气门弹簧新产品开发先期质量策划应用研究

上海交通大学硕士学位论文气门弹簧新产品开发先期质量策划应用研究姓名：刘艳梅申请学位级别：硕士专业：工业工程指导教师：明新国;张健20090601ivQFDDOEAbstractvResearchontheapplicationofAPQPofNewProductDevelopmentforvalvespringAbstractAPQPisastructuralmethod,whichusedtoensurethefinalproductstomeettheclients’requirementbydeterminingprocessflow.Asthematteroffact,mostenterprisesareconfusedonhowtoapplyAPQPinthebeginningofnewproducts,especiallythosesmallscalespringenterpriseswithobviousshortages:weaknessofqualitymanagementandlackoftechnicalplanning.Drivenbyautomobileindustry,theapplicationofAPQPcouldincreasecorecompetitionofenterprise,andbringcontinuoussuperioritiesinfurthermarket.ThispaperstartsfrommethodofqualitymanagementandAPQP,probesintothepossibilityofmanagementandprocess’improvementsbyresearchandanalysisofnewproductdevelopmentandqualityplanningofWUXISAWANESPIRNGCO.,LTD..Baseontheactualprocessflow,combineswithcharacteristicofthespringindustrialfield(smallscale,simpleframe,productseries),integratesspecialrequirementofVW,Ford,Cheryetc,reconstructstheAPQPofvalvespring,andbuildsacompatibleprocedureframeofAPQPforvalvespringindustryfinally.Newprocedurerefersthestage-dividedmodeofVWandfactor-controlledmodeofFord,assessesineverystage,fencebrokenbetweendifferentdepartment,responsibilityisdefinedintoindividual.Stageflowchartisproposedtoindicatetherelationofallassignments;differentprocedurecorrespondingwithdifferentlevelofproductsisselectedaccordingtodifficultiesinR&D.Forinstance,optimizedprocedureareappliedintheschemeofvalvespringandvalidated,furthermore,qualitytools,QFDandDOEisappliedinthedesignprocedureanddevelopmentofAPQP.ThispaperishelpfulforWUXISAWANESPIRNGCO.,LTD.toadoptasuitableAPQPfornewproductsdevelopmentandprovidesareferencefortheoptimization,controlandimplementationofnewproductsdevelopmentAPQPofspringindustry,therebythequalitycanbeimproved,thecostcanbeloweredandthemissionsuccessrateofnewproductsdevelopmentcanbeincreased.Keyword:ValvespringNewproductDevelopmentAPQP(AdvancedProductQualityPlanning)i2009626ii2009626200962611.11.1.1[1]40%[2]1.1.2QualityManagementSystemOEMQS9000VDA6.1AVSQEAQFISO/TS169491986VDA4243[3]APQP16949QS9000APQPAdvancedProductQualityPlanningAPQPAIAGAPQPQS9000VDA6.1ISO/TS16949APQP1.1.3OEMAPQP[4]31.21.2.1ISO90001.2.1.1—QS90001988GeneralMotorFord-Chrysler1988QS90001994199519983QS9000ISO9001:1994199911QS90001998ISO9000QS90001PPAPQSAAPQPMSAFMEASPC1QS9000Fig.1referancemanualsforQS9000APQP&CPFMEAMSASPCPPAPQS90004—VDA6.1ISO9000VDA6.1—AVSQEAQF1.2.1.2ISO/TS169492002ISO9001:2000QS9000AVSQEAQFVDA6.1IATFJAMAISO/TS16949ISO90012000IATFBMWDaimler-ChryslerFiatFordMotorCompanyGeneralMotorsPSAPeugeot-CitroenRenaultSAVolkswagenAIAGANFIAFIEVSMMTVDAISO/TS16949:2002200241.2.1.322Fig2mutualrelationsofqualitymanagementsysteminthecurrentautomotiveindustry5ISO/TS16949:2002ISO9001:2000ISO9001:2000TS16949:2002TS16949:2002TS16949QS9000APQP1.2.2APQP1.2.2.1APQPAPQP805APQPIAPQPISO/TS16949APQPAIAGAPQPAIAG[5]APQPAdvancedProductQualityPlanningQS9000,,(),[6]APQP,(),[7]APQPa)b)c)d)[8][9]3PDCAPlanning[10],6a)/b)41.2.2.2APQP43Fig.3Productqualityplanningcycle74[8]Fig.4APQPPlaning1.2.2.3APQPAPQP51.2.2.4APQPCOP8[11][12]APQPCOPCustomerOrientedProcess6/PPAPAPQPPPAP1.31.3.1aQS-9000VDA6.1ISO/TS169492002APQPAPQP9/—/—//—DFMEA-APQP,/APQP/(PFMEA)()()()()()5APQPFig.5InputandOutputofAPQPstage106APQPCOPFig.6relationsamongAPQP,COPandqualitymanagementsystem11(b)OEMANPQPQAVQPNAQPISO/TS16949:2002[13]APQP1.3.2501.4XX1277Fig.7Thesisframe132.11959MIL-Q-9858AISO19873ISO9000-ISO9004AIAGQS9000VDAVDA6.1QS9000VDA6.1ISO/TS16949ISO/TS16949GMFORDVWISO/TS16949QS9000APQPPPAPSPC1987ISO9001ISO/TS169497.1[14]208082“”“”1412345688[6]Fig.8Flowchartofqualityplanning“”——15“”VDA4.3APQPAPQPQS9000APQPAPQPDFMEAPFMEACPPPAPSPCMSAAPQPAPQPANPQPASESAPQP2.2APQPOEM116[4]2[15]APQPAPQPAPQPAPQP3IS0/TS16949ISO/TS16949:2002APQP[16]4172.32.3.12.3.2ISO/TS16949APQPaOEMAPQPbQFDDOE¾QFD¾DOE183.13.1.199Fig.9Linearsystemofthecompanyorganizationchart3.1.250%191MSASPCPPAPPPAPPFMEACP2/+PPAP10Fig.10GeneralProductProcess20APQP3.1.33.1.3.1[17]ISO/TS169497.3¾¾¾¾¾¾¾1/21ISO/TS169497.3APQPabc213CAD22APQP4ab2///12345678910/////1234567///2355zzzz63.1.3.211APQPAPQP1)()242)QFDDFMEAQFDDFMEA3)PFMEAMSASPCPFMEAMSASPC4)MSASPCPPAP5)APQPAPQPAPQPAPQP455PDCA25QFDDFMEAPFMEAMSASPCSPCMSA11Fig.11WorkflowofAPQP263.2APQP3.2.15¾¾IT¾¾¾3.2.21)[18]2)ISO/TS16949APQPAPQP3)OEM12XX2712Fig.12SourcingprocessbeforesourcingrecommendationapprovalOEMSORStatementofRequirementAPQP4)11APQP5QFDDFMEAPFMEAMSASPCPPAP283.2.3a3¾¾¾¾¾¾¾¾¾¾[19]b4///KAM571.60%//294%1/71.60%2/22.36%3/KAM1.51%43.02%51.51%c2.0Ld30,5M1EmanmachinematerialmethodenvironmentmeasurementeAPQPAPQPAPQPOEMf80[20]3.33.3.1VolksWagenVWVDAVDA4.3FormelQ31VDAVWFormelQQPNFormelQ132QPNformel-QNeuteileintegral13FormelQ[21]Fig.13FormelQsupplier’squalityabilityassessmentguidelinesQPNQualifizierungsprogrammNeuteileQualificationProgramforNewPartsQPNQPNQPNQPN14ABCFormelQFormel-QFahigkeitFormel-QNeuteileIntegral2“QPN“FormelQ-konkret32A3B3C6DCPVS4E2TP1F2EEMSOP2/A/QPNABCFAE-Mail14QPN[22]Fig.14QPNworkingmodule33QPNQPNFordAPQPStatusReportOTS--PVS-1--PVS-2(PVS