Optimization On Production Efficiency Of ECU Electrical Testing

This thesis relies on the lean production project of engine control unit in Continental's automotive electronics factory.Its purpose is to improve the production efficiency of the production line,reduce the production cost,improve the order response speed and customer satisfaction,and provide theoretical model and practical experience for long-term continuous improvement.The main three achievements of this thesis are as follows:a.As a part of the engine electronic control unit production line,the softwareand algorithm of the electronic test station are optimized,the chipboundary scan test technology is introduced,and the flashing mode of thesingle-chip microcomputer on the engine electronic control unit product isoptimized.At the same time,the other improved methods are described andevaluated briefly,which will be improved later as future direction.b.On the basis of software optimization and improvement,the hardware of theequipment is also intellectualized.The power control system of the testingmachine is used to control the automatic opening and closing of the testingequipment by the external mechanical arm,hook and cylinder.At the sametime,the ANDON system is installed to improve the visualization andintuitive operation of the testing machine.And standardized operation isadded to reduce operator's difficulty and operation time.c.Achieve a comprehensive record of the test data,and statistical analysisof the running data of the test system.According to the principle of leanproduction,establish a dynamic model among several variables,such as testtime,test machine capacity,one-pass rate,and so on,recalculate anddistribute the test resources for long-term continuous improvement.Based on the SMART principle and from the perspective of production efficiency,several key performance indicators(KPIs)are screened out and KPI improvement objectives are defined.These objectives follow several principles,namely,objectives must be specific,measurable,attainable,the target has a certain correlation with others and must have a definite completion time(Time-bound).Based on these objectives,we optimize and improve these KPIs one by one from three aspects:system software,system hardware and system interaction with production database,in order to achieve the preset goals.At the same time,we prove the effectiveness of lean production theory and the necessity of continuous improvement.This thesis creatively adds a mathematical model to the key performance indicators.Through the double validation of statistical data and empirical data,it has the authenticity and validity under certain conditions,can objectively reflect the law of production activities,and provides an improved input condition.The forward control system is achieved by influencing the input of the mathematical model.From this point of view,this study follows a continuously improved PDCA cycle,that is,plan-do-check-act cycle.As a part of lean production project,besides achieving the goal of improving KPI,the research of this thesis has more practical significance.It can help production managers to eliminate waste,reduce costs,increase customer satisfaction,and get more output with less input.Therefore,the process of data collection and analysis is supported by almost every department of the company.The research results are more convincing and higher gold content based on objective data.