本文關(guān)鍵詞： 質(zhì)量成本 PONC 重型機(jī)床 系統(tǒng)開發(fā) 制造過程　出處：《濟(jì)南大學(xué)》2011年碩士論文　論文類型：學(xué)位論文

【摘要】：制造業(yè)技術(shù)水平的發(fā)展使得各企業(yè)產(chǎn)品質(zhì)量水平逐漸提高,但在實(shí)際制造過程中報廢、返修等不增值活動給企業(yè)帶來了巨大的損失,因此降低制造過程質(zhì)量成本已成為企業(yè)贏得市場競爭的重要手段。本文以制造過程產(chǎn)生的報廢、返修成本為研究對象,對重型機(jī)床制造過程存在的不符合要求的成本(PONC, price of nonconformance)進(jìn)行研究,主要研究工作如下: (1)針對重型機(jī)床制造過程不符合要求成本給企業(yè)造成巨大損失的問題,分析了研究重型機(jī)床制造過程PONC的必要性,綜述國內(nèi)外制造過程質(zhì)量成本控制研究的現(xiàn)狀,提出制造過程質(zhì)量成本控制仍存在的問題,確定了論文的主要研究內(nèi)容。 (2)以車間生產(chǎn)過程為研究單元,基于PDCA的基本思想提出了PONC控制基本原理;構(gòu)建車間目標(biāo)PONC數(shù)學(xué)模型及其分配流程,并基于作業(yè)成本法原理將車間目標(biāo)PONC分配至車間加工零件以及零件各工序,從而形成了工序目標(biāo)PONC。采用系統(tǒng)工程理論將零件加工過程最底層可能產(chǎn)生的各類質(zhì)量損失成本逐級運(yùn)算,構(gòu)建工序PONC控制系統(tǒng)。運(yùn)用層次分析法對工序PONC影響因素進(jìn)行分析,建立了工序PONC與影響因素之間的函數(shù)關(guān)系,為實(shí)現(xiàn)質(zhì)量成本控制奠定基礎(chǔ)。 (3)以重型機(jī)床企業(yè)軸類加工車間及其傳動軸加工為研究對象進(jìn)行了工序PONC研究。分析軸類加工車間目標(biāo)PONC,建立了車間月份目標(biāo)PONC值與質(zhì)量損失率之間的函數(shù)關(guān)系,提出了傳動軸工序目標(biāo)PONC分配實(shí)施模型;確定了傳動軸加工過程各作業(yè)中心及其成本動因,建立了工序目標(biāo)PONC具體分配路徑。分析重型機(jī)床制造過程報廢、返修、復(fù)檢PONC所包含的成本項(xiàng)目,建立了制造過程質(zhì)量成本計算函數(shù)。分析制造過程影響PONC值的各種因素,計算各影響因素權(quán)重系數(shù),確定了各影響因素重要度。 (4)構(gòu)建重型機(jī)床制造過程PONC控制及其信息管理系統(tǒng)架構(gòu),分析了主要模塊功能及系統(tǒng)運(yùn)行流程,進(jìn)行了PONC控制及其信息管理系統(tǒng)設(shè)計,并根據(jù)已建立的實(shí)際加工過程工序PONC數(shù)學(xué)模型,采用Microsoft Visual C#語言對重型機(jī)床制造過程PONC控制及其信息管理系統(tǒng)進(jìn)行開發(fā),實(shí)現(xiàn)了重型機(jī)床制造過程報廢、返修PONC相關(guān)數(shù)據(jù)的采集、運(yùn)算、添加、存儲以及查詢功能,并可基于質(zhì)量成本控制指標(biāo)實(shí)現(xiàn)了制造過程PONC的預(yù)防控制及其工序PONC超標(biāo)診斷。 (5)以重型機(jī)床典型零件——大型傳動軸的制造過程為例,進(jìn)行了工序PONC案例分析。計算軸類加工車間月份目標(biāo)PONC值及大型傳動軸的目標(biāo)PONC值,采用作業(yè)成本法將大型傳動軸的目標(biāo)PONC值分配到各作業(yè)中心,確定各工序目標(biāo)PONC。針對大型傳動軸實(shí)際制造過程產(chǎn)生的工序PONC,與工序目標(biāo)PONC比較,尋找大型傳動軸制造過程工序PONC超標(biāo)的原因,給出相應(yīng)的改進(jìn)措施,驗(yàn)證了系統(tǒng)的有效性,并實(shí)現(xiàn)了大型傳動軸工序PONC的有效控制。
[Abstract]:With the development of manufacturing technology, the product quality level of each enterprise is improved gradually, but in the actual manufacturing process, the non-value-added activities, such as scrapping and reworking, have brought huge losses to the enterprises. Therefore, reducing the cost of manufacturing process quality has become an important means for enterprises to win the market competition. This paper studies the nonconforming cost of heavy machine tool manufacturing process, price of nonconformance. The main research work is as follows: 1) aiming at the problem that the manufacturing process of heavy duty machine does not meet the requirement cost, the necessity of studying the PONC of heavy machine tool manufacturing process is analyzed. This paper summarizes the current situation of quality cost control in manufacturing process at home and abroad, points out the existing problems of quality cost control in manufacturing process, and determines the main research contents of this paper. 2) taking workshop production process as the research unit, the basic principle of PONC control is put forward based on the basic idea of PDCA. The mathematical model of workshop objective PONC and its assignment flow are constructed. Based on the principle of activity-based costing, the workshop objective PONC is assigned to the workshop parts and their processes. Thus the process objective PONC. adopt the system engineering theory to calculate all kinds of mass loss cost that may be produced at the bottom of the parts machining process. The PONC control system of working procedure is constructed. The influence factors of process PONC are analyzed by analytic hierarchy process (AHP), and the functional relationship between process PONC and influencing factors is established. Lay the foundation for quality cost control. (3) the working procedure PONC research was carried out on the shafting workshop and its transmission shaft machining of heavy duty machine tool enterprise. The objective PONC of the shaft-type machining workshop was analyzed. The functional relationship between the PONC value of workshop month and the loss rate of quality is established, and the implementation model of PONC allocation for driving shaft process is put forward. The operation centers and their cost drivers in the manufacturing process of transmission shafts are determined, and the specific allocation path of process objective PONC is established. The scrapping and reworking of heavy machine tool manufacturing process are analyzed. Recheck the cost items contained in PONC, set up the cost calculation function of manufacturing process quality, analyze the factors that affect the PONC value of manufacturing process, calculate the weight coefficient of each factor. The importance of each factor is determined. The PONC control and information management system architecture of heavy duty machine tool manufacturing process are constructed, the main module function and system running flow are analyzed, and the PONC control and information management system are designed. And according to the established PONC mathematical model of actual processing process. The Microsoft Visual C # language is used to develop the PONC control and information management system of heavy duty machine tool manufacturing process, and the manufacture process of heavy duty machine tool is scrapped. Rework PONC related data acquisition, operation, addition, storage and query functions. Based on the quality cost control index, the prevention and control of manufacturing process PONC and the diagnosis of process PONC exceeding the standard are realized. 5) take the manufacturing process of a typical part of a heavy machine tool, a large drive shaft, as an example. A case study of working procedure PONC was carried out. The target PONC value of shaft workshop month and the target PONC value of large drive shaft were calculated. Activity-based costing method is used to assign the target PONC value of the large drive shaft to each operation center, and to determine the working procedure PONC for the actual manufacturing process of the large drive shaft. Compared with the process objective PONC, this paper finds out the reason why the working procedure PONC exceeds the standard in the manufacturing process of the large drive shaft, and gives the corresponding improvement measures, which verifies the effectiveness of the system. The PONC control of large drive shaft process is realized.
【學(xué)位授予單位】：濟(jì)南大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2011
【分類號】：TH186

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