新產品開發階段導入替代料之流程建模及潛在風險分析

The Process Modeling and Risk Analysis for using Alternate Parts during the Product Development Phase

李國華(Kuo-huo Lee)

指導教授 ： 高信培

國立中央大學/管理學院/工業管理研究所碩士在職專班/碩士(2012年)

摘要

目前電子設計代工業為了降低生產成本及避免原材料供應商非預期之斷料風險，使用替代料（second source, alternative part, substitute）已經非常普遍的做法。
然而導入替代料是一個跨採購、物控、零件工程部、RD及製造的流程。於新產品開發進入試產驗證階段（Production Verification Test，PVT0/1）之前導入替代料，可使整體成本及缺料風險降低，但相對的也就必需承擔較高的品質風險。其品質不良問題，往往於產品量產後發生，對公司造成極大的損失。
本論文以流程觀點分析電子設計代工業之替代料導入驗證流程，以分析出流程中之潛在風險，找出關鍵流程並對其作重點管理與改善，以達防患未然與降底品質風險之目的。本研究利用IDEF3流程描述方法論為基礎，描繪替代料導入流程，再以流程失效模式與效益分析（PFMEA）為分析工具，探討替代料導入流程中之潛在風險，找出其關鍵流程。最後，針對關鍵流程做重點管理與改善，以避免因替代料的品質不良，造成公司損失，並提高顧客之滿意度，及企業競爭力。

關鍵字

替代料 ； 新產品開發 ； PFMEA ； IDEF3

並列摘要

For electronics industry, application of second sources (or alternate parts, substitutes) has been a common and popular strategy to reduce production costs and to avoid unexpected raw material shortage from the original supplier.
　　Nonetheless, the utilization of second source is a process involving procurement, material control, parts engineering, RD and manufacture. On the one hand, utilizing second source before the phase of production verification test (PVT) for new product development can reduce the overall costs and the risk of supply shortage. On the other hand, it leads to a higher quality risk. The quality problem usually won’t be discovered until mass production of the product, whence will cause huge loss to the company.This study applied the process perspective to analyze the verification process of second source induction in electrical original design manufacturer (ODM) and OEM, to factor out risks in the process and to figure out key points for critical management and improvement. The goal is to take precautionary measures and to reduce quality risks.
　　This research was based on the IDEF3 approach to demonstrate the process of induction of second source. Then the model of Process Failure Mode and Effects Analysis (PFMEA) was adopted as an analysis tool in discussion of risks in second-source-induction and recognition of critical process. Finally, key management and improvement on key process was performed to prevent quality deficits of second source from causing loss to the company. It would be also helpful in raising the customer satisfaction and the business competitiveness.

並列關鍵字

second source ； NPI ； alternative part ； substitute ； IDEF3 ； PFMEA

參考文獻

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