基于重型机床制造过程PONC的质量成本研究

发布时间：2018-01-19 16:12

本文关键词： 质量成本 PONC 重型机床系统开发制造过程　出处：《济南大学》2011年硕士论文　论文类型：学位论文

【摘要】：制造业技术水平的发展使得各企业产品质量水平逐渐提高,但在实际制造过程中报废、返修等不增值活动给企业带来了巨大的损失,因此降低制造过程质量成本已成为企业赢得市场竞争的重要手段。本文以制造过程产生的报废、返修成本为研究对象,对重型机床制造过程存在的不符合要求的成本(PONC, price of nonconformance)进行研究,主要研究工作如下: (1)针对重型机床制造过程不符合要求成本给企业造成巨大损失的问题,分析了研究重型机床制造过程PONC的必要性,综述国内外制造过程质量成本控制研究的现状,提出制造过程质量成本控制仍存在的问题,确定了论文的主要研究内容。 (2)以车间生产过程为研究单元,基于PDCA的基本思想提出了PONC控制基本原理;构建车间目标PONC数学模型及其分配流程,并基于作业成本法原理将车间目标PONC分配至车间加工零件以及零件各工序,从而形成了工序目标PONC。采用系统工程理论将零件加工过程最底层可能产生的各类质量损失成本逐级运算,构建工序PONC控制系统。运用层次分析法对工序PONC影响因素进行分析,建立了工序PONC与影响因素之间的函数关系,为实现质量成本控制奠定基础。 (3)以重型机床企业轴类加工车间及其传动轴加工为研究对象进行了工序PONC研究。分析轴类加工车间目标PONC,建立了车间月份目标PONC值与质量损失率之间的函数关系,提出了传动轴工序目标PONC分配实施模型;确定了传动轴加工过程各作业中心及其成本动因,建立了工序目标PONC具体分配路径。分析重型机床制造过程报废、返修、复检PONC所包含的成本项目,建立了制造过程质量成本计算函数。分析制造过程影响PONC值的各种因素,计算各影响因素权重系数,确定了各影响因素重要度。 (4)构建重型机床制造过程PONC控制及其信息管理系统架构,分析了主要模块功能及系统运行流程,进行了PONC控制及其信息管理系统设计,并根据已建立的实际加工过程工序PONC数学模型,采用Microsoft Visual C#语言对重型机床制造过程PONC控制及其信息管理系统进行开发,实现了重型机床制造过程报废、返修PONC相关数据的采集、运算、添加、存储以及查询功能,并可基于质量成本控制指标实现了制造过程PONC的预防控制及其工序PONC超标诊断。 (5)以重型机床典型零件——大型传动轴的制造过程为例,进行了工序PONC案例分析。计算轴类加工车间月份目标PONC值及大型传动轴的目标PONC值,采用作业成本法将大型传动轴的目标PONC值分配到各作业中心,确定各工序目标PONC。针对大型传动轴实际制造过程产生的工序PONC,与工序目标PONC比较,寻找大型传动轴制造过程工序PONC超标的原因,给出相应的改进措施,验证了系统的有效性,并实现了大型传动轴工序PONC的有效控制。
[Abstract]:With the development of manufacturing technology, the product quality level of each enterprise is improved gradually, but in the actual manufacturing process, the non-value-added activities, such as scrapping and reworking, have brought huge losses to the enterprises. Therefore, reducing the cost of manufacturing process quality has become an important means for enterprises to win the market competition. This paper studies the nonconforming cost of heavy machine tool manufacturing process, price of nonconformance. The main research work is as follows: 1) aiming at the problem that the manufacturing process of heavy duty machine does not meet the requirement cost, the necessity of studying the PONC of heavy machine tool manufacturing process is analyzed. This paper summarizes the current situation of quality cost control in manufacturing process at home and abroad, points out the existing problems of quality cost control in manufacturing process, and determines the main research contents of this paper. 2) taking workshop production process as the research unit, the basic principle of PONC control is put forward based on the basic idea of PDCA. The mathematical model of workshop objective PONC and its assignment flow are constructed. Based on the principle of activity-based costing, the workshop objective PONC is assigned to the workshop parts and their processes. Thus the process objective PONC. adopt the system engineering theory to calculate all kinds of mass loss cost that may be produced at the bottom of the parts machining process. The PONC control system of working procedure is constructed. The influence factors of process PONC are analyzed by analytic hierarchy process (AHP), and the functional relationship between process PONC and influencing factors is established. Lay the foundation for quality cost control. (3) the working procedure PONC research was carried out on the shafting workshop and its transmission shaft machining of heavy duty machine tool enterprise. The objective PONC of the shaft-type machining workshop was analyzed. The functional relationship between the PONC value of workshop month and the loss rate of quality is established, and the implementation model of PONC allocation for driving shaft process is put forward. The operation centers and their cost drivers in the manufacturing process of transmission shafts are determined, and the specific allocation path of process objective PONC is established. The scrapping and reworking of heavy machine tool manufacturing process are analyzed. Recheck the cost items contained in PONC, set up the cost calculation function of manufacturing process quality, analyze the factors that affect the PONC value of manufacturing process, calculate the weight coefficient of each factor. The importance of each factor is determined. The PONC control and information management system architecture of heavy duty machine tool manufacturing process are constructed, the main module function and system running flow are analyzed, and the PONC control and information management system are designed. And according to the established PONC mathematical model of actual processing process. The Microsoft Visual C # language is used to develop the PONC control and information management system of heavy duty machine tool manufacturing process, and the manufacture process of heavy duty machine tool is scrapped. Rework PONC related data acquisition, operation, addition, storage and query functions. Based on the quality cost control index, the prevention and control of manufacturing process PONC and the diagnosis of process PONC exceeding the standard are realized. 5) take the manufacturing process of a typical part of a heavy machine tool, a large drive shaft, as an example. A case study of working procedure PONC was carried out. The target PONC value of shaft workshop month and the target PONC value of large drive shaft were calculated. Activity-based costing method is used to assign the target PONC value of the large drive shaft to each operation center, and to determine the working procedure PONC for the actual manufacturing process of the large drive shaft. Compared with the process objective PONC, this paper finds out the reason why the working procedure PONC exceeds the standard in the manufacturing process of the large drive shaft, and gives the corresponding improvement measures, which verifies the effectiveness of the system. The PONC control of large drive shaft process is realized.
【学位授予单位】：济南大学
【学位级别】：硕士
【学位授予年份】：2011
【分类号】：TH186

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