六標準差設計應用於高階智慧型手機開發模式之探討

The Application of Design for Six Sigma on High Level Smart Phone Development

10.6220/joq.2012.19(2).02

鄭春生(Chuen-Sheng Cheng)；李世傑(Shih-Chieh Lee)；陳佩雯(Shih-Chieh Lee)；黃國格(Kuo-Ko Huang)

六標準差設計 ； 品質機能展開 ； 智慧型手機 ； 創意問題解決理論 ； design for six sigma ； quality function deployment ； smart phone ； Theoria Resheneyva Isobretatelskehuh Zadach (TRIZ)

品質學報

19卷2期（2012 / 04 / 30）

117 - 136

繁體中文

在現今全球化的環境下，現代企業面臨了前所未有的嚴峻考驗，經營者必須思考各種策略來提升獲利、降低成本以維繫企業的生存及永續發展。近年來，許多公司相繼導入六標準差（Six Sigma）品質改善方法來改善企業體質以提升企業獲利，其成效相當顯著。本研究主要目的為應用六標準差設計（design for six sigma, DFSS）於國內某智慧型手機大廠，透過DFSS的DMADV五個階段進行智慧型手機新產品的創新開發使其達到六標準差品質水準。在定義階段，本研究首先利用KJ法找出重要的顧客心聲，並使用品質機能展開將顧客心聲轉換為技術需求；於衡量階段，將技術需求轉換為零件需求，運用設計潛在失效模式與效應分析，將潛在失效模式依風險優先指數排序，找出對應的失效肇因並提出改善及預防措施；分析階段則利用創意問題解決理論（Theoria Resheneyva Isobretatelskehuh Zadach, TRIZ），改善滑蓋機構的間隙及使用壽命；在設計階段，透過實驗設計找出手機外殼噴漆製程最佳參數，並利用Crystal Ball模擬軟體進行允差分析；最後以環境可靠度試驗等手法，進行產品可靠度驗證。本研究以TL－9000所定義之首年退貨率（year return rate, YRR）做為績效衡量指標。研究結果顯示，運用DFSS方法可以有效降低首年退貨率，大幅提升顧客滿意度、降低售後維修費用，並建立新產品設計開發模式，達到最低產品開發成本，奠定企業競爭優勢。

Design for Six Sigma (DFSS) has been utilized over the last few decades to deliver more robust products with more functionality and reduced cost. Enterprises that want to compete in the market must operate deploying flexibility, minimizing production costs, speeding up processes and assuring a high-quality level of output. For these reasons it is necessary to apply innovative and structured methodologies able to suggest techniques and methods to design organize and manage industrial processes. DFSS represents one of the most effective methods to attain increases in business performance and customer satisfaction using a smart problem-solving method (DMADV). This study shows an implementation of a DFSS project in smart phone to improve the performance level of the design process. The results of the case study demonstrate an effective approach that is able to design and reach Six Sigma level process, by applying KJ model, quality function deployment (QFD), TRIZ innovation, Monte Carlo simulation, reliability prediction of electronic equipment and design of experiments (DOE) tools. This case justifies the application of this method in order to improve the performance level of a designing process. Finally, we use an index year return rate (YRR) from TL-9000 to evaluate the measurable effect of telecommunication industry product design quality. This DFSS process was practiced in A company actually. We found the YRR of R project (with DFSS process) is 1.23% that better than K project (without DFSS process) YRR 5.05%. The results of this case study show that with DFSS process could shorten new products development period, selected suitable components, estimated product life cycles and make enterprises with competitiveness advantage.

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