标题: 以实验设计方法降低汽车水箱护罩之涂装缺点数-以A塑件涂装厂为例
Using Design of Experiments to Reduce Defects of Painting Process of Grille
作者: 黄俊雄
Huang, Chun-Hsiung
张永佳
管理学院工业工程与管理学程
关键字: 涂装;Painting
公开日期: 2013
摘要: 本次实验对象为汽车水箱护罩。为迎合消费者喜好,汽车零件制造商会将塑胶涂料涂装在汽车水箱护罩上,以提升光泽、遮盖射出成形时的瑕疵并增加金属质感,进而影响消费者的购买意愿并提升商品的价值。但台湾汽车零件制造业已进入微利时代,涂装品质不良会增加水箱护罩不良品,轻微之涂装不良状况经过整修后可再点交予汽车制造厂客户端进行组装,不良状况较严重之水箱护罩则必须直接报废,对于一家汽车零件制造厂而言,这是相当庞大也无谓的成本浪费。在涂装制程中,烘烤时间、烘烤温度、喷枪压力及各种参数及环境设定都会影响涂装品质。为协助A公司降低涂装不良缺点并提升涂装良率,本研究透过实验设计方法(Design Of Experiments ,DOE),找出涂装制程中影响品质之显着因子,透过变异数分析(Analysis of variance ,ANOVA),发现适当的烘烤温度及增加喷漆房的清洁次数有助于降低涂装品质之不良缺点数,并提升良率。
本研究找出之最佳参数设定可协助A公司快速提升产品涂装品质,并大幅降低A公司生产及重工成本,本研究成果可提供给其他汽车零件制造厂在提升涂装良率及降低生产成本之制程改善参考。
The purpose of this study is to test the effect of painting on the grille. In order to meet consumers’ preference, auto parts manufacturers paint the plastic-coating on the grille to improve gloss, cover injection defects and increase the metal texture. The improvement of the grille may affect consumers' willingness to buy and increase the value of the goods. The auto parts industry in Taiwan has entered the era of little profit. The poor quality painting on the grille will increase defective products. For example, if the grille painted has slight defect, these parts will be delivered to automobile assembly factory to refurbish; the other serious situations of painting on the grille will be scrapped. The defect for painting may increase tremendous cost for an auto parts manufacturer. The time of baking, temperature of baking, pressure of nozzle, and any other setting in the painting process will affect the painting quality. In this study, we use design of experiment (DOE) to find distinct factors which affect quality more of the process to help this company to reduce defect amounts of their products. Analysis of variance(ANOVA) was applied to find that the number of defects will be decreased if the parts baked moderately and cleaning frequency of Spray booth increased. The goal of this study is to help the company to find the optimum parameter improved painting yield quickly and reduce the cost of produce and rework. This study may also provide as a reference to improve painting quality and process improvement of cost reduction for auto parts manufacturers.
URI: http://140.113.39.130/cdrfb3/record/nctu/#GT070163318
http://hdl.handle.net/11536/74587
显示于类别:Thesis