circuit design. As the circuit design of printed circuit board becomes more and more complex and accurate, the rising and shrinking problem, which has been ignored by the industry, has been put on the agenda of more and more customers to control printed circuit board manufacturers. Company A, which has long been a technology and quality leader in the printed circuit board manufacturing industry, is facing the sudden demands of many customers for the control of the rise and shrink of printed circuit boards, although it has the industry's leading equipment. The most advanced technical and experienced engineers. However, it is difficult to control the increase and shrink of the large span of the manufacturing process because of the complexity of the influencing factors, and it is necessary to meet the requirements of the customers, and at the same time, the cost of the enterprise can be reduced to the lowest. Six Sigma management is the most effective quality management method. Under the guidance of six major themes of six Sigma, using the "DMAIC" step of six Sigma, starting from the analysis of customers' needs, this paper analyzes the current situation of current A Company's rising and shrinking problems, and the gap between the existing A Company and customer needs by using the six Sigma-specific "six Sigma" steps. Look for the factors that affect the increase and contraction of the company, and specify the improvement plan. Adding the idea of lean production, eliminating the non-value-added activities, standardizing the steps, simplifying the steps, and introducing the idea of preventing blunders and preventing errors, controlling and maintaining the effect of improvement. The six Sigma project team, which brings together engineers from various departments and processes, has revisited the current situation of Company A's rise and contraction from "zero" and has repeatedly used brainstorming and fish bone system search for possible influencing factors. Layer by layer check, collect data, narrow the scope of the affected process. The data collection, experiment arrangement and experimental results are carried out again for the process which is finally determined to be affected by analysis. The optimal process parameters and flow chart are worked out without affecting the important characteristics of other printed circuit board (PCB), and the optimal process parameters and flow chart are worked out without affecting the important characteristics of the other printed circuit board (PCB). Improve the parameters, re-establish the rules, and improve the process of the increase and shrink control process, which is based on the previous "experience" vaguely. The associated engineering systems are also improved to avoid any errors caused by manual operation, resulting in the scrapping of large quantities of products. At the same time, according to the existing production system, engineering system and monitoring system of A Company, a unique system of automatic increase and shrink is developed. The automatic rise-shrink system not only has warning function, but also feedback early warning function and automatic calculation and recommended compensation function. The system not only makes up for the fact that the operator may omit the overstandard product flow into the next process, when the trend of the product rises and shrinks is wrong, it can also get early warning to the relevant engineers in time, and at the same time, it will also go through the backstage calculation. Suggest specific changes to the value. And before the backstage calculation, the system will automatically check the relevant production and engineering information of the batch, and automatically filter the non-calculated product data. It greatly reduces the workload of engineers when dealing with large, multi-database information, and improves the efficiency and accuracy. For some special products, although the automatic increase and shrink system has not been used to control them, in order to avoid the non-conforming products coming into the hands of customers, a proper monitoring method and an all-round process of preventing inflation and shrinkage overspecification have also been added. The automation element is added to the monitoring method to monitor the rise and fall in time and effectively, in order to reach the satisfaction of the customers as much as possible.
【学位授予单位】：东华大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TN41

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