Study On Error Proofing System For Quality Advanced Planning On Automotive Parts

Error-proofing has become indispensable method during manufacturing process and quality control in automotive parts industry, as well as DFMA, Error Proofing Design for X, VR/VA etc., all better deploy prevention methodology. This thesis particularly for error features in manual assembly, builds an error-proofing system in quality advanced planning (or QPIE). It is 3 phases: phase I error-proofing for failure model when prototype design; phase II error-proofing for part features when specific parts design; phase III error-proofing for operation when process design, together with their feedback model.In Chapter 3, error-proofing design for manual assembly is analyzed synthetically, and the study center and the principal base of QPIE are delineated in three aspects of manual assembly management under ISO/TS16949, the features of manual assembly and TQM effects on manual assembly.On human error forecast, 2nd HRA technique CREAM is used, and rather accurate estimation is achieved, that can leverage the need and economy of error-proofing design. On evaluation of QPIE, Fuzzy complicated evaluation model is built, and many fuzzy evaluation index are evaluated to get optimized solution. Finally, this thesis introduces QPIE on one program for Nissan motor, and accomplishes both quality and economic targets.