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論文名稱(中文) 結合設計失效模式與Kano二維模式以改善汽車風扇之品質研究
論文名稱(英文) Combing Design FMEA and Kano Model in Quality Improvement of Vehicle Cooling Fan
校院名稱 成功大學
系所名稱(中) 工業與資訊管理學系碩士在職專班
系所名稱(英) Department of Industrial and Information Management (on the job class)
學年度 105
學期 2
出版年 106
研究生(中文) 趙偉傑
研究生(英文) Wei-Chieh Chao
電子信箱 mm200830924@gmail.com
學號 R37041082
學位類別 碩士
語文別 中文
論文頁數 74頁
口試委員 指導教授-呂執中
口試委員-傅新彬
口試委員-彭泉
口試委員-林耀欽
中文關鍵字 設計失效模式  品質機能展開  Kano二維分析  PWM 風扇 
英文關鍵字 Design-FMEA  QFD  Kano model  PWM Cooling Fan 
學科別分類
中文摘要 台灣汽車零組件產業具有少量多樣與彈性製造優勢,有相當多業者將產品定位在售後服務市場。雖然此產業屬於傳統產業,但由於其產品涵蓋層面相當廣,涉及光學、電機、電子、機械等相關專門技術,也因此為該產業建立相當高的技術門檻。由於能源有限而現有內燃機車輛又對於環境之影響日趨劇烈,所以節能減碳將為全球各大車廠研發趨勢。在此前提下,若要能在下一代汽車綠能零組件市場供應鏈中佔有一席之地,汽車零組件產業者也必須要有綠色科技與環保思維。

因售後服務(AM)汽車零組件本身是參照出廠原車設計(OEM)作為產品規劃主軸,在產品先期設計往往只注重功能性,忽略客戶對於產品之潛在性滿意。在本研究中,專業團隊利用Kano歸類方法進行產品功能、產品材料、產品設計三個構面分析,定義出具有綠色思維之Kano魅力品質因子與設計方向,同時經由失效模式與機能展開彙整出可提升產品附加價值及客戶滿意度之品質要素,發展出品質與客戶滿意度之系統架構。

本研究將以汽車風扇為例,進行本研究系統驗證,根據個案設計參數之分析結果,顯示運用此系統後,汽車零組件業者在滿足客戶之原則下,可尋找出最佳化設計經驗曲線。藉由實際案例的導入,進行本研究系統的驗證,根據個案分析結果,顯示運用此架構後,汽車零組件廠商可了解何種因素會影響其客戶滿意度及能在經營策略上更精準地投投入研發預算與節省成本,在面對市場競爭時,可快速並精準制定符合客戶與市場需求之研發決策,進而提升汽車零組件業者整體競爭力。
英文摘要 Automotive components industry is advantaged in terms of a high-mix low-volume structure and flexible manufacturing system. Many manufacturers position their products in the aftermarket (AM). Since automotive components AM is implemented with reference to the design of the Original Equipment Manufacturer (OEM) during the product design planning process, it usually focuses on the functionality and overlooks the potential customer satisfying ability of the products in the initial stage of product design.

In terms of research methods, a professional team utilizes the Kano model to analyze three aspects: product function, product materials & product design, as well as to define the attractive quality attributes and direction of design, which includes greening ideas. In addition, elements that may increase the added value of products and customer satisfaction level are summarized through the failure mode and effect analysis(FMEA), so as to develop a systematic framework that offers high-quality and high satisfaction level.

In this paper,we uses vehicle cooling fans as an example to verify the system invented by this study. According to the analyzed design parameters in the case study, it shows that automotive components names are able to find the optimized experience curve of design after adopting the system, provided that customers are satisfied.

By introducing the system in real cases and verifying its efficiency, findings show that automotive components manufacturers may understand the factors affecting customer satisfaction level while, in terms of their business strategies, investing resources and saving operational costs in a more accurate manner.
論文目次 摘要 I
Abstract II
誌謝 VII
目錄 VIII
表目錄 XII
圖目錄 XIV
第一章 緒論 1
第一節 研究動機 1
第二節 研究目的 2
第三節 研究流程與架構 3
第四節 研究限制 3

第二章 文獻探討 5
第一節 台灣汽車零組件產業概況 5
第二節 ISO/TS 16949與FMEA架構 7
2.2.1 ISO/TS 16949 架構 7
2.2.2 FMEA架構 9
第三節 Kano二維品質模式 11
第四節 QFD品質機能展開 14

第三章 品質改善架構 16
第一節 研究方法架構 16
第二節 研究方法步驟 17
第三節 Kano 二維模式 18
3.3.1團隊建立 18
3.3.2 Kano二維品質分析 18
第四節 QFD 品質機能展開 20
第五節 D-FMEA 失效模式建立 21
第六節 關鍵品質因子制定 24
3.6.1 資料敘述統計(Descriptive statistics) 24
3.6.2 資料常態檢定(Normality test) 25
3.6.3 管制圖分析(Control chart) 26
3.6.4 製程能力(Analysis of process ) 27
3.6.5 相關分析(correlation analysis) 28
3.6.6 時間序列(Time Series Analysis) 29

第四章 實證分析 30
第一節 汽車風扇技術概述 30
4.1.1 DC直流馬達構造 32
4.1.2 DC直流馬達運轉原理 33
4.1.3 扇葉設計理論 34
4.1.4 脈波寬度調變(Plus-Width Modulation PWM)控制 35
第二節 Kano客戶需求分析 36
4.2.1 團隊建立與歸類分析 36
4.2.2 Kano 品質要素 40
4.2.3 專利探討 42
第三節 產品品質機能規劃與展開 43
4.3.1 汽車風扇先期規劃 43
4.3.2 汽車風扇QFD品質機能展開 44
第四節 汽車風扇之D-FMEA失效模式建立 45
4.4.1 D-FMEA 失效評估表 47
4.4.2 汽車風扇關鍵失效原因與分析 51
第五節 汽車風扇關鍵零件品質驗證 52
第六節 馬達轉矩測試電流數據分析 53
4.6.1 觀測值與敘述統計(descriptive statistics) 53
4.6.2 觀測值常態分配假設 54
4.6.3 小批量試產規範制訂 55
4.6.4 小批量試產管制圖分析 55
4.6.5 小批量試產製程能力指數分析 57
4.6.6 小結 58
第七節 PWM晶片效能相關分析 59
第八節 汽車風扇500小時耐久測試 61
第九節 汽車風扇正式量產之檢驗規範 63
第十節 小結 65

第五章 結論與建議 66
第一節 研究結論 66
第二節 未來研究方向 67

參考文獻 68
中文文獻 68
英文/日文文獻 69
專利文獻 74
參考網站 74
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專利文獻
Ulrich, J., et al. (2014). Cooling fan and method for producing a cooling fan, Google Patents.
Yabe, H. (2009). Electric fan device and method of driving electric fan device, Google Patents.
參考網站
1.財團法人車輛測試中心 https://www.artc.org.tw/
2.台灣區車輛工業同業公會 http://www.ttvma.org.tw/cht/index.php
3.工業研究技術院 https://www.itri.org.tw/chi/index.aspx
4.產業經濟與趨勢研究中心 http://ieknet.iek.org.tw/
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