The Research And Application Of Door Panel Assembly Production In The Filed Of Zero Defect Management

In order to meet the consumers’ individual needs, more and more car manufacturers launched a solution called menu type configuration. Multiple configurations not only reflected in the choice of powertrain, but also embodied in the colors and materials of the interior parts. Facing to the variety of interior parts, on one hand, suppliers step up productions to meet car makers’ Just in Time delivery demand; on the other hand, they spend a lot of effort to choose the right parts of the car to meet the requirements of the flexible manufacturing. Therefore, to find a kind of low cost, high efficiency mistake proofing is the important way to make zero defect management applied.This research intends to analyze general methods of error-proofing of production and delivery in terms of car’s door panel trims in China market including updating the ultrasonic welding machine, adding combined sensor aiming at color and ordinary photo electricity, differentiating between trims by material and color as well as protecting and alarming for missing component by the usage of photographed visual recognition in the final checking process. All of above constitute a whole error-proofing process from production to delivery of car’s door panel trims. At last, this study summarizes advantages and disadvantages of present error-proofing methods and the improvement of the application of Bar-code system in terms of cost, cycle time and quality.Combined with the full automation and not artificial intervention mistake proofing system, makes the company meet the customer’s strict requirements easily, and further to win customers praise, to expand the influence of the company.