運用失效模式與效應分析方法於鋁錠生產品質改善之研究-以C公司為例

壓鑄製程係由鋁錠原料熔融鑄入模具並加壓生產鑄件，鋁製鑄件因其熔點較低、合金原料發展成熟，廣泛運用於航太、交通、結構等材料領域。由於製程對作業人員而言屬高溫作業環境，適當且最佳化之機械設備各參數無法於開發階段直接取得，僅可依賴不斷嘗試與修正調整至堪用狀態，一般壓鑄業界產品開發均採前述流程，大幅增加時間、人力及耗材成本。為提升產品開發效率、降低生產成本並達成品質改善之研究目的，本研究利用失效模式與效應分析、特性要因、品管手法，針對案例公司鋁錠壓鑄產品之異常、不良、瑕疵、結構瑕疵等問題，引入要因分析、失效模式與效應分析(FMEA)、風險優先值 (RPN)等方法，有效管理失效風險提升產品良率，並降低開發、驗證、量產等產品生命週期耗用成本。承上，本研究規劃之定義鋁錠加工製品自產線完成試製雛形至量產，各階段品管人員品質管控標準流程，並完成依產品品質現象分析結果機動調整進料速度、鋁錠溶融溫度、設備設定值及加工程序等製程參數，達成鋁錠壓鑄產業品質改善之研究目的，成效卓著。

關鍵字

鋁錠；品質；改善；失效模式與效應分析；風險

並列摘要

The die casting manufacturing process involves melting aluminum ingots, casting the molten metals into the mold cavity, and using high pressure to manufacture casted products. For having a low melting point and the sound development of aluminum alloy material, the casted aluminum products have been broadly employed in many fields such as aerospace, transportation, architecture, etc. However, the high temperature of the manufacturing process for operational workers made it almost impossible to obtain the most suitable and optimized parameter setting of the machines. So, the die casting businesses usually adopted another procedure, which was to adjust and fine-tune the setting whenever needed until the machines were in good working conditions. This procedure largely saves time, labor, and consumables costs. By the same token, the purpose of this Thesis concentrated on enhancing the efficiency of, reducing costs occurred during and improving the quality control of the manufacturing process. This Thesis relied upon the failure mode and effect analysis (FMEA), cause and effect analysis, and quality management tools to dissect an empirical case about Company C. With respect to Company C’s problems concerning its casted aluminum such as irregularities, abnormality, defects, structural flaws, etc., this Thesis applied the cause-effect diagram method, FMEA, and risk priority numbers (RPN) to formulate an effectively control over failure risk while enhancing yield rates and reducing consumed costs in the products’ lifecycle in terms of developing, testing, and mass-manufacturing products. Accordingly, this Thesis articulated a standard operational procedure (SOP) of quality control for quality control managers regarding aluminum processing products in each manufacturing phase from preliminary modeling to mass production. Further, it contemplated certain process parameters such as the feed rates, the fluxing temperature of aluminum ingots, the setting of manufacturing equipment, and the processing procedure. This Thesis accomplished the purpose to improve the quality of aluminum die casting business. The result was remarkably fruitful.