利用六標準差手法改善自行車碳纖維布料裁切製程良率—以B公司為例

Abstract

自行車製造材料從早期的鐵製、鋁製，發展到近年的複合材料-碳纖維，碳纖維製造過程，從前段的織紗、裁紗、包料到後段的熱壓成型，每一步驟都決定碳纖維自行車架的結構強度。而良好的碳纖維布料裁切品質，對於碳纖維車架的包料與熱壓成型有關鍵性的影響，因此碳纖維布料裁切製程就成為自行車業界專研的重點。由於碳纖維車架製品，百分之八十以上的成本是來自於碳纖維布料，因此碳纖維布料裁切工藝，是企業成本控管的關鍵項目之一。忽視了碳纖維布料此類源頭物料的穩定性，將會衍生許多品質問題，造成嚴重返工、報廢與產能瓶頸，甚至引起嚴重的交貨延期問題。因此，本研究的主要目的是應用六標準差手法，改善裁切碳纖維布料的製程良率與整體裁切效率過低的問題。本研究以台灣某自行車製造商為個案，透過六標準差DMAIC的改善步驟，以優化碳纖維布料裁切製程的品質，進而改善了個案公司自行車品質的問題。

The early bicycles were typically made from iron and aluminum. In recent years, the bicycles are made from carbon fibers. The carbon fiber manufacturing process, from knitting, cutting, cladding to thermoforming, determines the structural strength of the carbon fiber. Among these sub process, stable fiber cutting is the key factor of good cladding and thermoforming qualities. As fiber films contribute 80% cost of a carbon bicycle, good cutting process of carbon fibers becomes very important to lower the manufacturing cost. Ignoring the quality of carbon fibers may cause rework, scrap, capacity bottlenecks and delayed delivery. Thus, the main purpose of this study is to use Six Sigma(DMAIC) to improve the yield of cutting process of carbon fibers for bicycle. A case study of a bicycle company in Taiwan is utilized to demonstrate the effectiveness of the proposed method.