應用8D及品管手法提升製程良率 –以彈藥器械為例

國防產業廠商承接彈藥器械裝備產製任務，軍品品質之優劣為軍種所關切的議題，本研究主要目的係以引信體壓藥斷裂製程異常為例，探討如何應用8D及品管手法進行分析及改善，提升彈藥器械製程良率。引信體為鋅鋁合金壓鑄形成，透過材料缺陷分析與功能測試確認壓鑄過程是否存在缺陷，以及引信裝於全彈之功能是否符合規格要求。本研究結果經異常處理小組以8D及品管手法改善後，引信體壓藥製程不再發生斷裂異常情況，材料缺陷透過X-ray、金相試驗及秤重法驗證為異常原因，空引信體以大於41克篩選後已無再發生壓藥斷裂，引信體裝藥以大於43克篩選，完成重量較輕不良品阻流，全引信以68克以上進行篩選，較輕件共20件執行靜態及動態功能測試合格，證實壓藥過程引信體無發生斷裂不影響防水功能，故秤重篩選之矯正措施驗證有效並納入標準化作業。

關鍵字

8D ；品管手法； PDCA ；鋅鋁合金；壓鑄

並列摘要

The main purpose of this study is to take the abnormal fuse body pressure drug fracture process as an example to explore how to apply 8D and quality control methods to analyze and improve the yield of ammunition equipment manufacturing process. The fuze body is formed by zinc-aluminum alloy die-casting, and through material defect analysis and functional testing, it is confirmed whether there are defects in the die-casting process, and whether the function of the fuze installed in the full bullet meets the specifications. After the results of this study were improved by the anomaly handling team with 8D and quality control techniques, the fuze body pressure drug manufacturing process no longer had fracture abnormalities, material defects were verified by X-ray, metallographic test and weighing method as the cause of the abnormality, the empty fuze body was screened at more than 41 grams and no pressure drug fracture occurred, the fuze body charge was screened at more than 43 grams, and the light weight defective product flow was completed, the full fuze was screened at more than 68 grams, and a total of 20 lighter parts were tested for static and dynamic functions. It was confirmed that the fuse body did not break during the pressure process and did not affect the waterproof function, so the corrective measures of weighing screening were verified and included in the standardized operation.