Ƙarfe Quality Controling Quality: Matsayi, Hanyoyi & Lissafin dubawa
Ƙarfe mai kula da ingancin hatimi shine kashin bayan samar da sassa masu dogara. Lokacin da abin da aka hatimi ya gaza a cikin filin, farashin ya wuce nisa fiye da ɓangarori guda ɗaya - yana tashe ta hanyar sarƙoƙi, yana lalata suna, kuma yana iya haifar da tuno mai tsada. Ga injiniyoyi da masu dubawa masu inganci waɗanda ke aiki tare da masu siyar da tambarin ƙarfe, fahimtar cikakken yanayin yanayin kula da ingancin yana da mahimmanci don zaɓar abokin haɗin gwiwa da kuma tabbatar da daidaiton fitarwa.
Wannan jagorar ya ƙunshi ƙa'idodi masu inganci, hanyoyin dubawa, sarrafa tsari, da tsarin farashi waɗanda ke ayyana mafi kyawun ingancin sarrafa tambarin ƙarfe na ƙarfe. Ko kuna cancantar sabon mai siyar da tambari ko ƙarfafa ingantaccen shirin ku na yanzu, bayanin da ke ƙasa yana ba da fa'ida mai amfani, mai aiki.
Me yasa bugawa Stampers
Tsarin tambarin ƙarfe - ɓarna, lankwasawa, ƙirƙira, zane, da huda - suna aiki cikin sauri tare da juriya mai ƙarfi. Mutuwar ci gaba da ke gudana a bugun jini 200 a cikin minti ɗaya na iya haifar da dubunnan ɓangarori marasa lahani a cikin mintuna idan kayan aiki ya fashe ko abu ya canza. Ba kamar injina ba inda aka yanke kowane sashi daban-daban, yin tambari yana maimaita kurakurai a saurin samarwa.
Ingantacciyar sarrafa ingancin tambarin ƙarfe yana hana:
- Scrap da sake aiki farashi - kama wani batu a labarin farko yana ceton dubban sassan da aka ƙi.
- Tsayar da layin abokin ciniki - OEMs na kera motoci suna ɗaukar hukuncin $10,000- $ 50,000 a cikin minti ɗaya na raguwa.
- Rashin aminci - maƙallan hatimi, shirye-shiryen bidiyo, da kayan aikin dole ne su haɗu da ƙayyadaddun kaya da ƙayyadaddun gajiya ba tare da togiya ba.
- Rashin bin ka'ida - IATF 16949 da AS9100 duban dan tayi suna buƙatar takaddun shaida na sarrafa tsari a kowane mataki.
Matsayin Inganci don Tambarin Karfe: ISO vs. IATF Kwatanta
Matsayi guda biyu sun mamaye kula da ingancin ƙarfe: ISO 9001 don masana'antu na gabaɗaya da IATF 16949 don sashin kera motoci. Fahimtar bambance-bambancen su yana taimaka muku ƙayyadaddun buƙatun da suka dace don sarkar wadatar ku.
| Feature | ISO 9001:2015 | IATF 16949:2016 |
|---|---|---|
| Matsakaicin | Kowace kungiya, kowace masana'antu | Kera motoci da sassan sabis |
| Core Focus | Tushen tsarin sarrafa inganci | rigakafin takamaiman lahani na motoci |
| Gudanar da Hadarin | Tunanin tushen haɗari (Yanayin 6.1) | FMEA, tsare-tsaren sarrafawa, da APQP da ake buƙata |
| Hanyar Tsari | Ƙarfafa | Wajabta - dole ne taswirar duk COP (Tsarin Tsare-tsaren Abokin Ciniki) |
| Tsarukan Aunawa | Gabaɗaya bukatun daidaitawa | MSA (Binciken Tsarukan Ma'auni) wajibi |
| Hanyoyin ƙididdiga | Ana Magana amma ba a buƙata ba | SPC, Cpk/Ppk mafi ƙarancin buƙatun da aka ayyana |
| Gudanar da mai samarwa | Kima da saka idanu | Ƙaddamar da ƙaramar mai ba da kaya da dubawa da ake buƙata |
| Ci gaba da Ingantawa | Babban Tsarin Ingantawa | 8D, 5-Me ya sa, Kaizen - an duba ayyukan gyara |
| Takaddun shaida | Binciken ɓangare na uku ta ƙungiyar da aka amince da ita | Bincika na ɓangare na uku + Hukumar ba da takardar shaida ta IATF |
| Abubuwan Bukatun Abokin Ciniki | Ba a magance shi ba | Yarda da CSR wajibi ne (misali, Ford Q1, GM BIQS) |
Makullin ɗaukar nauyi: Idan sassan ku masu hatimi sun shiga cikin majalissar motoci, IATF 16949 shine tushen tushe. Don masana'antu gabaɗaya, likitanci, ko aikace-aikacen mabukaci, ISO 9001 tare da ingantaccen sarrafa tsari ya wadatar.
Bayan waɗannan biyun, masu ba da hatimi na sararin samaniya na iya ɗaukar AS9100D, kuma aikace-aikacen tsaro na buƙatar ITAR yarda. Koyaushe tabbatar da cewa iyakar takaddun shaida na mai siyarwa ya ƙunshi takamaiman matakai da ɓangaren iyalai da kuke buƙata.
Hanyoyin Dubawa don Ƙaƙƙarfan Hatimin Ƙarfe
Zaɓi hanyar dubawa daidai ya dogara da ɓangaren lissafi, ƙimar samarwa, buƙatun ƙima. Teburin da ke ƙasa yana kwatanta hanyoyin da aka fi amfani da su wajen sarrafa ingancin tambarin ƙarfe.
| Hanyar | Daidaici | Gudun | Mafi kyawun Ga | Iyakance | Yawan Kuɗi |
|---|---|---|---|---|---|
| CMM (Ma'auni mai daidaitawa) | ± 0.001-0.005 mm | Slow (minti kowane bangare) | Gometries verification | Yana buƙatar ƙwararren mai aiki; bai dace da 100% dubawar layi ba | $50K-$500K+ kayan aiki |
| Optical / Vision Systems | ± 0.005-0.02 mm | Mai sauri (dakika da kashi ɗaya) | Lebur sassa, bayanan martaba, gano lahani saman | Gwagwarmaya tare da fasali mai zurfi; saitin haske mai mahimmanci | $20K–$200K+ a kowane tasha |
| Go/No-Go Gauges (Pin & Plug) | Pass/Fail kawai | Mai sauri | Diamita na rami, zaren, da tabbacin ramin | Kawai yana duba girma ɗaya; ma'auni lalacewa akan lokaci | $50-$500 a kowace ma'auni |
| Laser Scanning / Tsarin Haske | ± 0.01-0.05 mm | Matsakaici | Cikakken kwatancen saman, dubawar labarin farko | Babban girman bayanai; fassarar yana buƙatar horo | $30K–$300K+ |
| Gwajin taurin (Rockwell/Vickers) | ±1 HRC | Mai Saurin | Zafi ko taurin hatimi | Mai lalacewa idan an gama saman ƙasa | $2K–$20K kayan aiki |
| Mai Gwajin Ƙarfin Sama (Profilometer) | ±0.01 µm Ra | Mai Saurin | Fuskokin aiki, fuskokin rufewa | Yana auna bayanin martaba guda ɗaya kawai | $3K–$15K |
| Ultrasonic / X-Ray (NDT) | Ya bambanta | Matsakaici-Slow | Ciki lahani a cikin lokacin farin ciki stampings, weld gidajen abinci | Babban kudin kayan aiki; ƙwararrun ƙwararrun ƙwararrun suna buƙatar | $20K-$500K+ |
Nasiha mai fa'ida: Yawancin shagunan bugawa suna amfani da matakan da suka dace - Go / No-Go gauges da tsarin hangen nesa don 100% dubawar layi, CMM don labarin farko da dubawa na lokaci-lokaci, da gwaji mai lalacewa (tensile, hardness) don tabbatar da kayan aiki.
Tsari na Duba matakai uku
A ƙaƙƙarfan ƙaƙƙarfan ƙaƙƙarfan ƙaƙƙarfan ƙaƙƙarfan tsarin kula da kayan aiki, yana aiki a cikin tsarin sarrafa kayan ƙarfe mai ƙarfi a cikin tsari guda uku. da dubawa na ƙarshe. Kowane mataki yana da manufa da hanyoyi daban-daban.
Mataki na 1: Duban Abu mai shigowa (IQC)
Raw kayan - nada karfe, aluminum, bakin, ko musamman gami - dole ne ya hadu da takamaiman bayani kafin ya shiga cikin latsa tambari. Rashin gazawa a wannan matakin yana hana lahani na ƙasa wanda ya fi tsada don gyarawa.
Maɓalli na ayyukan IQC:
- Binciken takaddun shaida - tabbatar da rahotannin gwajin niƙa (MTRs) don sunadarai, kaddarorin injina, da yanayin zafi/kuri akan tsarin siye da ƙa'idodi masu dacewa (ASTM, SAE, EN).
- Tabbacin girma - auna faɗin coil, kauri, da yanayin gefen ta amfani da micrometers da ƙididdiga na gefe.
- Duban saman saman - duba ma'auni, tsatsa, gurbataccen mai, karce, da lahani.
- Tabbatar da taurin - Rockwell ko gwajin tauri akan samfurin takardun shaida.
- Samfuran mai shigowa da yawa - yi amfani da samfurin AQL (Madaidaicin Matsayin da aka yarda da shi) ta ANSI/ASQ Z1.4 ko ISO 2859-1. Matakan AQL na yau da kullun don halaye masu mahimmanci: 0.65-1.0.
Takardu: Rahoton Bincike mai shigowa tare da karɓa/ƙi yarda, ganowa zuwa lamba mai yawa, da haɗi zuwa MTR na mai kaya.
Mataki na 2: In-Tsari Inspection (IPI)
Gudanar da cikin tsari yana hana lahani daga yaduwa yayin samarwa. Wannan shi ne inda ƙarfe bugawa ingancin iko yana ba da mafi girman ROI.
Maɓalli Ayyukan IPI:
- Yarjejeniyar Farko na Farko - sashin farko na sabon saitin dole ne a bincika gabaɗayan tsarin sarrafawa kafin fara samarwa. Duban girma, gani, da na aiki.
- Mai aiki na lokaci-lokaci cak - yawanci kowane minti 30-60, masu aiki suna auna ma'auni masu mahimmanci ta amfani da ma'auni na Go/No-Go, calipers, ko kayan aiki.
- Tsarin hangen nesa - kyamarori masu sarrafa kansu suna duba 100% na sassa don kasancewar / rashi na fasali, tsayin burr, da lahani.
- Mutu dubawa - duba yanayin mutu a ƙayyadadden lokaci (misali, kowane bugun jini 10,000-50,000). Saka idanu don chipping, galling, da rashin daidaituwa.
- SPC tarin bayanai - Ana auna ma'auni masu mahimmanci kuma an tsara su akan ginshiƙan sarrafawa a ainihin lokacin (duba sashin SPC a ƙasa).
Takardu: Tsare-tsaren Sarrafa (kowace tsarin AIAG), Log ɗin Binciken Cikin-Tsarin, Taswirar SPC, da Rubutun Kulawa na Die.
Mataki na 3: Binciken Ƙarshe / Mai fita (OQC)
abokin ciniki na ƙarshe. Wannan matakin yana tabbatar da cewa kuri'a ta cika duk ƙayyadaddun bayanai.
Maɓalli na OQC ayyuka:
- Duban girman - CMM ko ma'aunin ma'aunin ma'auni mai mahimmanci (CTQ) a kowane zane.
- Duban gani da kwaskwarima - duba ga scratches, dents, burrs, discoloration, da kuma gurɓata a ƙarƙashin ƙayyadadden yanayin haske.
- Gwajin aiki - karfin juzu'i, karfin turawa, gwajin yatsa, ko gwajin dacewa da haduwa kamar yadda ya dace.
- Tabbatar da marufi - tabbatar da daidaitaccen lakabi, yawa, zanen raba, da kariyar lalata.
- Tabbatar da Cpk/Ppk - tabbatar da fihirisar ikon aiwatar da biyan bukatun abokin ciniki (yawanci Cpk ≥ 1.33 ko 1.67).
- Certificate of Conformance (CoC) - fitar da takaddun jigilar kaya masu tabbatar da yarda da PO, zane, da ƙa'idodi masu dacewa.
Takardu: Rahoton Bincike na Ƙarshe, Nazarin Cpk/Ppk, Takaddun Takaddama, da Lissafin Taimako na jigilar kaya.
SPC in bugun karfe Quality Control
Statistical Tsari Control (SPC). Yana jujjuya inganci daga "duba da rarraba" zuwa "predict da hana."
Yadda SPC ke Aiki akan Layin Jarida
- Zaɓi Girman CTQ - aiki tare da abokin ciniki da injiniya don gano 3-8 girma da muhimmanci.
- Zaɓi nau'in ginshiƙi daidai:
– X-bar da R ginshiƙi - don bayanai masu ma'ana waɗanda aka auna cikin ƙungiyoyin ƙasa (misali, sassa 5 kowane minti 30).
– X-bar da S chart - lokacin da girman rukuni ya wuce 10.
– daidaikun mutane da Motsi Range (I-MR) - don ma'auni ɗaya ko gwaje-gwaje masu lalata.
– p-chart / np-chart - don bayanan sifa (ƙididdigar wucewa/ gazawa). - Tattara tushen bayanai - gudanar da ƙananan ƙungiyoyi 25 don kafa iyakokin sarrafawa.
- Saka idanu da amsa - lokacin da batu ya faɗi a waje da iyakokin sarrafawa ko tsari ya fito (misali, maki 7 da ke tasowa a hanya ɗaya), dakatar da samarwa, bincike, da kuma gyara.
Alamar iyawa
- Cp - auna yaduwar tsarin dangane da haƙuri. Cp = (USL - LSL) / 6σ.
- Cpk - asusu don tsakiya. Cpk = min [(USL - μ) / 3σ, (μ - LSL) / 3σ].
- Ppk - yana amfani da juzu'i na gaba ɗaya (dogon lokaci). Mai ra'ayin mazan jiya fiye da Cpk.
| Cpk Darajar | Tafsiri | Bukatu Na Musamman |
|---|---|---|
| < 1.00 | Tsari baya iyawa | Ana buƙatar matakin gyara nan da nan |
| 1.00–1.33 | Mai iyawa kaɗan | Ana iya karɓa tare da 100% dubawa |
| 1.33–1.67 | Mai iyawa | Daidaitaccen abin da ake buƙata na kera motoci |
| ≥ 1.67 | Ƙwararren Ƙwararren | Premium / aminci-mahimman aikace-aikace |
Misali: Haƙurin ramin rami shine ± 0.15 mm. Bayanan SPC yana nuna X-bar = 0.02 mm (a tsakiya), σ = 0.035 mm. Cpk = (0.15 - 0.02) / (3 × 0.035) = 1.24. Wannan gefe ne - bincika lalacewa kayan aiki ko bambancin kayan aiki don haɓaka tsakiya da rage yaɗuwa.
Ƙididdiga Ƙididdiga Mai Kyau: Ƙirar Tsarin Inganci
Fahimtar ƙimar ingancin yana taimakawa tabbatar da saka hannun jari a tsarin kula da ingancin ƙarfe. Samfurin "Cost of Quality" (COQ) yana karya kashe kuɗi mai inganci zuwa rukuni huɗu.
1. Kudin Rigakafi
Zuba jari da aka yi don hana lahani daga faruwa.
- Binciken ƙirar kayan aiki da FMEA
- Horon mai aiki da takaddun shaida
- Shirye-shiryen kula da mutuƙar rigakafin
- aiwatar da tsarin SPC
- Binciken cancantar masu samarwa
Matsakaicin rabo: 5-10% na jimlar kasafin kuɗi mai inganci.
2. Farashin Kima.
Kudaden aunawa da dubawa don gano lahani.
- Mai shigowa, cikin tsari, da aikin dubawa na ƙarshe
- CMM da kayan aikin hangen nesa da kuma kiyayewa
- Ƙididdigar ma'auni da nazarin MSA
- Gwaji da takaddun shaida na ɓangare na uku
Matsakaicin rabo: 20-30% na jimlar kasafin kuɗi mai inganci.
3. Kudin gazawar ciki
Farashin lahani da aka kama kafin jigilar kaya.
- Scrap and rework work
- Mutuwar gyara saboda gazawar da ke da alaƙa da inganci
- Sake dubawa
- Lokacin samarwa don batutuwa masu inganci
Matsakaicin rabo: 25-35% na jimlar kasafin kudin inganci.
4. Farashin gazawar waje
Farashin lahani kai abokin ciniki - mafi tsada category.
- Abokin ciniki ya dawo da da'awar garanti
- Rarrabawa da ƙullawa a wurin abokin ciniki
- Sauyawa sassa
- Hukunce-hukunce da caji
- Kasuwancin da ya ɓace
Matsakaicin rabo: Zai iya haɓaka zuwa 40%+ lokacin da gazawar waje ta faru.
Maɓalli maɓalli: Ƙara yawan kashe kuɗi na rigakafi da ko da 2-3% yawanci yana rage jimillar farashi mai inganci da 15-25% saboda gazawar ciki da waje suna raguwa sosai. Mafi kyawun maƙasudin COQ don babban aikin hatimi shine kashi 2.5-4% na kudaden shiga, tare da rarraba rigakafi-mai nauyi.
Lissafin Binciken Ƙarfe Mai Bugawa
Yi amfani da wannan lissafin don duba labarin farko, dubawa mai shigowa, ko duban cancantar mai kaya. Buga kuma ajiye a tashar dubawa.
LITTAFI MAI TSARKI KARFE
Sunan Sashe: __ Lambar Sashe: __ Zana Rev: ___
Mai bayarwa: __ Lot/Batch #: __ Kwanan wata: ___
Inspector: __ Lambar gidan waya: __ Die/Tool #: ___
SASHE A: BINCIKEN TAKARD
| # | Duba Abu | Wuce | Kasa | N/A | Bayanan kula |
|---|---|---|---|---|---|
| A1 | Takaddun Shaida (MTR) akan fayil kuma yayi daidai da PO spec | ☐ | ☐ | ☐ | |
| A2 | Bita na zana ya dace da sigar abokin ciniki-amincewa | ☐ | ☐ | ☐ | |
| A3 | Tsarin sarrafawa yana samuwa da na yanzu | ☐ | ☐ | ☐ | |
| A4 | FMEA ta sake dubawa kuma an sabunta ta | ☐ | ☐ | ☐ | |
| A5 | Ƙimar aiki (Cpk/Ppk) bayanan da aka bayar | ☐ | ☐ | ☐ |
SASHE NA B: GANIN DUMI
| # | Feature | Nominal | haƙuri | Auna | Wuce | Kasa |
|---|---|---|---|---|---|---|
| B1 | ☐ | ☐ | ||||
| B2 | ☐ | ☐ | ||||
| B3 | ☐ | ☐ | ||||
| B4 | ☐ | ☐ | ||||
| B5 | ☐ | ☐ | ||||
| B6 | ☐ | ☐ | ||||
| B7 | ☐ | ☐ | ||||
| B8 | ☐ | ☐ |
SASHE C: MATERIAL & MECHANICAL PROPER
| # | Duba Abu | Spec | Auna | Wuce | Kasa | N/A |
|---|---|---|---|---|---|---|
| C1 | Material daraja da yanayin | ☐ | ☐ | ☐ | ||
| C2 | Hardness (Rockwell / Vickers) | ☐ | ☐ | ☐ | ||
| C3 | Ƙarfin ɗamara | ☐ | ☐ | ☐ | ||
| C4 | Plating/coating thickness | ☐ | ☐ | ☐ | ||
| C5 | Gwajin gishiri / lalata | ☐ | ☐ | ☐ |
SASHE NA D: KALLON KYAU & SURFACE
| # | Duba Abu | Wuce | Kasa | Bayanan kula |
|---|---|---|---|---|
| D1 | No visible scratches, dents, or gouges | ☐ | ☐ | |
| D2 | Tsayin Burr tsakanin ƙayyadaddun ƙayyadaddun | ☐ | ☐ | |
| D3 | Babu fasa ko karaya (amfani da haɓakawa idan an buƙata) | ☐ | ☐ | |
| D4 | Ƙarshen Surface ya dace da ƙayyadaddun Ra | ☐ | ☐ | |
| D5 | Babu gurɓata (mai, tsatsa, kayan waje) | ☐ | ☐ | |
| D6 | Plating/rufin riga da mannewa abin karɓa | ☐ | ☐ |
SASHE E: AIKI & MAJALISAR DUBI
| # | Duba Abu | Wuce | Kasa | N/A | Bayanan kula |
|---|---|---|---|---|---|
| E1 | Fit-check tare da ɓangaren (s) | ☐ | ☐ | ☐ | |
| E2 | Gwajin karfin juyi ko turawa | ☐ | ☐ | ☐ | |
| E3 | Gwajin Leak / matsa lamba | ☐ | ☐ | ☐ | |
| E4 | Weld mutunci (idan an zartar) | ☐ | ☐ | ☐ |
SASHE NA F: KYAUTA & LABELING
| # | Duba Abu | Wuce | Kasa | Bayanan kula |
|---|---|---|---|---|
| F1 | Daidaitaccen adadin kowane akwati | ☐ | ☐ | |
| F2 | Lakabi ya dace da lambar sashi, bita, kuri'a # | ☐ | ☐ | |
| F3 | Isasshen zanen gadon raba / dunnage / kariya | ☐ | ☐ | |
| F4 | Ana amfani da kariya ta lalata (VCI, mai, da sauransu) | ☐ | ☐ |
KYAUTA: ☐ YARDA ☐ KI ☐ YARDA SHARADI (sake duba bayan: ___)
Sa hannun Sufeto: __ Kwanan wata: __
Amincewa da Ingancin Manajan Inganci (idan an ƙi): __ Kwanan wata: __
Mafi kyawun Ayyuka don Aiwatar da Ingancin Tambarin Karfe
Bisa la'akari da shekarun da suka gabata na ƙwarewar masana'antu, waɗannan ayyukan sun raba matsakaicin shirye-shirye masu inganci daga mafi kyau:
-
Zuba jari a cikin ƙira da kiyayewa - 80% na al'amurran da suka shafi ingancin tambarin sun koma ga kayan aiki. Zaɓin zaɓin ƙarfe da ya dace, jiyya na ƙasa, da jadawalin kiyayewa na rigakafi suna hana yawancin lahani da ƙima.
-
Binciken layi ta atomatik - masu duba dan adam gajiya; tsarin hangen nesa ba sa. Don hatimi mai girma, dubawar gani ta atomatik (AOI) tana ba da daidaito, ɗaukar hoto 100% a saurin samarwa.
-
Rufe madauki tare da SPC - tattara bayanai bai isa ba. Sanya ikon mallakar don amsawa ga sigina marasa sarrafawa. Taswirar sarrafawa wanda babu wanda ya karanta yana ba da ƙimar sifili.
-
Daidaita tsare-tsaren sarrafa ku - yi amfani da tsarin Kulawa na AIAG a duk shirye-shiryen. Wannan yana haifar da daidaito, yana sauƙaƙe dubawa, kuma yana tabbatar da cewa babu abin da aka rasa yayin ƙaddamar da sabon samfur.
-
Gudanar da karatun MSA na yau da kullun. - Ya kamata a yi nazarin Gage R&R akan duk tsarin ma'auni da aka yi amfani da shi don tattara bayanan SPC. Gage R&R wanda ya wuce 30% yana nufin tsarin ma'aunin ku yana ƙara amo mai yawa ga bayanan ku.
-
Gina haɗin gwiwar masu kaya, ba duba kawai ba. - aiki tare da masu samar da kayan don haɓaka inganci mai shigowa. Raba bayanan lahani, gudanar da FMEAs na haɗin gwiwa, da daidaita kan ƙayyadaddun bayanai.
-
Biyan ingancin farashi kowane wata - ba za ku iya inganta abin da ba ku auna ba. Rarraba COQ cikin rukunoni huɗun da ke sama kuma saita rage maƙasudin kwata fiye da kwata.
Amsoshi masu sauri akan kula da ingancin hatimin ƙarfe
Waɗannan amsoshi sun taƙaita yadda ya kamata a ayyana dubawa, takardu, sarrafa kayan aiki, da sarrafa tsari kafin amincewar samarwa.
Wadanne ingantattun sarrafawa ne ya fi dacewa ga sassan da aka hatimi?
Mahimman sarrafawa sun haɗa da duban abu mai shigowa, binciken labarin farko, cakuɗe-haɗe-haɗe, bita na burr, dubawa na ƙarshe, da bayanan ganowa.
Wadanne takardu yakamata masu siye su nema?
Takaddun gama gari sun haɗa da takaddun shaida, rahotannin girma, bayanan dubawa, tsare-tsaren sarrafawa, PPAP lokacin da ake buƙata, RoHS ko REACH, da rahotannin aikin gyara.
Ta yaya ake hana lahani a samarwa?
Ana rage lahani ta hanyar bita na DFM, kulawar kayan aiki, amincewar saitin, ɗimbin kayan aiki tsayayye, duban ma'aikata, ma'auni, da fayyace ma'aunin karɓa.
Tambayoyin da ake yawan yi
Menene bambanci tsakanin Cpk da Ppk a cikin kula da ingancin bugawa karfe?
Cpk yana auna ƙarfin aiwatarwa na ɗan gajeren lokaci ta amfani da bambancin rukunin rukuni (σ a ciki), yayin da Ppk yana auna ƙarfin dogon lokaci ta amfani da bambancin gabaɗaya (σ gabaɗaya). Cpk yana nuna yuwuwar tsarin idan an daidaita shi sosai, yayin da Ppk ke yin lissafin sauye-sauye da ɓata lokaci. A aikace, IATF 16949 yana buƙatar karatun iyawar farko ta amfani da Ppk (mafi ƙarancin sassa 300) da ci gaba da saka idanu ta amfani da Cpk. Cpk na 1.33 ko sama shine daidaitaccen abin da ake buƙata na kera motoci, ma'ana tsarin yaɗuwar ya dace tsakanin haƙuri tare da gefe.
Sau nawa ya kamata a duba mutuwar tambari yayin samarwa?
Mutuwar dubawa ya dogara da kayan, rikitarwa, da ƙarar samarwa. Don tambarin ƙarfe na gabaɗaya da ke gudana a matsakaicin matsakaici, bincika yana mutuwa kowane bugun 10,000-25,000. Don mutuwa mai saurin ci gaba (> 300 SPM) ko kayan abrasive kamar bakin karfe, duba kowane bugun jini 5,000-10,000. Tambayoyi masu mahimmanci ko masu alaƙa da aminci na iya buƙatar bincikar mutuwa kowane motsi. Koyaushe rubuta yanayin mutu da bin tsarin lalacewa don inganta jadawalin kiyayewa na rigakafi.
Wane tsarin samfurin AQL zan yi amfani da shi don duba kayan da ke shigowa?
Don albarkatun kasa mai shigowa (karfe na aluminium), ANSI/ASQ Z1.4 (daidai da ISO 2859-1) Level II na al'ada na yau da kullun shine daidaitaccen aiki. Yi amfani da AQL 1.0 don halaye masu mahimmanci (sunadarai, kaddarorin inji) da AQL 2.5 don ƙananan halayen kwaskwarima ko girma. Don ɓangarorin aminci-mahimmanci ko sabbin masu siyarwa, ƙara matsawa zuwa AQL 0.65 ko aiwatar da dubawa 100% har sai mai siyarwa ya nuna daidaiton inganci sama da kuri'a 5-10 a jere.
Za a iya amfani da SPC don sifa data (wucewa/ gazawa) a cikin tambarin ƙarfe?
Ee. Duk da yake ana fifita bayanai masu canzawa (ma'aunai na gaske) koyaushe don SPC, sigogin sifa suna aiki don fasikanci/ gazawar sakamakon. Yi amfani da p-chart don bin diddigin rabon ɓangarori marasa lahani ga kowane samfuri, ko ginshiƙi na np don ainihin ƙidayar lahani lokacin da girman samfurin ya kasance akai-akai. Siffofin sifofi ba su da hankali fiye da sigogi masu canzawa - kuna buƙatar manyan girman samfurin don gano canje-canje. Idan nau'in lahani yana maimaituwa, yi la'akari da canzawa zuwa ma'auni mai canzawa (misali, auna tsayin burr maimakon fasfo/farar burr burr) don ba da damar ingantaccen saka idanu na SPC.
Menene farashin da aka saba amfani da shi na aiwatar da tsarin kula da inganci don aikin tambari?
Ga wani tsakiyar size bugawa shago (10-30 presses), wani cikakken ingancin management tsarin ciki har da ISO 9001 takardar shaida, asali SPC software, CMM kayan aiki, hangen nesa duba a kan m Lines, da horo yawanci halin kaka $150,000-$400,000 $000 a farkon shekara 1 $1. a cikin farashin aiki na shekara-shekara. Ƙara takaddun shaida na IATF 16949 yana ƙaruwa farashin shekara ta farko da $80,000-$200,000. Koyaya, dawowar yana da mahimmanci: yawancin ayyuka suna ganin ƙimar raguwar raguwar 30-50% kuma da'awar garanti ta ragu 40-70% a cikin watanni 18 na farko na tsarin da aka aiwatar da kyau.
Kammalawa
Kula da ingancin hatimin ƙarfe ba aiki ɗaya ba ne - tsari ne na ƙa'idodi, hanyoyi, matakai, da kuma horo waɗanda ke aiki tare don sadar da daidaitattun sassa masu dacewa. Daga tabbatarwar abu mai shigowa ta hanyar samarwa da SPC ke sa ido zuwa duban CMM na ƙarshe, kowane Layer yana ƙara kariya daga lahani da ke kaiwa abokin cinikin ku.
Mafi inganci masu samar da hatimi suna ɗaukar inganci azaman fa'ida mai fa'ida, ba cibiyar farashi ba. Suna saka hannun jari a cikin rigakafi, bincika ta atomatik inda yake da mahimmanci, kuma suna amfani da bayanai - ba zato ba - don fitar da yanke shawara. Lokacin da ake kimanta abokin haɗin gwiwa na ƙarfe, nemi bayanan Cpk, duba tsare-tsaren sarrafa su, da ziyarci tashoshin binciken su. Ingancin sarrafa ingancin su yana gaya muku duk abin da kuke buƙatar sani.
Shirye don tattauna aikin bangaren aikin ku na gaba? Tuntuɓi ƙungiyar injiniyarmu don duba ingancin buƙatun ku da tsarin sarrafawa.