PECASE: A Unified Methodology for Variation Management and Reduction in Multistage Manufacturing Processes

提案标题：PECASE：多阶段制造过程中差异管理和减少的统一方法机构：亚利桑那大学这项PECASE赠款资助研究和教学工作，以开发多阶段制造过程(MMP)中差异管理和减少的统一方法。制造过程通常涉及多道工序来生产一个产品，这在许多工业过程中都可以找到，如汽车车身装配、加工生产线、级进冲压和半导体制造。在多道工序图中，每个操作在没有故障发生时添加固有的设计变化，以及在出现故障时将特殊的可分配变化添加到工件变化中。一道工序的输出件就是下一道工序的输入。最终的产品偏差是所有操作的偏差的累积。因此，MMPs的变异传播特征是非常复杂的，这取决于产品和工艺设计。该项目的研究工作将制定方法，通过同时解决设计和制造问题，以最小的差异实现目标生产。研究的重点是发展：(A)一个基于数学的模型，用于描述变异在制造过程中的传播；(B)通过设计综合和优化来管理变异的综合方法；(C)由工程模型驱动的统计方法，用于快速识别根本原因和预防产品缺陷。除了研究，还将开发新的课程和课程。该项目将与工业界、国际大学和K-12学校在研究和教育方面进行各种合作。如果成功，该项目结果将丰富MMP在减少差异和过程控制方法方面的科学基础和技术，其中包括：(A)分析(而不是经验)对MMP变化及其传播的建模；(B)合成(而不是分析)产品/过程容差，以优化管理固有设计变化，将其对最终产品的影响降至最低；(C)实时识别根本原因(而不是变化检测)，用于制造过程控制和持续改进；以及(D)在整个制造生命周期中预防缺陷的预测(而不是缺陷检查)。开发的统一方法将在使用MMP的工业部门产生重大的经济影响。该项目最初是作为职业奖资助的，并于2004年5月转换为总统工程师和科学家早期职业奖(PECASE)奖。

Proposal Title: PECASE: A Unified Methodology for Variation Management and Reduction in Multistage Manufacturing ProcessesInstitution: University of ArizonaThis PECASE grant sponsors research and teaching efforts in developing a unified methodology for variation management and reduction in Multistage Manufacturing Processes (MMPs). A MMP generally involves multiple operations to produce a product, which can be found in many industrial processes such as automotive body assembly, machining lines, progressive stamping, and semiconductor manufacturing. In a MMP, each operation adds inherent design variation when no fault occurs, and special assignable variation when a fault occurs, to the workpiece variation. The output workpiece of one operation is the input of the next operation. The final product variation is an accumulation of variation from all operations. Therefore, the characteristics of variation propagation is very complex in MMPs, depending on both product and process design. The research efforts in the project will develop methodologies to achieve on-target production with minimum variance by addressing both design and manufacturing concurrently. The research focus is to develop: (a) a math-based model to describe the variation propagation in a MMP; (b) an integrated methodology for variation management through design synthesis and optimization; and (c) statistical methods driven by engineering models for quick root cause identification and product defect prevention. In addition to research, new curriculums and courses will be developed. Various collaborative efforts with industry, international universities, and K-12 schools will be conducted in research and education in the project.If successful, the project results will enrich the science base and technologies in variation reduction and process control methodologies for MMPs, which include: (a) analytical (rather than empirical) modeling of MMP variation and its propagation; (b) synthesis (rather than analysis) of product/process tolerance for optimal management of inherent design variation to minimize their impact on final products; (c) real-time root-cause identification (rather than change detection) for manufacturing process control and continuous improvement; and (d) prognostics (rather than defect inspection) for defect prevention throughout the manufacturing lifetime. The developed unified methodology will generate significant economic impacts in industrial sectors where MMPs are used.This project was originally funded as a CAREER award, and was converted to a Presidential Early Career Award for Engineers and Scientists (PECASE) award in May 2004.