以精密沖壓模具創新設計提升品質與降低成本之個案研究

Case Study of Quality Improvement and Cost Reduction by Innovative Design of Precision Stamping Die

梁正庸(Cheng-Yung Liang)

指導教授 ： 林均燁

朝陽科技大學/理工學院/工業工程與管理系/碩士(2017年)

摘要

板金沖壓使用的機械設備稱為沖床，而使用的模具則稱之為沖壓模具。沖壓過程所產生的粉屑會造成產品有印痕、壓傷外觀問題，成為不良品，進而造成沖壓量不足、重工、工時加長，廠商換貨、退貨、求償及公司商譽受損，成本提高、利潤降低等公司經營問題。尤其沖壓行業跟許多台灣傳統產業模式一樣，乃以代工為主，如果不在工程管理節省成本，賺的將是微利的勞力工錢。
模具乃各種終端產品量產的一項重要生產基本工具，有工業產品之母之稱。模具是由多種零組件製作及組立而成之關鍵工具，經由精密設計的模具進行沖壓才能夠產出低成本、大量生產、品質均一的產品。日常生活中的產品越來越輕薄短小，功能卻越來越多，品質要求越來越嚴苛，因此在這微利時代，如何降低不良率、提升總體效能，將是在這傳統產業競爭中生存的重要課題。
本研究採用個案研究法，以六標準差設計理論、田口實驗方法以及TRIZ等方法針對模具連續沖壓所產生的粉屑現象和模組化設計目標及物流現況改善等，從模具設計端到模具沖壓生產等步驟加以改善，用以提高產品生產良率與客戶滿意度，進而增加市場競爭力。最後本研究在各個創新設計個案以其創造之經濟效益指標作為結論。

關鍵字

模具沖壓設計 ； 六標準差設計 ； 田口實驗 ； TRIZ ； 經濟效益

並列摘要

The machine used for punching sheet metal is called stamping machine. And, the molds are called stamping molds. The metal bits released during stamping process usually will cause dents on the product, and the poor quality products will further result in a lot of rework, longer work hours, replace or reject of delivery by customers, customer claims, etc. and cause OEM companies a lot higher cost and lower profit. Especially in the highly competitive OEM business, it is very important to reduce cost by engineering management to earn more profit.

Mold is a fundamental tool for mass production of a lot variety of end products, therefore it is usually called the mother of industrial products. Mold is an assembly of many components, and manufacturing with precisely designed molds is the key to produce low-cost, mass quantity, uniform quality products. Because end products are getting thinner and thinner, lighter and lighter, but with more and more functions and better and better quality requirements, how to reduce the defective rate, improve overall performance are the most important issues the traditional OEM industries to survive in this low-profit era.

This study uses case study method. By adopting six sigma design theory, Taguchi experimental method and TRIZ to resolve mold design problems including dust issue, modular design and material handling issues. The case studies cover from mold design to stamping production process to improve product yield and customer satisfaction, and thereby increase market competitiveness, while using TRIZ innovative problem-solving methods to reduce the cost of mold, improve the efficiency of innovative design improvements. Finally, this study uses economic performance index of three design case studies as the conclusion of the research.

並列關鍵字

stamping mold design ； design for six sigma ； Taguchi experiment ； TRIZ ； economic performance index

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