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系統識別號 U0002-1001201211580400
中文論文名稱 建構整合FMEA、TRIZ及AHP研發創新工具之產品改良決策程序--以車用沖壓零件為例
英文論文名稱 Constructing Integrated FMEA, TRIZ, and AHP Methods for an Innovative Product Improvement Decision Process using the Automobile Vehicle Stamping Product
校院名稱 淡江大學
系所名稱(中) 管理科學學系企業經營碩士在職專班
系所名稱(英) Executive Master’s Program of Business Administration(EMBA) in Management Sciences
學年度 100
學期 1
出版年 101
研究生中文姓名 潘曉鋒
研究生英文姓名 Hsiao-Feng Pan
學號 798620281
學位類別 碩士
語文別 英文
第二語文別 中文
口試日期 2011-12-17
論文頁數 68頁
口試委員 指導教授-林長青
委員-郭人介
委員-牛涵錚
中文關鍵字 失效模式分析  創新問題解決理論  分析網路程序法  創新設計  車用沖壓零件 
英文關鍵字 FMEA  TRIZ  AHP  Innovative Design  Automobile Vehicle Stamping 
學科別分類
中文摘要 由於科技的發展快速,消費性產品市場的競爭也日趨激烈,綜合這些因素進而導致產品生命週期快速縮短。因此企業必須不斷推出新產品或新服務來滿足市場需求,同時維持本身的競爭優勢。傳統的產品研發過程,於開發完成後缺乏整合性的設計改善以及開發評估工具,針對產品在開發生產過程當中,顧客需求與產品生產所可能發生的問題改善的方法、選擇及測試的發展階段,對於生產產品改良的創新思考較無具體工具得以應用,產品改良方法的評選也沒有明確的量化工具。因此,在此階段如何去發展產品設計改良開發的規劃模式,妥善地整合客戶需求,並進行產品創新且挑選最佳的產品方案,將是本研究的動機與目的。
本研究利用三個方法的結合,包括了失效模式分析 (FMEA) 、TRIZ創新理論及分析層級程序法 (AHP) ,在產品設計改良開發的概念發展建立一套評選的程序模式。研究中首先以FMEA作產品實際生產階段中所可能衍生的問題作一闡述並針對可能造成顧客端品質問題因素作階段展開,同時將失效模式與效應分析中的風險優先係數(RPN)實施評估,並提列矯正與預防措施的有效性。在針對須實行改善需求的項目以創新解決問題理論(TRIZ)作為產品設計改良方向時的創新方法構思程序以及衝突檢驗工具的重要依據;進而透過FMEA分析的RPN風險係數須立即改善項目,由TRIZ產生的改良創新概念方案,將目標及各方案與屬性建立起階層關係,同時考量各方案與屬性之間的矛盾影響,並展開成網路架構;輔以AHP法作成對比較以求得相對權重來進行產品改良方案概念的評選及決策。
本研究將以車用沖壓件之製作改良設計的實際案例進行實證分析。驗證在產品製作改良設計與改良開發過程中,建立選擇改良方案發展的評選流程模式,以提供研發人員作為相關的決策參考。
英文摘要 Because of the recent growth of technology improvement, market competition toward products has become intense. This situation has caused a short product life cycle, forcing enterprises to present new products and services to satisfy continual market demand in efforts to maintain competitive advantage. Traditional product research and development processes for new products lack integrated design improvement and estimation of development tools. Therefore, no proper tool exists to estimate/judge real production, which might cause a potential risk to customers. How to develop a product design improvement model to meet customer demand and select the optimal product improvement/corrective solution is the study background and motivation for this research.
This study integrates three major methods, including the FMEA (Failure Mode Effective Analysis), the TRIZ, and the analysis hierarchy process (AHP) as a system to build an evaluation model in the product improvement phase of the product design and development stage. This study first uses the FMEA method to extend the possible quality problem and the potential risk on the customer side. This research then investigates the Risk Priority Number (RPN) in each production process and focuses on the RPN to find the necessary corrective action. This work defines the top major failure item, and uses the TRIZ as the reference background and the product analysis system. An expert questionnaire sets the target and sums up each criterion to build a hierarchy relationship. The AHP method is used for pair comparison.
This paper uses the automobile stamping product as an illustration to provide a relevant decision-making reference for R&D personnel, and sets up a model of concept development for product design and development.
論文目次 Contents
CHAPTER 1 INTRODUCTION 1
1.1 BACKGROUND AND MOTIVATION 1
1.2 RESEARCH METHODOLOGY AND GOAL 2
CHAPTER 2 LITERATURE REVIEW 4
2.1 FMEA (FAILURE MODE AND EFFECTS ANALYSIS) 4
2.2 THE BACKGROUND OF FMEA 4
2.3 D FMEA AND PFMEA 6
2.4 ESTIMATION OF THE RISK PRIORITY NUMBER 8
2.5 THEORY OF INVENTIVE PROBLEM SOLVING (TRIZ) 11
2.6 ANALYTIC HIERARCHY PROCESS (AHP) 21
CHAPTER 3 RESEARCH METHODOLOGY 27
3.1 FMEA ANALYSIS AND STUDY METHOD 28
3.2 BUILDING FMEA STEPS 29
3.3 TRIZ FOR GENERATING AN INNOVATION IMPROVEMENT SOLUTION 30
3.4 COMPOUNDING THE INNOVATION CONCEPT AS THE IMPROVEMENT SOLUTION 31
3.5 BUILDING THE IMPROVEMENT SOLUTION ESTIMATE STRUCTURE 33
3.6 DETAILED EXPLANATION FOR THE ESTIMATE STRUCTURE 34
3.7 SOLUTION ESTIMATE MODEL 35
3.8 DESIGN FOR THE IMPORTANCE NOMINAL SCALE LIST 37
CHAPTER 4 CASE STUDY 41
4.1 QUALITY CERTIFICATION IN FMEA 42
4.2 TRIZ IMPROVEMENT CONCEPT 44
4.3 AHP FINAL SOLUTION SELECTION 49
4.4 AHP DATA ANALYSIS 51
4.5 CHOOSING THE FINAL IMPROVEMENT SOLUTION 53
CHAPTER 5 CONCLUSIONS AND SUGGESTIONS 55
5.1 CONCLUSION AND REVIEW 55
5.2 MODEL BENEFIT AND DISCUSSION OF MANAGEMENT 56
5.3 STUDY LIMITATIONS AND REVIEW 56
5.4 STUDY CONTRIBUTION 57
5.5 FUTURE STUDY SUGGESTIONS 57
REFERENCES 59
APPENDIX A 61
APPENDIX B 62

Figure Contents
FIGURE 1-1 FLOWCHART OF THE RESEARCH. 3
FIGURE 2-1 FMEA PROCEDURE 7
FIGURE 2-2 TRIZ STRUCTURE 12
FIGURE 2-3 TRIZ CONTRADICTION SOLVING FLOW 14
FIGURE 2-4 BASIC S-FIELD MODEL. 18
FIGURE 2-5 AHP HIERARCHY DIAGRAM 22
FIGURE 2-6 AHP FLOW CHART 23
FIGURE 3-1 STUDY PROCESS FLOW 28
FIGURE 3-2 CONCEPT RESULT FLOW OF TRIZ 31
FIGURE 3-3 IMPROVEMENT SOLUTION ESTIMATE STRUCTURE 33
FIGURE 3-4 IMPROVEMENT SOLUTION ESTIMATE FLOW 36
FIGURE 4-1 PARTS PHENOMENON COMPARISON 42
FIGURE 4-2 ANALYSIS BY PROBLEM ESSENCE 45
FIGURE 4-3 PRINCIPLES 5 AND 7 47
FIGURE 4-4 RIVET DESIGN 47
FIGURE 4-5 IMPROVEMENT SOLUTION A 48
FIGURE 4-6 PRINCIPLES 10 AND 34. 48
FIGURE 4-7 IMPROVEMENT SOLUTION B 49
FIGURE 4-8 MAIN FRAME OF IMPROVEMENT SOLUTION 50

Table Contents
TABLE 2-1 FMEA DEVELOPMENT COURSE INFORMATION: CHARTERED, LTD (1996) 5
TABLE 2-2 RECOMMENDED ESTIMATE STANDARD FOR SEVERITY IN PFMEA. 9
TABLE 2-3 RECOMMENDED ESTIMATE STANDARD FOR OCCURRENCE IN PFMEA. 10
TABLE 2-4 RECOMMENDED ESTIMATE STANDARD FOR DETECTION IN PFMEA. 10
TABLE 2-5 INNOVATION LEVEL & DEFINITION 13
TABLE 2-6 39 ENGINEER PARAMETERS (6 GROUPS) 16
TABLE 2-7 CONTRADICTION MATRIX EXAMPLE 17
TABLE 2-8  SEPARATE PRINCIPLE OF PHYSICAL CONTRADICTION 17
TABLE 2-9  40 PRINCIPLES 18
TABLE 2-10 REPRESENTATIVE MEANING OF THE LINE IN S-FIELD 19
TABLE 2-11 76 STANDARD ANSWER 19
TABLE 2-12 ARIZ PROGRESS FLOW 20
TABLE 2-13 37 TREND CHART 20
TABLE 2-14 ANALYTIC HIERARCHY PROCESS COMPARISON MATRIX SCALE. 24
TABLE 2-15 RANDOM CONSISTENCY. INFORMATION: SAATY(1995) 26
TABLE 3-1 FMEA COLUMN 29
TABLE 3-2 EXAMPLE FOR CONTRADICTION ITEM AND INNOVATION CONCEPT CONSTITUTE LIST. 31
TABLE 3-3 OPPOSITE IMPORTANCE SCALE 37
TABLE 3-4 SECOND LAYER IMPORTANCE ANALYSIS 38
TABLE 3-5 THIRD LAYER OF THE IMPROVE TECHNOLOGY FACTOR IMPORTANCE ANALYSIS. 38
TABLE 3-6 THIRD LAYER OF THE FINANCE FACTOR IMPORTANCE ANALYSIS. 39
TABLE 3-7 THE THIRD LAYER OF THE INNER/ OUTER ENVIRONMENT FACTOR IMPORTANCE ANALYSIS. 39
TABLE 3-8 THIRD LAYER OF THE INNER/ OUTER ENVIRONMENT FACTOR IMPORTANCE ANALYSIS. (CONTINUE) 40
TABLE 4-1 FMEA INDICATION 43
TABLE 4-2 ANALYSIS BY PROBLEM ESSENCE 45
TABLE 4-3 LAYER 2 CALCULATION RESULT 51
TABLE 4-4 LAYER 3 IMPROVEMENT TECHNOLOGY FACTOR CALCULATION RESULT. 51
TABLE 4-5 FINANCE FACTOR CALCULATION RESULT. 52
TABLE 4-6 INNER/ OUTER ENVIRONMENT FACTOR CALCULATION RESULT. 53
TABLE 4-7 IMPROVEMENT SOLUTION A & B CALCULATION RESULT. 53
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English
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