建構整合FMEA、TRIZ及AHP研發創新工具之產品改良決策程序--以車用沖壓零件為例

由於科技的發展快速，消費性產品市場的競爭也日趨激烈，綜合這些因素進而導致產品生命週期快速縮短。因此企業必須不斷推出新產品或新服務來滿足市場需求，同時維持本身的競爭優勢。傳統的產品研發過程，於開發完成後缺乏整合性的設計改善以及開發評估工具，針對產品在開發生產過程當中，顧客需求與產品生產所可能發生的問題改善的方法、選擇及測試的發展階段，對於生產產品改良的創新思考較無具體工具得以應用，產品改良方法的評選也沒有明確的量化工具。因此，在此階段如何去發展產品設計改良開發的規劃模式，妥善地整合客戶需求，並進行產品創新且挑選最佳的產品方案，將是本研究的動機與目的。本研究利用三個方法的結合，包括了失效模式分析 (FMEA) 、TRIZ創新理論及分析層級程序法 (AHP) ，在產品設計改良開發的概念發展建立一套評選的程序模式。研究中首先以FMEA作產品實際生產階段中所可能衍生的問題作一闡述並針對可能造成顧客端品質問題因素作階段展開，同時將失效模式與效應分析中的風險優先係數(RPN)實施評估，並提列矯正與預防措施的有效性。在針對須實行改善需求的項目以創新解決問題理論(TRIZ)作為產品設計改良方向時的創新方法構思程序以及衝突檢驗工具的重要依據；進而透過FMEA分析的RPN風險係數須立即改善項目，由TRIZ產生的改良創新概念方案，將目標及各方案與屬性建立起階層關係，同時考量各方案與屬性之間的矛盾影響，並展開成網路架構；輔以AHP法作成對比較以求得相對權重來進行產品改良方案概念的評選及決策。本研究將以車用沖壓件之製作改良設計的實際案例進行實證分析。驗證在產品製作改良設計與改良開發過程中，建立選擇改良方案發展的評選流程模式，以提供研發人員作為相關的決策參考。

關鍵字

失效模式分析；創新問題解決理論；分析網路程序法；創新設計；車用沖壓零件

並列摘要

Because of the recent growth of technology improvement, market competition toward products has become intense. This situation has caused a short product life cycle, forcing enterprises to present new products and services to satisfy continual market demand in efforts to maintain competitive advantage. Traditional product research and development processes for new products lack integrated design improvement and estimation of development tools. Therefore, no proper tool exists to estimate/judge real production, which might cause a potential risk to customers. How to develop a product design improvement model to meet customer demand and select the optimal product improvement/corrective solution is the study background and motivation for this research. This study integrates three major methods, including the FMEA (Failure Mode Effective Analysis), the TRIZ, and the analysis hierarchy process (AHP) as a system to build an evaluation model in the product improvement phase of the product design and development stage. This study first uses the FMEA method to extend the possible quality problem and the potential risk on the customer side. This research then investigates the Risk Priority Number (RPN) in each production process and focuses on the RPN to find the necessary corrective action. This work defines the top major failure item, and uses the TRIZ as the reference background and the product analysis system. An expert questionnaire sets the target and sums up each criterion to build a hierarchy relationship. The AHP method is used for pair comparison. This paper uses the automobile stamping product as an illustration to provide a relevant decision-making reference for R&D personnel, and sets up a model of concept development for product design and development.

並列關鍵字

FMEA ； TRIZ ； AHP ； Innovative Design ； Automobile Vehicle Stamping

參考文獻

房治國，Innovative R&D process KPIs Establishment and Evaluation by Incorporating TRIZ — An Case study for Notebook，國立台北科技大學，民99。

曾俊傑、童超塵、廖乃毅、國立雲，運用品質機能展開及失效模式與效應分析建構顧客稽核管理系統，林科技大學工業工程與管理研究所，民97年。

Carlson, W. D., Vallance, G. R. and Carlson, C. S., 2001, Potential Failure Mode and Effects Analysis, 3th ed., AIAG.

Cooper, R.G., Edgett, S.J., and Kleinschmidt, E.J., “Optimizing The Stage-GateProcess: What Best Practice Companies Are Doing— partII”, Research Technology Management, Vol. 45, No. 5, 2002.

Deming, W. E., 2000, The New Economics: For Industry, Government, Education, MIT Press, Massachusetts.

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建構整合FMEA、TRIZ及AHP研發創新工具之產品改良決策程序--以車用沖壓零件為例

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