整合品質機能展開(QFD)、萃智(TRIZ)和失效模式與效應分析(FMEA)之精實創新研發與研究實證

The synergy of QFD, TRIZ and FMEA for Lean Innovation - An Empirical Study for Research and Development Process

胡昌明(Chang-Ming Hu)

指導教授 ： 葉繼豪

國立臺北科技大學/管理學院/工商管理研究所/博士(2013年)

摘要

台灣現今傳統製造業發展相當競爭，急需要開發更多創新的產品，來滿足客戶要求與增加產品競爭力。目前中小企業困境，研發過程往往是以傳統試誤技術解決方式，如此，將無法創新研發產品以達成時效與技術突破要求。因此，如何利用品質機能展開(QFD1-2)更深入瞭解客戶端之需求，迴避現有專利與符合ISO、API、IEC等國際驗證標準，導入設計開發步驟，轉換為設計品質特徵，並利用萃智(TRIZ)提出創新解決方案，並評估理想性，給予更快速有效的理想解決方案，整合為精實創新研發流程，至為重要。首先，於產品概念的發展階段，整合能夠解決主要困難和矛盾問題，並建立一套防錯的前端預防機制，在產品開發規劃時，將較多時間花在前端預防設計階段，以減少額外時間與材料的花費。第二，明確定義問題與發現的問題後，再運用萃智(TRIZ)創新原則以迅速解決工程矛盾與啟發創意。再延伸至設計失效模式與效應分析(DFMEA)，分析潛在失效模式並採用創新方法來解決。運用整合二階段品質機能展開(QFD1-2)、萃智(TRIZ)和失效模式與效應分析(FMEA)的精實創新研發機制，導入於台灣傳統製造業產品的創新研發方法上，達成高附加價值新產品研發目標。本研究，將運用上述方法提出「電動照護醫療床」和「高性能流量控制閥」兩種不同產品類型的實證研究，以產品創新研發實證流程為例，以驗證所提出研究方法的有效性和實務性。

關鍵字

品質機能展開(QFD) ； 萃智(TRIZ) ； 失效模式與效應分析(FMEA) ； 精實創新研發 ； 電動照護醫療床 ； 高性能流量控制閥

並列摘要

In order to survive the tough competition nowadays, Taiwan’s traditional manufacturing industry is in urgent need to develop more and more innovative products to improve product competitiveness and satisfy customers requirements. At present, small and medium enterprises(SMEs) are confronted with a predicament they might not be able to develop innovative products that meet timeliness and technical breakthrough requirements with traditional try-and-error approach.Therefore, it is very important to get in-depth knowledge of customers’ needs with QFD and use TRIZ to promptly propose innovative and effective solutions that circumvent existing patents and work in line with ISO, API and IEC standards by means of an integrated lean innovation R & D process featuring the introduction of design development step, the conversion of designed quality characteristics, and the evaluation of ideality. First, at product concept development stage, the proposed integrating methodology can address major difficulties and conflicting problems and establish an error-proof front-end prevention mechanism to reduce the extra time and materials spent during product development planning by emphasizing front-end prevention at design stage. Second, TRIZ is used to solve the engineering conflicts and inspire originality promptly based on the principles of innovation after problems are defined and identified. Finally, Design Failure Mode and Effect Analysis (DFMEA) is used to analyze potential failure modes for solving problems with innovative methods. A lean innovative R & D mechanism featuring the integration of two-phase QFD(QFD1-2), TRIZ and FMEA is introduced into the R & D of products in Taiwan’s traditional manufacturing industry for achieving the goal of developing high value-added new products. The effectiveness and practicability of the above- mentioned methodology is verified in this paper on an empirical study of the product innovation and R & D of electric medical care beds and high performance flow control valves.

並列關鍵字

Quality Function Deployment(QFD) ； TRIZ ； FMEA ； Lean Innovative Reasearch ； Electric medical care bed ； High performance control valve

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