Upload
others
View
22
Download
0
Embed Size (px)
Citation preview
. . 2556
16-18 2556
ISO/ TS16949
A Design Of Product Development Process For New Product Model Certified
With ISO/ TS16949
1* 2 1,2
E-mail: theerawa @ buu.ac.th*
Theerawat Somsirikarnjanakoon1* Anawat Booncharoen2
1,2Department of Industrial Engineering, Faculty of Engineering, Burapha University
E-mail: theerawa @ buu.ac.th *
ISO/ TS16949
(EGR Pipe) : Ø25.4x220Lx5N
PERT
2
28 ISO/ TS 16949 25
3 10.71%
ISO/ TS16949
Abstract
The objective of this research is to design the product development process for the new product model
corresponding to the ISO/ TS16949 certification. This study also aims to control the duration of the product development project as required by the customers. The new process proposed in the research
was designed with emphasis on the reduction of product cost and non-value added activities, while the
product qualities were maintained. In addition, the new process was flexible to the product changed by the customer order and the requisition for annual price reduction. This study designed the product
development process for the exhaust gas recirculation pipe modeled EGR Pipe: Ø 25.4x220Lx5N. The project tasks were studied and controlled to finish the project on time as required by the customers
or the co
applied inwas 28 w
25 weeks
Keyword
1.
(Cost D
(Lead t
ISO/TS16
TS 16949
ompany finish
n this study. Tweeks, where
s. In other wo
ds: Product D
Down)
ime)
6949 ISO
9
hing time targ
The results ofas the duratio
ords, 10.71% t
Development,
(N
ISO/ TS 1
9001
ISO/ TS
(EGR
(
get of 25 day
f the study shon of the proj
time reduction
Process, New
ew Model)
16949
1 6 9 4 9
R Pipe)
(New Mode
ys. Project ma
howed that duject for the ne
n was accom
w Product Mo
l) ISO/
2.
TS
3.
3.1
anagement te
uration of the ew process c
plished.
odel, Certifica
(EGR Pipe
16949
: Ø25
1 2
1
2
16-1
echnique inclu
project beforeertified with IS
tion of ISO/ T
e)
5.4x220Lx5N
Ø25.4x220Lx
18 2556
uding PERT
e the improveSO/ TS16949
TS 16949
ISO/ T (EGR
(EGR Pip
x5N
. . 2556
was
ement 9 was
ISO/
TS 16949 R Pipe)
pe) :
ISO/ TS
. . 2556
16-18 2556
16949 7-8 7
1 3
1 (New Model)
ISO/ TS 16949
( )
A
1 -
B 1 A
C* 2 B
D** Dummy 0 C
E* / , ,
, , ,
2 B
F
1 D(C),E
G 2 F
7
3
ISO/ TS 16949
PERT
(EGR Pipe) : Ø25.4x220Lx5N 2
3
2
(New Model) ISO
A
B
C*
D* (APQP Plan)
E** Dummy
F / , , ,
G
H*
I*
J** Dummy
K PPAP
L (Sign Off)
3
( )
a m b t
A - 1 1 1 1 0.00
B A 1 1 1 1 0.00
C* B 1 1 1 1 0.00
D* B 1 1 1 1 0.00
E** C 0 0 0 0 0.00
F D,E 2 3 4 3 0.11
G F 2 3 4 3 0.11
H* G 8 12 16 12 1.78
I* G 8 12 16 12 1.78
J** I 0 0 0 0 0.00
K H,J 1 1 1 1 0.00
L K 1 2 3 2 0.11
: C,D H,I
(*), E J Dummy (**)
(Critical Path)
4
. . 2556
16-18 2556
4
(Critical Path) 4
1) A 1-2-3-4-5-6-7-9-10-11= 24
2) B 1-2-3-5-6-7-8-9-10-11 = 24
3) C 1-2-3-5-6-7-9-10-11 = 24
4) D 1-2-3-4-5-6-7-8-9-10-11= 24
24
6
= 2.112
24 50% 25
75.49% 26 91.62%
25 F /
, , , , , / , ,
/ 3 4
3.2
(EGR Pipe) ISO/TS 16949
1. (1
) 1.
(2 ) 2.
(4 ) 3. (2 )
2 1 4
4
Plan Actual
2. (Feasibility New Model, 1 ) 1.
(2 ) 2.
(2 ) 3.
(3 ) 4.
(2 )
1.
2. , , ,
(Gauge Check)
. . 2556
16-18 2556
,
3.
5
5
3. (1 )
1. Process Flow Chart Control Plan (7 ) 2. FMEA
(7 ) 3.
Drawing (3 ) 4. Drawing Drawing
(4 ) 5. (WI) (7 ) 6.
(Check Sheet) (7 ) 7.
(Inspection Standard) (7 ) 8. (Packing Standard) (7
) 9. (7 )
4. (APQP
Plan) (1 ) 1.
, (5 ) 2. (APQP Plan)
(2 ) 1
1 5
5 (APQP Plan)
5. / , , , , , (4 ) 1.
(4 ) 2.
(7 ) 3. , , , , ( ) (5 ) 4.
(21 ) 5. / ,
, , , (21 ) 6. / , , , (7 ) 6
6 / , ,
INABA (THAILAND) CO.,LTD.
: Yarnapund (Public) Co.,Ltd. : 06-Jun-2011
: Bellow Pipe "EGR Pipe" : SUS 304 (0.8 x 78.1)
: Ø25.4x220Lx5N (1582A151-01) Model : MMT-031-01
( )
1) , ,
(Spec New Model)
2) (Capacity)
3) (
)
4) Material
( Supply , )
5)
( )
6) / ( )
( Process)
8) Tooling Supports
(Jig & Fixture)
9) Plant Lay Out
( )
(Mold)
New Model 15-20 1-2
Supplier Stock
Order Order
/ Factory Manager / 6-Jun-2011 / PC Manager / 6-Jun-2011
/ Quality Control Manager / 6-Jun-2011 / Supervisor / 6-Jun-2011
/ Supervisor / 6-Jun-2011 / Supervisor / 6-Jun-2011
/ /
/ /
/ /
/ /
/ /
/ /
. . 2556
16-18 2556
1 1
6.
(3 ) 1. (3 ) 2.
(3 ) 3. (3 ) 4. , ,
, , (3 ) 5. (3 )
6. (3 ) 7. (3 ) 8. (15 )
9. Ppk
(15 ) 10. /
(15 ) 11. (Sample Product) (3 ) 12.
(21 ) (Trial
New Model)
30-50 (100%)
/ Ppk
Ppk 1.67 ISO/
TS16949 Ppk 7
(Sample Product)
(Inspection Data)
7. (12 ) 1.
(14 ) 2. (14 ) 3.
7 Ppk
, , , (14 ) 4.
(14 ) 5. (7 ) 6. (Mass
Production) (12 ) 7. Cpk (12 ) 8. /
(12 ) 9. 100% (12 ) 10.
MSA, FMEA, SPC, QC 7 Tools (12 ) 8
8
. . 2556
16-18 2556
1 4
2554
2554 (100%) 3
(First Stage Control) (Customer Complain) /
(Customer Claim)
Cpk ( 1.33) 9
(%NG)
2554 10
8. (12 ) 1. Process Flow Chart, Control
Plan (7 ) 2. FMEA (8 )
3. (14 ) 4. MSA (14 ) 5.
(14 ) 6. PPAP (14 )
9 Cpk
( Cpk)
1 3 Pipe
O.D
Ø25.4
+ 0.2
1.39 1.35 1.36
2 4 Bellow
O.D
Ø34.1
+ 0.5
1.35 1.34 1.35
3 6 Pitch
Dimen
sion
Ø 26.4
+ 1.0
1.43 1.57 1.59
4 9 Total
Length
220.0
+ 3.0
2.29 2.27 2.62
5
10 (%NG)
- 2554
3%
1 Pipe Forming
& Cutting 1.5% 0.57 0.69 0.55
2 Bellows
Forming 1.5% 1.20 1.13 0.60
3 3.0% 1.77 1.82 1.14
9. PPAP (1 )
1. PPAP (5 ) 2. PPAP
(2 )
10. (Sign Off) (2 ) 1. (
1-2 ) (2 ) 2.
(2 ) 11
11 (Sign Off)
4.
(New Model) ISO/TS 16949 (EGR
Pipe) : Ø25.4x220Lx5N 2
1
(New Model) ISO/ TS 16949
. . 2556
16-18 2556
2 (EGR Pipe) : Ø25.4x220Lx5N
1
ISO/TS 16949 28
ISO/ TS 16949 25
(New Model)
(EGR Pipe) : Ø25.4x220Lx5N
25 3 ( 10.71%)
2 (Pipe Forming & Cutting)
,
(Grinding)
() 12
12
1.
28 25 3
( 10.71%)
2.
7 5
2
3.
7 5 2
12
( )
4.
7 5 2
5.
690 250 440
( % 63.77%)
6.
- Pipe
Forming &
Cutting
700 900 200
( 28.57%)
- Pipe
Chamfer 700 700 -
- Bellows
Forming 700 700 -
- Leak
Test 1,400 1,400 -
7.
(Scrap)
Pipe Cutting
to Size
(1 30
mm; 1 70
; 2,100
mm)(1 mm.
= 0.48 g;
2,100 x 0.48
= 1.0 Kg)
-
2,100 mm.
(1 Kg.) (Scrap)
2,100 mm.
(1 Kg.) (
25
25 Kg.
8.
(NG)
3.0%
3.0% 1.77%,
1.82%,
1.14%
(
, ,
.54)
. . 2556
16-18 2556
2555 1 1 0 / 2 5 5 5
[1] , (MSA), ( -
), 19 - 113 [2] ,
2, ( -
), 261 � 290, 367 - 407 [3] ,
, ( - ), 135 � 173, 249 �
252 [4] ,
ISO/TS 16949:2009, 34 � 229, 2553. [5] , ,
[6] , , , 274 � 284
[7] ,
, 2551.
[8] ,
, 2552
[9] Kachen Impro Consultant, (APQP),
ISO/TS16949:2009, 2553. [10] Kachen Impro Consultant,
(FMEA),
ISO/TS16949:2009 [11] Kachen Impro Consultant,
(MSA),
ISO/TS16949:2009, 2553. [12] Kachen Impro Consultant,
(SPC),
ISO/TS16949:2009, 2553. Physical Review Letters, 82: 4671-4674.