臺灣博碩士論文加值系統

在台灣汽車零件(After Market,AM)製造產業中，客戶對於品質要求也越來越嚴格，如何有效地以最短時間、正確、快速、低成本地在電著塗裝(Electrophoretic deposition,ED)生產線上提供最穩定品質，也是目前汽車零件製造產業核心競爭能力之一。
汽車零件製造業中不僅需要在產品的價格上有所競爭力，也要需滿足顧客的需求並生產各種高品質商品，導致生產過程必須趨向更嚴謹更準確的高品質要求，然而在台灣汽車零件製造產業中，客戶對於品質要求也越來越嚴格，如何有效地以最短時間、正確、快速、低成本地在電著塗裝生產線上提供最穩定品質，也是目前汽車零件製造產業核心競爭能力之一。且少量多樣的產品與複合材質都是目前的生產模式也是未來的趨勢，為了正確地估計與準確地推論製程能力指標Cpk與Ppk，許多文獻分別以各種方法或各種觀點來進行研究與分析，並提出使用Cpk與Ppk來管制先前品質，以避免初期品質落差造成市場抽驗或檢驗不合格或造成顧客風險大增。對業者而言，在Cpk與Ppk計算數據下可以提供最低之製程能力的重要資訊，對於品質工程師在監控製程與評估製程之績效，可提供製程或產品之品質保證，以提高顧客滿意度之服務水準。
本研究目的以國內某汽車零件業工廠，在塗裝電著製程階段使用Cpk與Ppk製程能力指標與製程能力分析做塗裝電著製程階段管制，透過此方法來提升塗裝電著底漆品質，增加產業競爭力。

In the automotive aftermarket (After Market,AM) industry in Taiwan, customers are getting more and more demanding on their quality requirements. How the electrophoretic-deposition (Electrophoretic deposition,ED) production line can provide the most stable quality at the shortest time and in an accurate, fast and low-cost manner is also one of the core competitive factors in the current automotive AM industry.
In the automotive AM industry, the product must not only be competitive in price, but must also must satisfy the customer’s needs for high quality. This requires more strict and accurate quality standards in the production process. However, in the automotive AM industry in Taiwan, customers are getting more particular about quality requirements. How the ED production line can provide the most stable quality in the most efficient, accurate, fast and low-cost manner is also one of the core advantages of the current automotive AM industry. The production of diversified products in small quantities and the use of composite materials are the current production modes and also constitute a future trend. To correctly estimate and accurately evaluate the process capability indices Cpk and Ppk, researches and analyses have been made with various methods or in various viewpoints in many literatures. These indices Cpk and Ppk are utilized to control first-stage quality to avoid preliminary quality differences, resulting in unsatisfactory random market inspection or examination results or in giving a significant risk to customers. For manufacturers, Cpk and Ppk calculation data can provide important information on the minimum process capability. For quality engineers involved in the monitoring process and in estimating the process performance, these data can provide quality assurance on the process or product so that a satisfactory customer service level can be upgraded.
This study is intended to take the example a local factory of the automotive AM industry that uses the process capacity indices Cpk and Ppk in the electrophoretic-deposition process and uses process capability analysis for the control of the ED process. By using this method, this factory upgrades its ED primer quality, thus increasing its competitiveness in the industry.

中文摘要 ...................i
英文摘要 ...................ii
誌謝 ...................iv
目錄 ...................v
表目錄 ...................vi
圖目錄 ...................vii
第一章 緒論...............1
1.1 研究動機...........1
1.2 研究目的...........3
1.3 研究範圍...........3
1.4 研究流程...........4
第二章 文獻探討...........5
2.1 汽車板金塗裝程序...5
2.2 美國汽車售後維修市場銷售與CAPA認證流程........10
2.3 金屬材質克服耐濕耐腐問題......................15
2.4 塗裝藥劑環保問題..............................17
2.5 製程能力指標CPK與PPK..........................18
第三章 研究方法與設計................................30
3.1 初期試片測試擬定方針..........................30
3.2 實際線上實作驗證與試產........................30
第四章 研究結果與討論................................32
4.1 研究假設......................................32
4.2 104年4月份塗裝前製程生產數據分析..............32
4.3 105年4月份塗裝前製程生產數據分析..............43
4.4 104年4月與105年4月塗裝前製程調整差異比較......54
第五章 結論..........................................55
參考文獻..............................................57
附錄 專有名詞說明..................................59
英文論文大綱..........................................60
簡歷..................................................64

[1]曾斐金(2006)。供應商配合導入綠色供應鏈管理之研究，政治大學企業管理研究所學位論文1-209。
[2]金屬中心(2011)。Alcan Automotive Inc/金屬中心 ITIS 計畫整理。
[3]盛威群(2010)。Cpk與Ppk指標於製程開發之應用-以自行車前叉豎管為例。
[4]行政院(2001)。行政院勞工委員會勞工安全衛生研究所.
[5](2015)，鴻光電著塗裝。
[6]李慧瑜(2006)。“RoHS 指令下的綠色風潮” 產經資訊，第 29 頁。
[7]劉文海(2011)。中國大陸非鐵市場特輯─鋁金屬篇。
[8]許元良、顏家鈺(2008)。熱軋鋼帶盤捲缺陷與製程穩定之改善，鑛冶，52：2，頁34-40。
[9]ISO/TS 16949(2002)。全球汽車產業品質管理系統。
[10]Vincen,2012,終生超跑。
[11]CAPA,1987) ,The Certified Automotive Parts Association.
[12]Rutešić, S., Ćetković, J., Žarković, M., Knežević, M., & Vatin, N. (2015). Analysis of the situation in montenegrin civil engineering sector from the point of application of national regulations and the EU technical standards in construction. Procedia Engineering, 117, 905-915.
[13]Menon, S., George, E., Osterman, M., & Pecht, M. (2015). High lead solder (over 85%) solder in the electronics industry: RoHS exemptions and alternatives. Journal of Materials Science: Materials in Electronics, 26(6), 4021-4030.
[14]Lunder, O., Walmsley, J. C., Mack, P., & Nisancioglu, K. (2005). Formation and characterisation of a chromate conversion coating on AA6060 aluminium. Corrosion science, 47(7), 1604-1624.
[15]Palomino, L. E., Suegama, P. H., Aoki, I. V., Pászti, Z., & de Melo, H. G. (2007). Investigation of the corrosion behaviour of a bilayer cerium-silane pre-treatment on Al 2024-T3 in 0.1 M NaCl. Electrochimica Acta, 52(27), 7496-7505.
[16]Palanivel, V., Huang, Y., & van Ooij, W. J. (2005). Effects of addition of corrosion inhibitors to silane films on the performance of AA2024-T3 in a 0.5 M NaCl solution. Progress in Organic Coatings, 53(2), 153-168.
[17]Almeida, E., Fedrizzi, L., & Diamantinio, T. C. (1998). Oxidising alternative species to chromium VI in zinc-galvanised steel surface treatment. Part 2—An electrochemical study. Surface and Coatings Technology, 105(1), 97-101.
[18]Long, Z. L., Zhou, Y. C., & Xiao, L. (2003). Characterization of black chromate conversion coating on the electrodeposited zinc–iron alloy. Applied Surface Science, 218(1), 124-137.
[19]Totik, Y., Sadeler, R., Kaymaz, I., & Gavgali, M. (2004). The effect of homogenisation treatment on cold deformations of AA 2014 and AA 6063 alloys. Journal of materials processing technology, 147(1), 60-64.
[20]Carrillo, J. E., & Franza, R. M. (2006). Investing in product development and production capabilities: The crucial linkage between time-to-market and ramp-up time. European Journal of Operational Research, 171(2), 536-556.
[21]Chang, Y. T., Wen, N. T., Chen, W. K., Ger, M. D., Pan, G. T., & Yang, T. C. K. (2008). The effects of immersion time on morphology and electrochemical properties of the Cr (III)-based conversion coatings on zinc coated steel surface. Corrosion Science, 50(12), 3494-3499.
[22]Wen, N. T., Chen, F. J., Ger, M. D., Pan, Y. N., & Lin, C. S. (2008). Microstructure of trivalent chromium conversion coating on electrogalvanized steel plate. Electrochemical and Solid-State Letters, 11(8), C47-C50.
[23]Chen, W. K., Bai, C. Y., Liu, C. M., Lin, C. S., & Ger, M. D. (2010). The effect of chromic sulfate concentration and immersion time on the structures and anticorrosive performance of the Cr (III) conversion coatings on aluminum alloys. Applied Surface Science, 255(16), 1672-1680.