Research On Quality Improvement Of Boosters Production Line Of Bs Company Based On Total Quality Management

As a well-known foreign-funded enterprise in the auto parts industry,BS company has been playing a leading role.The business of BS company contains the research and development of auto brake system technology and products,production process and solution output.The booster production line of the third factory provides diversified and reliable products for many well-known automobile manufacturers.However,in recent years,the growth rate of the automobile industry in China tends to be flat.The higher requirements of automobile manufacturers for the quality of safety parts and the further increase of the diversification of production line orders make the quality management level of the production line be tested.In June 2018,the non-performing rate of the plant increased significantly year on year,and serious quality accidents occurred twice in the second quarter.Therefore,the factory decided to carry out a new round of TQM optimization.The main quality management problems faced by the vacuum booster production line of the third factory of BS company are as follows: First,the production process is complex,and multiple production departments and processes and production departments shift the responsibility of quality problems to each other,failing to determine the quality bottleneck and the priority of improvement process.Second,in the actual production process,the defective parts of some parts flow into the next process without timely containment,which leads to a large amount of labor cost wasted during the full inspection of the finished products;Third,the quality awareness of workers is not strong,some workers with long service life and new employees lack of quality awareness,blindly pursue production,resulting in the increase of the defective rate of some processes.The research of this paper has taken TQM theory as the core guiding ideology,used failure mode and consequence analysis,measurement system analysis and statistical process control as the main tools,and mainly completed the following work: First,using FMEA method to make a comprehensive analysis of the failure mode and impact of vacuum booster,and found out the reasons of human,machine,material,method,environment,measurement and other aspects,The urgency of various failure modes and their cause improvement is evaluated by calculating the sequence number of evaluation risks,and the quality characteristic of the thickness of self-produced membrane plate is confirmed as the main research object in the follow-up;Second,the measurement system is analyzed as the premise of statistical process control,and the measurement system of the quality characteristic of the thickness of membrane plate corresponding to the production line is comprehensively analyzed.Its stability,repeatability and reproducibility,bias and linearity were evaluated.It is confirmed that it is qualified as a measurement system,and it also provides a way to further optimize the measurement system.Third,taking statistical process control and process capability index as the core theory,the quality of film stamping process was monitored,evaluated and improved,and the process was analyzed and evaluated again after improvement.It was found that the process capability index rose from unacceptable 0.69 to normal 1.47,the whole production process did not lose control again after improvement,and the product quality was significantly improved Upgrade.Through the research on the quality management of the vacuum booster production line from macro to specific process,this paper provides a reliable case of quality management improvement for manufacturing enterprises,especially for auto parts industry,and also provides an effective reference for the application of TQM ideas and tools in production practice.The paper has 32 pictures,15 tables and 66 references.