應用FMEA and IDEF0於航太產品製程改善之研究

Production improvements on an aviation product by FMEA and IDEF0

吳忠信(Chung-Hsin Wu)

指導教授 ： 楊康宏

中原大學/電機資訊學院/工業與系統工程研究所/碩士(2016年)

https://doi.org/10.6840/cycu201600226

摘要

航太產業具有技術專業、技術獨佔、以及技術密集與系統整合的獨特性，更是國家工業水準的指標。航太產業具有供應關聯性高、市場潛力大、品質要求嚴格、低汙染等特性。航太產品首重品質與安全，而品質與安全的根本，就是遵守航空法規與技術標準。
本研究使用失效模式與效應分析(FMEA)方法找出產品於生產流程之失效因子，藉由衡量失效模式之風險數值來進行風險分級與排序，將風險優先數值最高的失效因子搭配IDEF0之結構圖形化，以瞭解系統的運作和需要的資源與限制，進而達到生產流程改善。最後，將改善後的流程再以IDEF0方法繪製出來，並進行改善後之效益分析。
本研究結合FMEA與IDEF0二種改善方法來研討案例公司之航太產品的進料檢驗、測試與外觀檢驗、出貨檢驗等流程運作與改善，都獲得具體的成效，證實本研究方法對生產流程之進料檢驗、測試與外觀檢驗、出貨檢驗等有明確的執行步驟，以建立產品生產作業標準化，成效如下：
(1)作業流程明朗化：藉由IDEF0方法分析案例公司之進料檢驗、測試與外觀檢驗、出貨檢驗等流程運作與資源，使作業人員能更清楚作業流程。
(2)不良品的降低：改善後的進料檢驗、測試與外觀檢驗、出貨檢驗等流程，可降低作業人員於生產流程未依照作業規範導致檢驗失誤之不良率。
(3)客戶抱怨的降低：改善後的生產流程可降低失效產品流出至客戶端，顯著的降低客戶反映產品不良。
本研究分析使用的改善手法，日後可供航太產業或其他科技產業改善流程生產流程之參考。

關鍵字

FMEA、IDEF0、生產流程、航太

並列摘要

The technical capabilities of aerospace industry represent the industrial level of a country. The attributes of that has the uniqueness of technological professionalism, domination, concentration, and system integration. The aerospace industry has the features of high supply chain relevancy, great potential market, strict quality demand and low pollution. Quality and Safety are the main concern in the aerospace industry. The foundation of safety and quality control is to comply with aviation regulations and technical standards.
This study starts to use the FMEA method to figure out the failure modes from the production process. By applying the results, RPNs are determined. The risk factors are sorted and classified through failure modes and RPNs from the largest value to the smallest value. On the other hand, IDEF0 is constructed to realize the present system. The potential failures by FMEA are the inputs for the improved IDEF0 to promote the production process efficiency and productivity. Finally, this study suggests modifications of the present system with the improved IDEF0 and analyzes the benefits after the improvement to validate the solution approach by this study.
The contributions of this research are as follows. The study combines with FMEA and IDEF0 to analyzes and modifies the aviation product production process including incoming inspection, testing and appearance check, and out-going inspection from the example company and obtain the significant improvement. Thus, this study is proved to have the following effect which can be standardized as the operation procedure.
(1)Operational clarification: To analyze the example company incoming inspection, testing and appearance check, out-going inspection via IDEF0 method can make operators much more familiar with their operational procedure.
(2)Decrease the failure rate: The modify processes including incoming inspection, testing and appearance check, out-going inspection can reduce the failure rate result from operators who do not comply with operation standard.
(3)To reduce customer complaints: The modify production process will not only reduce the failure rate but also prevent defective product occurrence from the customer’s end. Hence, this can efficiently reduce the number of customer complaints about quality concerns.
The improvement method of this study can serve as a reference for Aerospace Industry or other technology industry in attempt to effectively optimize the production process.

並列關鍵字

FMEA、IDEF0、Production Process、Aerospace

參考文獻

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