六西格玛DMAIC模型在变速器噪声中的应用课程设计.docVIP

六西格玛DMAIC模型在降低变速器噪音中的应用 工业工程课程设计论文 学生姓名：温阳春 指导教师：伍建军 专 业：工业工程 学科门类：工 学 江西理工大学工业工程实验室 二O一五年六月 摘 要 格特拉克IB5变速器一直是从国外进口的，曾应用在很多汽车型号上，以性能稳健博得消费者好评的一款手动变速器，但自从格特拉克（江西）传动系统有限公司引进IB5生产线，并把IB5更名为B5A，进行全面国产化后，B5A变速器的质量问题不断被曝光。本课题以型号为B5A变速器为切入点，通过顾客需求表展开，了解顾客之声（VOC），并针对顾客反映次数最多的变速器异响问题进行研究，把送到售后维修点的B5A变速器进行拆解分析，发现变速器因拉手刹时制动器发生明显异响，通过帕累托图分析发现，制动毂内圆内径超差和制动毂内圆(刹车面)失圆是影响制动器异响质量的主要因素，并进一步将其转化为关键质量特性——制动毂内圆内径尺寸，通过计算其过程能力指数发现质量水平远远达不到6水平。项目组通过建立6sigma DMAIC(Define，Measure，Analyze，Improve，Contro1)业绩改进模型，对搜集的数据用Minitab软件进行分析，并利用鱼骨图、潜在失效模式（FMEA）分析造成制动毂内圆尺寸缺陷的严重度最高的起因——车床的参数（进给量、背吃刀量、切削速度）设置不当，从而提出了一套具体的改进方案，包括SPC过程能力控制，DOE正交实验来择出最优车床的参数（进给量、背吃刀量、切削速度），最后通过实施，SPC指数接近6水平，格特拉克变速器厂提高了汽车变速器的过程能力，改善了噪声过大的质量问题，提高了顾客满意度。 关键词:格特拉克；B5A；制动毂；Minitab；DMAIC ABSTRACT Getrag IB5 transmission has been imported from abroad, has used in many car models, in order to win consumer praise robust performance of a manual transmission, but since GETRAG (Jiangxi) Transmission Co., Ltd. introduced IB5 production line, and The IB5 renamed B5A, after a comprehensive localization, B5A transmission quality problems continue to be exposed. In this paper model B5A transmission as an entry point table by customer demand to start to understand the voice of the customer (VOC), and conduct research for the customer to reflect the highest number of abnormal sound transmission problems to the point of sale maintenance of the transmission B5A be demolished Solutions for analysis and found that transmission occurred due to brake handle instantly obvious abnormal sound, through Pareto diagram analysis found that the inner diameter of the inner circle within the larger brake hub and brake drum circle (brake side) out of round is affecting the quality of the main brake abnormal sound factor, and further converted into key quality characteristics - an inner diameter of the inner circle brake hub, by calculating the process capability index found that the quality level far below the 6 level. Project Group (Define, Measure, Ana