Modeling, Analysis, and Control of Variation Propagation in Manufacturing Processes

制造过程中变异传播的建模、分析和控制

• 批准号: 0322147
• 负责人: Shiyu Zhou
• 金额: $ 17.56万
• 依托单位: University of Wisconsin-Madison
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2003
• 资助国家: 美国
• 起止时间: 2003-09-01 至 2007-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0322147&HistoricalAwards=false
• 关键词: Modeling; Analysis; Control; Variation; Propagation

This grant provides funding for the development of a methodology for modeling, analysis, and control of variation propagation in complicated manufacturing processes. Process variation and inconsistency are the major quality concerns in a manufacturing process. For a complicated manufacturing process involving multiple operation steps, the process variation at different steps will be accumulated on the product and propagates along the process. This project aims at developing a systematic methodology to describe and reduce the process variation and hence improve the process quality. A quantitative variation propagation model will be developed. Both analytical and empirical methods based on product/process design and engineering knowledge are used to link the key process variation sources and key product quality characteristics in this model. This quantitative model allows system theory and advanced statistical techniques (e.g., variance component analysis of linear mixed models) to be adopted in order to conduct forward and backward analysis of variation propagation. The forward analysis can identify important process stages and provide guidelines for design improvement, while the backward analysis can quickly identify the root causes of quality variations. The research results will be finally validated in industrial settings.If successful, this research project will contribute to the science base of process control and quality improvement for manufacturing processes. Using the developed methodology, vast amounts of information from product design, process design, in-process sensing, and product quality inspection will be integrated under a quantitative model. This integrated model lays a foundation to develop effective techniques of variation propagation analysis and quick variation root cause identification. Effective implementation of the developed methodology in industry will provide a set of powerful tools for computer-aided product/process design and process monitoring and diagnosis for variation reduction, and thus provide a competitive boost to U.S. industry. The research accomplishments will be transferred into undergraduate and graduate curricula as well, which will generate long-term impact on the education of quality engineering and manufacturing.

该赠款为开发复杂制造过程中建模，分析和控制变异传播的方法的发展提供了资金。过程变化和不一致是制造过程中的主要质量问题。对于涉及多个操作步骤的复杂制造过程，将在产品上积累不同步骤的过程变化并在过程中繁殖。该项目旨在开发一种系统的方法来描述和减少过程变化，从而提高过程质量。将开发一个定量变化传播模型。基于产品/过程设计和工程知识的分析和经验方法均用于将关键过程变化源和关键产品质量特征联系起来。该定量模型允许采用系统理论和先进的统计技术（例如，线性混合模型的方差分析分析），以便对变异传播进行正向和向后分析。远期分析可以确定重要的过程阶段，并为设计改进提供指南，而向后分析可以快速识别质量变化的根本原因。研究结果将最终在工业环境中进行验证。如果成功，该研究项目将有助于制造过程的过程控制和质量改进的科学基础。使用开发的方法，将在定量模型下集成了产品设计，过程设计，过程中传感和产品质量检查的大量信息。该集成模型为开发有效的变异传播分析和快速变异根本原因识别的有效技术奠定了基础。有效地实施开发的工业方法将为计算机辅助产品/过程设计和过程监控和诊断减少变化，从而为美国行业提供竞争力的增强。研究成就也将转移到本科和研究生课程中，这将对质量工程和制造业的教育产生长期影响。