The Application Research On The Quality Improvement Of The Engine Control Unit

Siemens VDO Automotive ChangChun Co., Ltd. establishes in 1995.As the independent proprietorship subsidiary company of German Siemens VDO Automotive Co., Ltd, it follows the customers'requirement and helps them to promote the competition ability with more advanced technique and frist-class product quality.In order to satisfy customer's requirement that the accessory and product should be systematized and integrated, Siemens VDO Automotive Co., Ltd introduces the whole series to China.Siemens VDO Automotive ChangChun Co., Ltd will commit itself to provide advanced innovative technology and high quality product and service continually. It will set up permanent cooperated relation with the external world and achieve the success based on respect, trust and benefit with Chinese enterprises .We have obtained very outstanding result, but there are many aspects need to be improved. I will make use of six Sigma to improve the product line ,based on the MINITAB software.This thesis introduces the basic principle and process of six Sigma. Six Sigma is a management strategy, it can realize the customers'satisfaction to maximize, and make a blemish minimum of cause the customer disaffection. Solving problem is the remarkable characteristic of Six Sigma management. It includes five processes, each one is the basic of next step.In the definition step, the task is to confirm the serious problem and set up a project team with corresponding responsibility an resources to solve problem. In the measuring step, the task is to collect and analyse data, in order to achieve an accurate description of circumstance. Meanwhile, we will get a initial result in this step. In the analysis step ,the task is to put forward the assumption that may cause the problem and find out the root cause through the analysis. In the improving step ,the task is to implement the improvement project to eliminate the problems In the control step , the task is to design and implement the improved plan to prevent the recur of problem and keep the income that the improvement bring. In the generalizing step, the task is to correct other quality problems and find out the improvements to other project using the acquisition of the knowledge, insight and abilities . This thesis also introduces the quality management actuality of the ECU(engine control unit) of Siemens VDO Automotive ChangChun Co., Ltd, including the produce method , the analysis to the quality management actuality of ECU ,the necessity and possibility of design and implement.Six Sigma management has two meanings: First, the quality characteristic has to be satisfied the request of the customers; Second, the quality characteristic formation process should avoid defects and attain the Six Sigma levels.The quality characteristic have to been rightly defined quality to satisfy the request of the customer, with the accurate language to describe the product quality characteristic and full consider to the benefits and cost two aspects. The core characteristic of Six Sigma is the highest customer satisfaction with the lowest resources cost. To customer, it means that acquire a satisfied product in time by the most acceptable price; To business enterprise, it means that carry out possibly biggest profits by the possibly small cost and the possibly short period.The Six Sigma level is more high, the process satisfaction ability to the customer request is more strong, the process appears the possibility of the blemish is more small; Whereas, the Six Sigma level is more low, satisfaction ability to the customer request is more low, the process appears the possibility of the blemish is more big.Now, more and more first-class enterprises in the world seem the six sigma management not only as the quality tool ,but also seem it as the core strategy of the corporate culture and management . It is clear that we have to know the principle of statistics to understand the six sigma at first step. The implement of Six sigma can be seen as a process that measure , analyse the quality characteristic and put forward the implement plan using the principle of statistics.We have six focus factory in our plant and layout is not the same for six focus factory, it's mainly depend on the difference product and difference process for each division in our company. But our focus factory for engine control units layout is according to our lean manufacturing and delete waste and so on. The original layout is consist of SMT center, assembly line and so on. We have totally seven SMT production line, SMT center is managed by one department center, they will arrange production order and customer requirement, and then transfer the conformity product to the next working station by SMT center, and assembly line get the semi-finished product from SMT center, according to our customer order and emergency plan order. We control the process by statistics process control to control our product. Different product and different working station will apply for different control chart, error proofing and so on. We improve our layout for engine control unit production line by six sigma project , we change SMT center from one center to three focus factory such as SC, ED, IC and then each focus factory will manage each division accordingly. We make production plan according to customer order, sample quantity and so on. It's easy for management production line by each focus factory.We often control manufacturing process by first pass yield and evaluate the process good or not in the production line, first pass yield is evaluate manufacturing process quality parameter, that is first through time. Six sigma management is quality method by process continue improvement, excellence, improve customer satisfaction, decrease quality cost. We are the best in the same business .at the meanwhile we have also implemented statistics process control effectively: we continue quality improvement for this six sigma project for one year, we reduction defective rate 50%, DPM decreased from 2561 to 1000, scrap rate is decreased from 0.25% to 0.1% and FPY (first pass yield) is increased, we decrease customer complains, hard saving is 150K RMB. Six sigma management process was more and more better, six sigma management is changed from six sigma improvement to six sigma design, from change quality decrease product cost and process error to design quality ,avoid product error and process problem, six sigma design display especially quality economically.