Process Management过程管理.ppt

process management 过程管理 class objective学习目的 hto familiarize operators with the process使操作者熟悉过程 hto have the ability to trouble shoot the parts and machine具有解 决零件及机器问题的能力 hto reduce scrap and downtime减 少废料及停机时间 hto improve productivity提高生产 率 what is process什么是过程 ？ definition a定义a a series of steps, actions, or operations used in making something or bringing about a desired result. 一系列的步骤 、行动或者操 作，带来预期 的结果。 definition b定义b a series of actions, changes, etc., by which something passes from one condition to another.一系列 的举措、变更 等，导致某事 物从一状态转 为另一状态。 process management 过程管理 hninety percent of all defects are made because of reasons other than machine settings, however in all die cast companies personnel tend to adjust (compensate for ) settings rather than identifying and fixing the problem. one reason for this is that there are so many variables associated with our die casting process. sometimes the operator does not know where to start looking. 90%的产品缺陷归咎于各种非机器设置原因。但所 有压铸公司的人员都宁愿调整设置，而不是分析及补救问题 。原因之一是在我们压铸过程中使用到很多的变量。有时操 作者甚至不知道该从哪里开始寻找原因。 hone important thing to remember as you run your machine , if the process has been running ok and then suddenly you experience defects, it is unlikely that someone has adjusted settings on your machine. therefore do not adjust any settings to correct the problem until you have checked and fixed any other problems.在操作机器时必须记得很重要的一点就是，如果过 程运行顺利而你突然遭遇到废件，这就不可能是因为有人调 整过你机器上的设置。因此在你检查及修理过其他问题之前 不要调整任何设置。 if its not broken, dont fix it.如果机器没有坏 ，那么不要去修理它。 process management 过程管理 here at smmp when we talk about the process it is usually understood to be the parameters used to cast a good part.在 smmp当我们谈及“过程”时，通常的理 解是我们用来铸造一个好零件所用到的 参数。 however the process can also be the sequence of events that the machine / cell or other equipment moves through during a cycle .但是过程也可以是机器/机床或其 他设备在一个周期内移动时发生的一系 列事情。 process management 过程管理 hfirst of all lets look at the cycle of the machine / cell and see how a process can be effected.首先让 我们看一下机 器/机床的运作 周期，了解如 何控制过程 process management 过程管理 tubes comes down and pours, shot delay begins管子伸下来 且倒料，压射延时开始 shot takes place 压射发生 intensifier fires ( if used ) and dwell time starts增压开始（ 如果是用增压的话），保压时间开始 die opens ( cores pull ), robot moves to part模具打开（ 抽 芯 ）机械手开始取出零件 part ejects from die零件从模具中顶出来 die lube is applied , robot leaves machine with the part喷涂 模具，机械手带零件离开机器 part is quenched while dcm begins to cycle again当压铸机 开始新的压射周期时零件放置冷却 part is placed on trim tool and trimmed零件被放在切边机 上切边 part is delivered to the operator and inspected零件被交给操 作工进行检查 part is packed or sent to next operation.零件被包装或被送至 下一道工序。 assume for the moment that the pot is full, the dies have locked up and you have a shot ready light. what happens next ?假设现在料勺是满的且模具已经合起而你收到一 个准备压铸的信号，接下来会怎么样？ process management 过程管理 hwhat will happen if one of these steps does not occur ?如果其中一个步骤并未进行会发生什么 事？ _ _ hwhat effect if any will this have ?如果有后果产生的话，会是什么后果？ _ _ _ process management 过程管理 hthe cycle will stop. 停止压铸。 htherefore knowing the process of the machine will help you trouble shoot the problem much better.因此了解机器工作的过程会帮你更好地预 见到机器会发生的问题。 what will happen if one of these steps does not happen ? 如果其中一个步骤没有进行会发生什么事？ what effect if any will this have ?如果有后果产生的 话，会是什么后果？ _ _ _ process management 过程管理 hmachine cycle will stop.机器停止运行。 hcycle time will be longer, possible loss of part over the length of shift.运行周期会变长，或者在 长时间的运行中丢失零件。 hpossible scrap, dies may have chance to cool off. part may be left on the tool too long and stick. etc,可能产生废料；模具可能会冷却下来；零件 可能会由于在模具中存留时间过长而难以与模 具分离等等。 what will happen if one of these steps does not happen ? 如果其中一个步骤并未进行会发生什么事？ the cycle will stop.压铸停止。 what effect if any will this have ?如果有后果产生的话， 会是什么后果？ process management 过程管理 as with the machine it is important for you to know the elements that effect you part process.只要 跟机器在一起，了解影响到过程的各个因素就 是很重要的。 in order to make a good casting it is important that we operate to a defined process as much as possible. to that end a process sheet has been developed.为了能够做出好的铸件，我们应尽最 大可能地遵循一个既定的详细的过程。由此而 产生了过程指引手册。 process management 过程管理 there should be a process sheet at each of the machines. this is a qs 9000 document that should be the same as the part that is currently running in your machine.在每台机器上都应 该有一份过程指导书。这 也是一份qs9000文档，应 该与机器的零件一样永远 在你的机器上。 if there is not a process sheet for the job currently running in youre machine one can be obtain one from your function leader.如果你的机器上没 有过程指导书你可以向你 的直接领导领取一份. “ i make part我制 造零件” process management 过程管理 the process sheet is an important document. this is the latest information available to you on how to run the part in your machine.过程指导书是非常重要的 文件。它将是一份最新的可以指导你如 何操作机器的各个部件的文件。 the process sheet also gives you a reference point to check from when things go wrong and you start making scrap. 过 过程指导书在问题及废件开始出现时可 以作为指导性文件，告诉你可以参考哪 些要点来寻找问题根源。 process management 过程管理 hto often the process sheet is taken as a joke. lets take some time and review a sheet. if you feel that the sheet on your machine does not reflect the part that you are running then you should make sure that you have the latest revision. if you do have the latest revision then you may need to complete a process deviation and process change form.很多时 候过程指导书都没能被严肃对待。让我们花点时间来看一下指引 手册。如果你觉得你手头的过程指导书并不符合你现在用的机器 的实际情况，你可以确认一下你拿到的是否最新版本。如果的确 是最新版本，那么你就应该做变更汇报并填报变更表格。 “ it does say that ha, ha, ha哈哈哈 它的确是这么说 的！” process sheet过 程指引 手册 process management 过程管理 shot speed压射速度 firing points压射点 metal temp金属温 度 biscuit size料柄尺 寸 pressures压力 shot delay压射延时 die temp模具温度 cycle time周期 die lube模具喷涂 in the process to make a good casting there is a multitude of different variables.在做出好铸件 的过程中有许多的参数变化需要参考。 process management 过程管理 if your machine is making good parts then for some reason the parts change and now youre making scrap one of the variables have changed.如 果你的机器本来是好的但由于某些原因部件更 换了，现在你开始出现废品。其中一定有某个 参数变化了。 too often we tend to make a quick evaluation of the situation, adjust one or more set points with out finding the route cause.很多时候我们都不是 去寻找问题的根源，而是很快地判断一下局势 然后就调整其中一个或多个设置。 generally speaking going from a good to a bad situation only one variable has changed, we need to determine which one and why ?通常来说从一个 好的局势转变为坏的局势是因为其中某个参数 变化了。我们需要决定的是，是哪个参数变化 了以及为什么？ process management 过程管理 when most variables change they effect many others, it is important to understand the changes and what they will effect.绝大多数的参数变化会 引致很多其他的一些变化。因此了解这些变化 及其可能导致的影响是非常重要的。 the number one cause of process problems is biscuit size ironically this is also often the hardest to control.过程问题中的最首要的因素就是料柄 尺寸。具讽刺意味的是，这也通常是最难控制 的一个因素。 lets review some of the effects that a change in some of the variables will have.让我们来看一下参 数变化可能引起的一些变化。 process management 过程管理 biscuit size料柄尺寸 biscuit too small料柄太小 out of process不受过程控制 poor fill填充不足 increased shot speed压射速度增加 note enough pressure压力不足 scrap废料 partial shot possible stuck part部分压射可能粘模 down time停机 die spitting逃料 scrap废料 overtime超时 scrap废料 overtime超时 process management 过程管理 biscuit size料柄尺寸 overtime超时 scrap废料 cold shot porosity lack of fill cracks 冷压射气缩孔,压铸 不足、裂缝 slow shot speed 慢压射速度 overtime超时 scrap废料 no intensification 无增压 shot ends too early压射完成 太早 overtime超时 scrap废料 porosity in casting 压铸气缩孔 house keeping safety环境、安全 mag coming back out ofpour hole镁 自浇注孔退回 不受过程控制 biscuit too big 料柄太大 out of process increased turbu- lance in shot sleeve料缸问题 process management 过程管理 shot speeds压射速度 overtime超 时 scrap废料 over time超时 down time停机 possible stuck part零件可能受 阻 metal frozen before it reaches thegate金属在到达 进料口前凝固 too slow太慢 over time超时 fires down time点火问 题引起停机 die spits 逃料 over time超时 die unable to lockup next cycle 模具无法正常进行 下一次压射 heavy flash- ing强烈闪光 over time超时 scrap and or stuck part废料 及/或零件受阻 solder build up焊料堵塞 metal enters die at highspeed金 属以极快速度进入 模具 too fast太快 shot压射 process management 过程管理 firing points着火点 over time超时 die spits fires housekeeping 逃料,点火,存留 increased fast shot speed快压射 速度增加 overtime超时 scrap废料 accumulator runs out of oil before end of shot增压器在 压射结束前油已耗尽 too soon太快 overtime超时 scrap废料 metal too cold to properly fill part金属太冷无 法充填零件 not enough time to reach desired speed没有足够时 间来达到理想速度 too late太慢 different firing points不同的着火点 process management 过程管理 metal temp金属温度 overtime超时 down time停机时间 multiple scrap problems多种废 料问题 metal too cold to fill casting 金属太冷无法 铸造 over time超时 cycle time machine down to allow metal to heat up周期停 机以加热镁液 too cold太冷 cycle time周期 metal too hot requires more dwell time金属太热,需要更 多的保压时间 over time超时 de solder die scrap去除粘模 solder build up粘模 overtime超时 down time due to fires因燃烧停机 die spits & multiple scrap problems逃料及 多种废料问题 too hot太热 different metal temps金属温度 不同 process management 过程管理 pressures压力 overtime超时 scrap related to fill problems因充 填问题而引致废料 casting doesnt fill properly未能 正确充填 shot speed slow 压射速度太慢 too low太低 overtime超时 scrap usually cracked castings 断裂废料 die spits causes fires逃料导致起 火 shot speed high 压射速度太快 too high太高 different pressures不同压力 process management 过程管理 shot delay压射延时 metal too hot see flow chart for metal temp金属太热,参见 金属温度流程图 overtime超时 scrap废料 metal not given chanceto settle too turbulent金属 没有机会充填 too low太慢 overtime超时 scrap废料 metal too cold see flow chart for metal temp金属太冷,参见 金属温度流程图 too high太快 different times时间不同 process management 过程管理 die temps模具温度 scrap废料 scrap废料 die life reduced模 具寿命减短 shock dies 模具不稳定 /振动 overtime超时 broken core 型心断裂 stuck casting 铸造受阻 too low 太低 process management 过程管理 cycle time周期 overtime超时 scrap废料 die gets too hot furnace cant keep up模具变得太热,熔 炉无法与之适应 too low太慢 overtime超时 scrap废料 die gets too cold模具变得 太冷 too high太快 different times 不同时间 process management 过程管理 die lube模具润滑 down time停机 scrap废料 borken core 型心断裂 down time停机 scrap废料 need to desolder die需 要粘料 solder build up粘料堵塞 overtime超时 scrap废料 stuck castings铸件 受阻 too lean润 滑油太少 overtime超时 scrap废料 porosity气缩孔 black parts 部分发黑 too rich润 滑油太多 different set- tings不同设置 process management 过程管理 on the die cast machine you have the ability to monitor many of the variables associated with the process.在压铸机上你 可以监控与过程有关的各个参数。 several variables may change from shot to shot what you have to be able to do is figure out which change(s) caused the others to change.在不同的压射过程中可 能会有多个参数的变化,你应该能够分辨 出哪些变化是导致了其他哪些变化的。 process management 过程管理 for example例如: int shot speed二次压射速度 hi快 fast shot speed快压射速度 hi快 intensification hold增压 low慢 int. to fast transition二次压射转快压射 hi快 biscuit size料柄尺寸 low低 what is the probable problem ?可 能有什么问题发生？ process management 过程管理 lpot level液面高度 ltube temp充液管温度 lmetal temp金属温度 lis the end of the tube clean导管末端是否洁净 ldid the metal flow from the tube miss the sleeve.充料时没有对准料缸 lcondition of the pot is there a lot of dross.坩埚 的状态，是否有很多渣滓。 now that we can see that the biscuit size is the probable cause now we need to look and find the root cause.我们现 在可以发现料柄的尺寸就是问题可能产生的直接因素 。现在我们需要找到问题的根源。 we should look at the following before making adjustments在做出判断前我们需要看一下以下因素. even once we have determined what the cause is from the possible above then we need to find out what caused that to happen until the question can no longer be asked.只有当我们判断出了以上列出的 因素中哪些是问题的可能性根源我们才能知道 是哪个因素导致了什么问题，直到问题全部解 决。 process management 过程管理 wmost process related problems can at least be trouble shot to within a fairly close proximity of the problem area with the use of some basic logic.运用 一些基本的逻辑可以大概地预见到绝大多数与 过程相关的问题可能发生的范围。 a part with flow problems usually referred to as cold shut is a direct result of the metal either being too cold at the start or cooling off quickly in the die. now we have to find out was the metal cold before the shot took place, or did it cool down in the die. 有流动问题的零件通常指冷隔，它是金属在一 开始就太冷或者在模具中很快冷却的直接结果 。现在我们需要分辨的就是金属是在压射之前 就已经冷却下来还是在模具中冷却下来的。 a part with a heat sink in it is usually attributed to large wall thickness and temperature variation in the die. it can also be attributed to a large biscuit especially if the biscuit is so big that intensification did not occur.有热缩 的零件通常是因为铸件较厚 而模具温度有差异。这也可以归因于料柄太大 ，尤其是当料柄太大而使增压过程无法发生的 时候。 process management 过程管理 apart that has porosity can be the result of too much die lube shown as a black area on the part, it can also be associated with a small biscuit. or an erratic shot that traps the air in the metal during the shot itself.有气缩孔 的零件有可能是因为模具润滑油太多，在零件上表现 有发黑现象，也有可能是因为料柄太小，或者压射时 的不稳定因素使得压射过程中没有有效地排干净料缸 中的空气。 a part with a crack is often the result of one of the following,有裂缝的零件通常是由以下某原因造成的： ltoo much pressure during intensification增压过 程中太多压力 lthe part sticking to the die零件难以与模具脱离 lpoor intensification hold持压时间不足 lthe metal cooling off at different rates due to die temp and wall stock.由于模具温度及壁厚因素 使金属冷却的程度不一。 wthese are not all of the scrap related problems that you will encounter however these are the most common. 以上所列并不是铸件缺陷的所有可能但却是铸件缺陷 最常见的情况。 process management 过程管理 bit is also important for you to realize that the possible reasons given here are not always the reasons for the problems.我们这里列出的各种因 素并不一定总是问题的原因，这一点也很重要 。 lwe are able to compensate for many problems with adjustments to the process however some problems are inherent to the design of the part or even the die. the process that you follow at smmp may not be the best possible for the job, it is important though if you do run the machine out of process that the proper permission is obtained and that the proper paper work is completed.我们可以 对过程进行一些调整，但有些问题可能是跟零 件的设计或者模具是有关系的。你在smmp学 习的这些可能不一定是最适合你现有工作的方 法，但对你来说很重要的是你的过程是在适当 的许可下进行且经过了适当的文件手续。 l process management 过程管理 if you are unable to correct a problem with the part do not be afraid to ask, anyone that has wor