硕士论文-六西格玛管理法在轧钢质量控制中的应用

上海交通大学硕士学位论文六西格玛管理法在轧钢质量控制中的应用姓名：宋建新申请学位级别：硕士专业：工业工程指导教师：苗瑞;姜正连2009010111#T2TheApplicationofSixSigmaManagementMethodintheQualityControlofSteelRollingABSTRACTAsamainproductionunitinBAOSTEELcoldrollingmillforrollingautomobilesheet,theNO.1rollingmillcanproduceproductswithbiggestwidthspan,widestwidthandhighesthouroutputamongthemillsforeachunit.However,thedefectofimpressedextraneousmatterhappenedinrollingmillorpicklingunitalwayspuzzlesproduction,anditbecomesthemajorproblemtoaffectproductquality,whichneedstobeimprovedurgently.Aimedatthedefectofimpressedextraneousmatterthatpuzzlestheproductqualityofpicklingandrollingmillunit,theworkofqualityimprovementhasbeentakenbyutilizationofthefivestepmethodofsixsigmawhichincludesdefining,measuring,analyzing,improvingandcontrolling,andbetterresultshavebeenobtained.Thispaperhascarriedoutrelativelydetailedanalysisemphaticallyforeachphaseofproblemsolving.First,theworkofmeasuringphasestepwastakenafterdefiningthegoalofqualityimprovement.Inthisphase,startingfromtheanalysisofunitflowprocess,theplanhascarriedoutfordatacollection,anddatameasuresystemanalysiswasdoneaccordingtotheclassificationofdefectfeature.Forthenextanalyzingphasestep,thepotentialmaincauseineightaspectshasbeenidentifiedthroughthedelaminationoftheflowprocess.AndsixcrucialinfluencingfactorsweredeterminedbyverificationofthepotentialmaincauseonebyonewithTtestandANOVAanalysistools.Intheimprovingphasestep,eightsolvingschemaswereformedbybrainsstormmethod.Throughevaluation,threebestschemeswereconfirmedandprocessedindetails.Inthefinalcontrollingphasestep,improvedschemeshavebeencarriedoutintheplant,whichformedsolidifiedaccomplishmentandgotextendedapplication.KeywordsSixsigma,impressedextraneousmatter,coldrolling,qualitycontrol□□“√”1111.1121924(W.A.Shewhart)1930(H·FDodge)(H·G·Romig)12“”12343[1]60[2~5]123420602070(PavidGarvin)2013[6]ParetoPrinciple)“”“”QC100%[7~11]30500“”ISO900003[12~17]141.21.2.16σ“σ”3.4“”““”DMAIC“”15“”(CTQCriticaltoQuality)3.4PPM()3.4PPM1)2)3)/DMAIC20901987“σ”8419981995“16”“”1)DPUDPMO2)3)4)“”5)6)1.2.2DefineMeasureAnalyzeImproveControlDefineCTQCTQ17CTQMeasureAnalyze“Y”“X”“X”“Y”“X”ImproveDOEControl181.2.31Fig1SixSigmaorganizationalchart19“”1.2.42080Motorola2090·JackWelchGE1996GE·JackWelchGE1996GE152150GE98%3.5%199513.6%199916.7%·JackWelch“”GE“”GE110“”σ3.4PPM4σ6σDMAIC“”1.320045002007235640%1112Fig2Productionflowchartforanironandsteelcompany15~20200100050%20071121#896“1#”[18]12344601.421322.10.001mmCDCMCDCM[19][20]CDCM2142.21#19851#20802.2.11#210111#mm/t10.33.59001850150000020.33.59001850250000GI100%60700g/m230.33.59001550900003/350/50g/m20/100/40g/m23/2020/30g/m240.33.590015501600002.5200um51000002152.2.23Fig3Generalplanofrollsysteminthepicklingline432.2.2.11#S44Fig4Processschematicfortheentryuncoilerfeedingsection2161#S1#S2.2.2.21#S1#CPC4#CPC55Fig5Processschematicfortheentryloopersection1#1#CPC33×1232#CPC3#CPC4#4#CPC4#21736692.2.2.366Fig6Processschematicforthepicklingandexitloopersection5#CPC5#451296#CPC6#2182#S2#22×1237#CPC8#CPC8#2.2.3.478#CPC3#S9#CPC3#S7Fig7Processschematicfortheexitcoilingsection3#S3#9#CPC9#3#S2194#2.2.313221#2#2#328Fig8Generalplanofrollsystemintherollingmillline482.2.3.11#S[21]92209Fig9Processschematicfortheentryuncoilerfeedingsection1#S11CPC1#2212#CPC3#CPC4#CPC4#2.2.3.24#2A#S5#CPC2#S6#CPC1010Fig10Processschematicfortherollingmillentrysection2A#S2A#5#CPC5#2#S2#2226#CPC6#12.2.3.31111Fig11Processschematicforthe5-standrollingmillsectionCVC[22]15223142515145514142.2.3.4121#2#12Fig12Processschematicforthe5-standrollingmillexitsection1#224400mm1#2#122#222.32.3.1[23]2.3.1.1225313l0µmFeO50Fe3O440Fe2O31013Fig13Stripsurfacestructureofironoxidescale230502262(min)Fe2O3Fe3O4FeOFe2O3Fe3O4FeOFe2O3Fe3O4FeO2.10.452.553.20.543.741.80.512.313.61.04.62.31.84.12.40.532.93FeOFe2O3Fe3O42.3.1.2[24](1)Fe2O3Fe3O46015150s1555s8070s30s(2)7833(3)(4)()0.40.50.60.7100t2000t(5)()()700227280m/min(28s)(1)9836HCl(2)(3)19592.3.1.3(1)225125520315(2)FeSO4FeCl2FeCl2140g/l(3)402.3.1.41#1#500t/h22.5s2284140m35853/g·L-1HCI/g·L-1123410012080100608040603460608686112112138808080802.3.22.3.2.1[25]σsσbσsbσσσ≤(1)sσσbσσ2.3.2.2229[26]1ABCDabcd14141-2-ABCD-abcd-Fig14Metalflowdiagramwithinrollingdeformationzone1-roll2-stripABCD-uppercontactfaceabcd-lowercontactface22301515HBL—hbl—Fig15StripdimensionchangebeforeandafterrollingHBL—stripthicknes,widthandlengthbeforerollinghbl—stripthicknes,widthandlengthafterrollingV1V2**V1=HBLV2=hblV1=V2HBL=hbl(2)32.3.2.3[27]B0h0V0B1h1V1B2h2V2……BnhnVn(3)VHiVHi+1(4)23144mmmmmm%123452.001.521.150.870.661.521.150.870.660.500.480.370.280.210.1624.024.324.324.124.2232()2.4“”3DMAIC333DMAIC3.1(VOC)3CTQ(Critical-To-Quality)CTQDefine“”DefineDefine“”“Y”“N”“Y”5“”5Y/N)YYYMetricYYBenefitHardSavingYSoftSavingCashFlowDefectYVOCYYYBenefitCYQMetricVOC3DMAIC341616Fig16Idealprojectmatrix3.2CVCA(CustomerValueChainAnalysis)071#89619643DMAIC3546066203089649632046020079-11200712-2008220085-92008101-1220091-4200951-6436*(2000)1046.43.3(VOC)(CCR)CCR(CBR)8964603.4“”17193DMAIC36SIPOC17Fig17Macroflowchart18Fig18Picklingprocessflowdiagra