運用六標準差找出銑床U型管狀加工物件穩定性最佳化製程之研究

A Research of Six Sigma to Identify U-tube Milling Process Object Process to Optimize the Stability of Study

黄俊明(Jiung-Ming Huang) ； 林文燦(Wen-Tsann Lin) ； 賴柏成(Bon-Tsang Lai) ； 鍾宜達

《管理學術研討會》 第七屆 (2009/11) Pp. 201-209

https://doi.org/10.29893/NCUTMAN.200911.0201

摘要

對於一家零件專業加工廠而言，某些形状複雜之薄體加工件由於剛性低、容易振動使得幾何尺寸及表面品質控制不易。一般採取較爲複雜的程序以因應之，然而卻導致加然速度降低、成本提高的現象，在遭遇金融風暴、訂單大量減少、利潤下滑之際，企業必須趁此檢討加工製程，提出富創意的方法，以降低成本、減少加然時間及提高加然品質，以維持利潤。本研究針對U型薄管切槽銑削加工，提出改善加工品質及提高加工效能的實驗設計方法。相關之加工參數包括主軸轉速、刀丸數目、進給率與切削深度；目的在於找出並掌握最佳加工參數，建立穩定性加工及提高製程能力。
本研究運用六標準差手法改善步驟DMAIC五階段，以國內某機械加工廠管狀加工物件U型開口之製程進行實證研究，建構銑床加然穩定性之製程最佳化模式。研究方法結合田口品質工程的參數設計方法，找出管狀加工物件在加工製程時最佳化的實驗水準組合結果，實驗結果顯示Cpk由0.89提升爲Cpk 1.44對製程能力值有顯著提升，預測結果誤差率亦可達要求準確度，確實有助於管狀加工物件產品製程能力及品質的提升，而本研究之結果亦可提供台灣機械加然產業提升品質之參考。

關鍵字

銑床 ； U型管狀加工物件 ； 田口方法

並列摘要

A machining manufacturer may often deal with thin hollow and complex shape parts, which have low rigidity and easy to vibrate during machining, so the tolerances of geometric dimensions and surface quality are hard to control. It, of course, can be improved by some more processes, but the production will slow down and the cost will be raised. In the recent years during financial turmoil-orders are reduced and profits are declined, enterprises should review the process and propose innovative methods in order to reduce costs and processing time and improve the quality, so as to maintain profitability. This study aims to provide an experimental method improving the groove-milling quality for parts with thin U-tubes. The related machining parameters include spindle speed, blade number, feed rate and cutting depth, in this experiment. The optimal machining parameters will be acquired which will give stable and high performance machining.
DMAIC, The five stages of Six Sigma are used to improve the process of experimental design. The Taguchi parameter design is also implemented in the experiment for tubular machining process. It, at last, found an optimal experimental level of parameters, and the result showed the upgrade of Cpk from 0.89 to 1.44, which means significant improvement of machining performance, and showed an prediction that rate of error can also satisfy the accuracy demand. This obviously helps bring up the process capability of tubular work-pieces and enhance their quality. The results of this study may also provide a guide line for manufacturers of Taiwan to improve the quality of machining.

並列關鍵字

milling machine ； U-type tubular work-piece ； Taguchi Method