機車產業隨著經濟成長,尤其亞洲地區更是機車產業的發展重心。隨著油價高漲,加上台灣地小人稠,機車儼然成為國人重要的代步工具,因此也成為都會區多數人口使用的交通工具。在機車維修方面,需求也日益增加,加上近年來大陸製品銷售已經影響到台灣零組件銷售額。本研究之個案公司,在市場上有一定的佔有率,但是在競爭激烈的機車零組件市場,顧客端堅持採用台灣製品的同時,供應商該如何提昇品質,保持產品穩定性而降低不良率,是一大課題。 失效模式與效應分析是全面品質管理的一環、是一種動態的分析、事前預防的工具,藉由專案團隊的運作,以發掘設計與製造的關鍵潛在失效問題及其影響。透過對失效問題的嚴重度、難檢度與發生頻率的排序,可以幫助生產者決定問題處理的優先順序,並進而透過相關改善技術、工具、方法來解決問題。 本研究根據問題分析提出改善對策與建議,讓研究對象依據風險優先數與相關的對策,採取適當的措施來消除機車零組件銷售品質的潛在失效模式。在歷經一年的改善,不僅降低退貨率10%~15%,亦節省了個案公司的成本,也讓其更加重視員工教育訓練,以及跟OEM廠商協調進行改善,將產品品質提昇。
In this research, the maker under case study has its own share in the local market. However, in the violently competitive market of motorbike spare parts, along with the customers’ persistence on Taiwan-made products in the local market, how to improve product quality, keep product stability but reduce defect rates is a critical issue for local suppliers. FMEA is a part of the overall quality control and it is a tool of dynamic analysis and anterior prevention. Through teamwork operation, it aims to discover the problems and influence of the key failure modes happening in design and production. Through the ranking of the severity, detection and occurrence of failure modes, it is available for producers to determine the priority for problem solving. The problems can be solved through relevant improvement techniques, tools and methods. Based on problem analysis, improvement countermeasures and suggestions are proposed in this research available for researchers to take appropriate measures eliminating the potential failure modes for the sales quality of motorbike parts based on risk priority numbers and relevant countermeasures. After a year of improvement, the return rate is not only reduced to 10%~15%, the project cost is also saved with stronger emphasis on employees’ education and training programs. Also, the coordination with OEM makers and product quality are both improved.