福特BB项目案例

-(VOCs)71.111996EPA(VOCs)110g/m22001/52002/5VOCs71.0g/m2VOCsPrimerapplication)Baseapplication)Clearapplication)Solventclean6-sigmaVOCs21.(VOCs110g/m2)2.(CriticaltoCostCriticaltoEnvironment-4VOCs5PVC8%ED1%Primer12%Base43%Clear16%Purge&clean20%39Input(X)Step(X)TypeY1.SOP1.2.Contr2.3.(TackRag)Contr3.4.Noise4.,(,,)5.1.SOP1.2.Contr2.3.()SOP3.4.ManualInteriorContr4.5.(BeforeAuto)Noise6.Contr7.()Contr1.Contr1.2.Contr2.3.AutoSprayNoise3.4.PM()SOP4.5.Contr6.Contr7.Contr\1.SOP1.2.Contr2.3.()SOP3.4.ManualInteriorContr4.5.(AfterAuto)Noise5.6.Contr7.()Contr8.SOP1.SOP1.2.,/SOP()3.PMHoldingZoneSOP2.4.&OvenContr3.5.Contr6.Contr7.,SOP6Input(X)Step(X)TypeY1.SOP1.2.Contr2.3.(basecoatManual#1)SOP3.4.SOP4.5.SOP5.6.Contr6.7.1.Contr1.()2.ESTAContr2.3.ESTA(basecoatESTAAuto)Contr3.4.Contr4.5.6.1.Contr1.()2.SpraymateContr2.3.Spraymate(SpraymateAuto)Contr3.4.Contr4.5.6.1.SOP1.2.Contr2.3.(basecoat-Manual)SOP3.4.SOP4.5.SOP5.6.6.1.Contr1.()2.ESTAContr2.3.ESTA(ClearcoatESTAAuto)Contr3.4.Contr4.5.6.1.SOP1.2.Contr2.3.(ClearcoatManual)SOP3.4.SOP4.5.SOP5.6.6.1.SOP1.2.,/SOP()3.PMHoldingZoneSOP2.4.&OvenContr3.5.Contr6.Contr7.,SOP71.Contr1.()2.ESTAContr2.3.ESTA(ClearcoatESTAAuto)Contr3.4.Contr4.5.6.1.SOP1.2.Contr2.3.(ClearcoatManual)SOP3.4.SOP4.5.SOP5.Contr6.1.SOP1.2.,/SOP()3.PMHoldingZoneSOP2.4.&OvenContr3.5.Contr6.Contr7.,SOPInput(X)Step(X)TypeY1.SOP1.2.Contr2.3.(basecoatManual#1)SOP3.4.SOP4.5.SOP5.6.Contr6.7.1.SOP1.2.Contr2.3.(basecoat-Manual)SOP3.4.SOP4.5.SOP5.6.Contr6.1.SOP1.2.Contr2.3.(basecoat-Manual)SOP3.4.SOP4.5.SOP5.6.Contr6.8RatingofImportancetoCustomer8105103535123456789TotalProcessStepProcessinput1101031811827721111111149311151111894PM11111111495111111114961111111149711111111498111111114910333355311531188108315130812551111111211355111133137141010101581083651587101878831716AUTO101071578733417ESTA7871788730118Spraymate71071333726919/111111114920111111114921111111114922111111114923991010588139624888101751342Processoutputs8109753110MSAGageR&R1.GageR&R2.GageR&RT.H.Chang5/28/2002Misc:Tolerance:Reportedby:Dateofstudy:Gagename:080706050321XbarChartbyOperSampleMeanMean=63UCL=63.62LCL=62.380210321RChartbyOperSampleRangeR=0.6042UCL=1.555LCL=08765432180706050PartOperOper*PartInteractionAverage12332180706050OperByOper8765432180706050PartByPart%Contribution%StudyVarPart-to-PartReprodRepeatGageR&R100500ComponentsofVariationPercentGageR&R(ANOVA)forMichaelSu6/22/2002Misc:Tolerance:Reportedby:Dateofstudy:Gagename:0155150145140321XbarChartbyOperSampleMeanMean=149.2UCL=150.5LCL=148.003210321RChartbyOperSampleRangeR=1.208UCL=3.111LCL=087654321155150145140PartOperOper*PartInteractionAverage123321155150145140OperByOper87654321155150145140PartByPart%Contribution%StudyVarPart-to-PartReprodRepeatGageR&R100500ComponentsofVariationPercentGageR&R(ANOVA)forFilmBuildGageR&R16.74%GageR&R4.14%11VOCs110g/m2(FLH)90g/m22001/52002/5VOCsweighted71.1g/m2Cpk=3.18PPM=0.012001/52002/5VOCsYear01-May01-Jun01-Jul01-Aug01-Sep01-Oct01-Nov01-Dec02-Jan02-Feb02-Mar02-Apr02-MayVOCs(Weighted)70.8771.7567.2967.1467.8869.5670.4469.6177.6977.0572.3470.4272.26507090110g/m2VOCs(Weighted)71.1g/m2121201101009080706050FLHUSLProcessCapabilityAnalysisforVOCs(weight)PPMTotalPPMUSLPPMLSLPPMTotalPPMUSLPPMLSLPPMTotalPPMUSLPPMLSLPpkPPLPPUPpCpmCpkCPLCPUCpStDev(Overall)StDev(Within)SampleNMeanLSLTargetUSL0.010.01*0.000.00*0.000.00*1.89*1.89**3.18*3.18*3.337851.980641371.1**90.0Exp.OverallPerformanceExp.WithinPerformanceObservedPerformanceOverallCapabilityPotential(Within)CapabilityProcessDataWithinOverallRegulationKPIV-AnalyzeDataCollectionPlan)2001/51314VOCsHerbertsVOCssolventbaseVOCsAquabasesolventbaseSolventEmissionper㎡CoatedSubstrate(g/)ClearcoatSolvent1KSolvent2K-HSSolvent2K-HSAquaClearPowderoClearBasecoatSolventLSSolventMSAquaMetallicAquaMetallicAquaMetallicSurfacerSolventMSSolventMSAquaFillAquaFillAquaFillCEDAqua~ECAqua~ECAqua~ECAqua~ECAqua~ECHerbertsAutomotiveSystemsSolventEmissionofAutomotiveOEMPaintSystems0306090120CEDSurfacerBasecoatClearcoatsolventbasedsolventbasedsolventbasedsolidcolorsolidcolorlowsolidmediumsoildhighsoildbasecoatblackbasecoatwhite10-1218-2035-36~23~37VOCxx▲x▲PerformanceTechnicalproperties●●●◙◙Colorflipflop●◙◙◙◙Durability●●◙◙◙ApplicationFilmbuildcontrol●◙▲◙◙Appearance●◙◙◙●good◙acceptable▲fairxpoorNVvol.%(volumesolids)VOCsSolventbaseN.VVOCs(1)N.V.3536VOCsappearanceN.V.1012(1)(1)15PA,11.98%HR,1.42%SW,7.19%HG,0.97%TY,1.42%,0.95%AZ/AP,30.11%TS,38.89%TG/YG,4.00%DB/YB,3.05%PAHRSWHGTYAZ/APTSTG/YGDB/YB2.183.261831AZ/AP2.773.191934TS3025N.V(%)1.953.2139SW1.672.3635PA(L/unit)(L/unit)N.V(%)(2)200141.TS38.89%2.AZ/AP30.113.PA11.984.SW7.19488.17(2)(2)TSAZ/APN.V19%1880PASWTSAPVOCs(2)(2)16ESTAESTA1.=0.04cm2.A=0.1256cm23.L=140cm4.=AL=0.1256*140=18c.c.5.colortree=7c.c6.=117.=1811=198c.c.8.colortree=2511=275c.c17C206/J39C224/J54U204/J14CD132CD1322788L2788L6462701088784(L)6462701088784(L)948666531790211059(m2)a.VOCs=(1-)=2788(1-0.5)0.86=1198.84kgb.VOCs=(1-)=2788(1-0.2)0.86=1918.14kga+bVOCs3116.98kgCD13218&191(colorchange)(cleantimes)TotalVOCs2.03.0TotalVOCsColor4050rchange4404.015602