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

PECASE：多阶段制造流程中的变异管理和减少的统一方法

• 批准号: 0549306
• 负责人: Jionghua (Judy) Jin
• 金额: --
• 依托单位: Regents of the University of Michigan - Ann Arbor
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2005
• 资助国家: 美国
• 起止时间: 2005-07-01 至 2008-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0549306&HistoricalAwards=false
• 关键词: PECASE; Unified; Methodology; Variation; Management

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.

提案标题：PECASE：多阶段制造过程中的变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) 中的变异管理和减少的统一方法。 MMP 通常涉及多种操作来生产产品，这可以在许多工业流程中找到，例如汽车车身装配、加工线、级进冲压和半导体制造。在 MMP 中，每个操作都会将未发生故障时的固有设计变化以及发生故障时的特殊可分配变化添加到工件变化中。一次工序的输出工件是下一次工序的输入。最终产品的变异是所有操作变异的累积。因此，MMP 中的变异传播特性非常复杂，取决于产品和工艺设计。该项目的研究工作将开发方法，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。研究重点是开发： (a) 一个基于数学的模型来描述 MMP 中的变异传播； (b) 通过设计综合和优化进行变异管理的综合方法； (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。除了研究之外，还将开发新的课程和课程。该项目将在研究和教育方面与业界、国际大学和 K-12 学校进行各种合作。如果成功，该项目成果将丰富 MMP 变异减少和过程控制方法的科学基础和技术，其中包括：（a）MMP 变异及其传播的分析（而不是经验）建模； (b) 综合（而不是分析）产品/过程公差，以优化管理固有设计变异，从而尽量减少其对最终产品的影响； (c) 实时根本原因识别（而不是变化检测）以进行制造过程控制和持续改进； (d) 在整个制造生命周期内进行缺陷预防的预测（而不是缺陷检查）。所开发的统一方法将对使用 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 月转换为工程师和科学家总统早期职业奖 (PECASE) 奖。