Study Of Performance Shaping Factors On Human Factor's Quality Accident In Automotive Electronic Components' Assembly Process

With the development of science and technology, the production system becomes more automated, and the reliability of equipments is improved greatly. However, the relative inaccuracy rate caused by human is increased instead of being decreased, and human errors have gradually become the primary reason for quality accidents. At the same time, Total Quality Management, the third stage of quality management, has come, which emphasizes "people-oriented" and "full participation"; and highlights the core status of human. Therefore, it's imperative under the situation to combine the researches in the field of human reliability and quality management.At present, interiorly, it's infrequent to research human reliability in the field of quality management. This thesis is to research the factors which affect human reliability in the accidents caused by human, according to automobile electronic industry, especially the automotive electronic components' assembly process. Finally, it distinguishes the primary performance shaping factor.The study purpose, significance and study route are introduced in the first chapter. According to analyze the current situation of the automotive electronic components' assembly process, the operators' behavior mode and causal diagram of inaccuracy are built. The primary performance shaping factors that affect operators' behaviors are identified. And these factors from both theory and practice are analyzed. In this chapter it provides theoretical basis for improving human reliability, as well as grounds for researching human reliability in the field of quality management.In the second chapter, the current research situation of human reliability and its application profile, and how to emphasize the role of human in various stages of quality management are introduced. On the basis of the above-mentioned theory, the concept and research characteristics of human factor's quality accident are proposed. In the end of this chapter, two research methods used in this thesis are introduced. One of them is to make complicated human factor simple and mechanical, by using which it is easier to establish mathematical model. The other is to research human errors from cognitive perspective.The third chapter discusses the research and development of performance shaping factors. In accordance with actual production situation, based on the "Stimulus-Organism-Response" cognitive model, the operators' behavior model is constructed, and the causal diagram of inaccuracy is outlined. Combining with the views of experts, some important factors of behavior are selected, and the selected factors are analyzed by using principal component analytical method. Finally, the "workload" is considered to be the primary performance shaping factor. The identification about the primary performance shaping factor in human factor's quality accident in automotive electronic components' assembly process is finished.The fourth chapter introduces workload mechanism from the point of energy consumption. Combining with actual production situation, in the light of the standard of classifying labor intensity made by Japan Energy and Efficiency Association, operators' workload are divided into three grades. Human error model is established under the condition of changed workload levels. The average human error time and switch rate between various states are calculated, and the relationship of human error under various state is concluded. Ultimately, the key to reduce human error is proved to reduce the workload.In the fifth chapter, Quick Exposure Check (QEC) by combining with characteristics of automotive electronic components industry is improved, that the contents of the neck assessment are enriched, and crura assessment entries are added. In accordance with the principle of interaction among factors, in the framework of the original QEC methods, the improved QEC score table is constructed and the workload of the operators who are responsible for quality accidents in the workshop has been assessed. The assessment results have shown the advantages of improved QEC. Compared with assessment results and statistics datum of quality accidents, it certificates that workload is the primary performance shaping factor which causes quality accidents. At the same time, compared with two operators' workload, it shows that the workload of the operators who make worse production quality is higher than another, which means that workload is closely related to production quality. Finally, corresponding improved measures is proposed based on the evaluation results as reference for enterprises. In summary, operators' behavior mode and causal diagram of inaccuracy is built and human factors which cause quality accidents are identified by using principal component analytical method. With the actual production situation and related research papers, workload of the operators in automotive electronic components assembly process is divided into three grades and the human error model is established under the condition of changed workload levels. At the same time, the QEC is improved according to the characteristics of automotive electronic industry, and then the workload of the operators who are responsible for quality accidents in a workshop is assessed by using the improved QEC. According to analyze assessment results, the workload is proved to have an important impact on quality. Because of the limitation of author's knowledge and time, only workload is studied deeply in this thesis. It needs to research other performance shaping factors in future.