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1、焊线参数最佳化之研究 专题成员： 胡鸿生经理 赵一虎主任 蔡大川课长 陈俊源先生 一、选题理由 此产品为制程能力不足之老问题，因此希望能藉由此次学习DOE的机会进行诸项试验，期能从各项实验数据之比较，确定焊线机台之最佳参数，进而改善良品率及提升生产力。二、实验条件 a.KAIJO FB-131焊线机 b.RHESCA PTR-1000推力机 c.SPT UTS-18B-C1-16XL瓷嘴 d.TANAKA M3 TYPE 金线三、特性要因分析 四、实验因子筛选表 小要因控制力 (母数)*1技术力 (强)*2因子 代号Bg FORCEAUS POWERBUS TIMECSEARCH FORCED
2、温度FSEARCH HEIGHTGSEARCH SPEEDHPRE TIMEIPOST TIMEJ压板US CALIBK金线芯片支架人员操作教育训练认识系统1.凡是属于母数之小要因请打其余打 2.技术力筛选请用符号表示：(强)(中) (弱) 五、第一阶段直交配置（2N） 1.因果水平对照表 注意：两水平是否符合两极化原则 2.点线图 六、(L16)直交配列表 配置因子BCB CHDAA BFJC FGKB KIG H列号NO12345678910111213141511111111111111112111111122222222311122221111222241112222222211115
3、122112211221122612211222211221171222211112222118122221122111122921212121212121210212121221212121112122121121221211221221212121121213221122112211221142211221211221121522121121221211216221211221121221 七、实验指示书(16) 实验随机 编号实验配置 顺序ABCDFGHIJKBall shear avgball shear cpk1312222211221122.13.31112221122222298
4、3.09163122112221178.22.2714111111111119.71.64155122111212278.72.0236211221221254.90.171472222221112117.75.11282211212111112.92.929121212112120.91.27910121212112165.41.95611212121112242.90.21012121211121256.81.12513212122121112.70.44414211222212177.61.65715112212211244.50.22816112211222177.61.65BALL
5、SHEAR: BCB CHDAA BFJC FGKB KIG HDATAROW/COL12345678910111213141519.7111111111111111120.9211111112222222254.9311122221111222277.6411122222222111112.7512211221122112242.9612211222211221144.5712222111122221177.6812222112211112265.4921212121212121256.8102121212212121219811212212112122121112.912212212121
6、211212122.113221122112211221117.71422112212112211278.71522121121221211278.216221211221121221BALL SHEAR CPK: BCB CHDAA BFJC FGKB KIG HDATAROW/COL1234567891011121314151.6411111111111111111.2721111111222222220.1731112222111122221.6541112222222211110.4451221122112211220.261221122221122110.22712222111122
7、22111.6581222211221111221.9592121212121212121.12102121212212121213.09112122121121221212.9122122121212112123.31132211221122112215.1142211221211221122.02152212112122121122.2716221211221121221BALL SHEAR: FACTORSiDFVF%B8977.56218977.56291.4987449.86286*A2425.56212425.56224.7211713.0698*H1685.10211685.10
8、217.174458.91174*D1455.42211455.44214.833577.62197*AB1335.90211335.90213.615436.95080*F490.62251490.62255.0003932.20412J460.10251460.10254.6893352.03273C290.70251290.70252.9628211.08146e686.8175898.116788.26464St=17807.79 t=91.7353 F=12.2* F=5.59* BALL SHEAR CPK: FACTORSiDFVF%B13.1769113.176949.4045
9、548.3341*AB5.475615.475620.5298319.5014*BC2.14622512.1462255.5409067.03665A1.392411.39245.2205674.21442BK1.2202511.220254.5780263.57281F0.688910.68892.5829131.58061CF0.61622510.6162252.3104311.30852C0.12602510.1260250.4725090.52672e1.86770.26671413.9247St=26.7103 t=86.0752 F=12.2* F=5.59*八、BALL SHEA
10、R CPK交互作用回应图 1.本回应图分析之交互作用为AB贡献率为18.8% 2.因子组合比较表因子组合原始数据平均值A1 B11.64+1.27+0.22+1.651.195A1 B21.95+1.12+2.02+2.271.84A2 B10.17+1.65+0.44+0.20.615A2 B23.09+2.9+3.31+5.13.63.交互作用回应图 九、BALL SHEAR交互作用回应图 1.本回应图分析之交互作用为AB贡献率为6.8% 2.因子组合比较表因子组合原始数据平均值A1 B119.7+20.9+44.5+77.640.675A1 B265.4+56.8+78.7+78.269
11、.775A2 B154.9+77.6+12.7+42.938.025A2 B298+112.9+122.1+117.7112.6753.交互作用回应图 十、CROSS TABLE 十一、第二阶段直交配置（3N） 1.因子水平对照表 2.点线图 3.实验常数项因子设定条件US TimeC温度FSearch HeightGPre TimeIChange TimeJChange DelayK 十二、L27313直交配列表 配置 因子ABA BA B BeeeeDHeee列号No12345678910111213111111111111112111122222222231111333333333412
12、221112223335122222233311161222333111222713331113332228133322211133391333333222111102123123123123112123231231231122123312312312132231123231312142231231312123152231312123231162312123312231172312231123312182312312231123193132132132132203132213213213213132321321321223213132213321233213213321132243213321
13、132213253321132321213263321213132321273321321213132 十三、实验指示书（27） 实验 随机 编号实验 配置 顺序ABA BA B BeeeeDHeeeBALL SHEAR AVGBALL SEHAR CPK91111111111111181.51.871021111222222222103.51.351331111333333333110.52.162141222111222333105.11.562651222222333111116.12.2866122233311122289.81.541171333111333222110.21.682
14、48133322211133397.21.751291333333222111111.82.31102123123123123118.21.14511212323123123187.41.181712212331231231296.51.481613223112323131297.22.4623142231231312123110.82.1715152231312123231109.32.432162312123312231115.62.6141723122311233121182.6727182312312231123101.22.383193132132132132104.41.54203
15、132213213213111.21.962521313232132132190.91.3219223213132213321114.71.827233213213321132110.41.3518243213321132213111.51.720253321132321213114.51.812226332121313232195.12.79827332132121313289.11.89BALL SHEAR: FACTORSiDFVF%H930.31402465.15706.2927127.2091*D323.09402161.54702.185436.09415AB312.2081478
16、8.052031.055900.57475B229.90512114.95251.555092.85367A45.37854222.689250.306943.56290e1034.8781473.9198959.7053St=2875.778 t=40.6622 F=6.51* F=3.74*BALL SHEAR CPK: FACTORSiDFVF%B1.95200720.9760039.6919829.7072*AB1.55908140.3897703.8705219.6216A0.36369620.1818481.805802.75404H0.33916220.1695811.68399
17、2.33772D0.26907420.1345371.335991.14833e1.409829140.10070244.4310St=5.892851 t=55.5689 F=6.51* F=3.74*BALL SHEAR: COLFACTORSiAVE(L1)AVE(L2)AVE(L3)1A45.37851102.8555106.022104.6442B229.9051100.4555107.211105.8553AB169.6540107.4333101.311104.7774ABB142.5540101.2777105.811106.4335e157.2718106.8222105.5
18、22101.1776e95.48740102.2777104.366106.8777e217.1207100.5106.377106.6448e204.1918102.7777102.355108.3889D323.0940100.7111109.077103.73310H930.314096.67777106.033110.81111e44.36962104.8333105.888102.812e54.03185106.4777103.822103.22213e262.4051102.4888102.122108.911St=2875.778BALL SHEAR CPK: COLFACTOR
19、SiAVE(L1)AVE(L2)AVE(L3)1A0.3636961.8322222.056661.793332B1.9520071.5511111.923332.207773AB0.3219181.9888881.741111.952224ABB1.2371622.1033331.978881.65e0.0063401.8266661.944441.911116e0.0584511.9444441.832221.905557e0.2938961.7822221.866662.033338e0.0197851.9322221.877771.872229D0.2690741.8977771.77
20、2.0144410H0.3391621.741.938882.0033311e0.1767181.8755551.805552.0011112e0.3696512.0588881.798881.8244413e0.4249852.0655551.768881.84777St=5.892851 十四、第二阶段实验结论 1.使用LSD手法期望找出操作WINDOW。 2.Ball shear 显著因子(*)H LSD=t(e、) =t(14、0.01) =2.9772.18381 =6.5012 H1H2H3H19.3552314.13323H24.778H3 由于H2与H3只差4.778小于LSD
21、(6.5012),表示H2与H3相互差异不显著,但BALL SHEAR特性值愈大愈好,所以选取H2与H33.BALL SHEAR CPK 非常显著因子(*) B LSD=t(e、) =t(16、0.01) =2.921*0.103312 =0.30177B1B2B3B10.3722190.656659B20.28444B3由于B2与B3只差0.28444小于LSD(0.30177),表示B2与B3相互差异不显著,但BALL SHEAR CPK特性值愈大愈好,所以选取B2与B3 4.最适条件: A:Bg FORCE 60100 B:US POWER 100120 D:SEARCH FORCE 6
22、0100 H:SEARCH SPEED 1214 十五、第三阶段再现性实验 实验条件: 因子代号参数范围Bg FORCEAA1A3US POWERBB2B3US TIMECC1C2SEARCH FORCEDD1D3温度FF1F2SEARCH HEIGHTGG1G2SEARCH SPEEDHH2H3PRE TIMEI0CHANGE TIMEJ0CHANGE DELAYK0实验结果 AvgCpk后测不良率(ppm)实验前81.766211.19651.243432805实验后81.2278.8271.556858十六、检定统计 1.BALL SHEAR Two-Sample Analysis Re
23、sults -Sample Statistics:Numbrer of Obs. Average Variance Std. Deviation MedianIR939.SHEAR 1155 81.7654 125.112 11.1854 81IR939B.SHEAR 1155 82.5238 1055.96 32.4956 81Pooled 2310 82.1446 590.538 24.301 81Difference between Means=-0.758442 Conf. Interval For Diff. in Means: (Equal Vars.)Sample 1-Sampl
24、e 2 (Unequal Vars.)Sample 1-Sample 295Percent -2.741881.2252308 D.F. -2.742531.225651423.7 D.F.Ratio of Variances=0.118481 Conf. Interval for Ratio of Variances: 0 Percent Sample 1 v Sample 2Hypothesis Test for H0:Diff=0 vs Alt:NE at Alpha = 0.05Computed t statistic = -0.750022 Sig. Level = 0.453318
25、 so reject H0. 2.BALL SHEAR CPK Two-Sample Analysis Results -Sample Statistics:Numbrer of Obs. Average Variance Std. Deviation MedianCPK1.CPK 15 1.38616 0.0715963 0.267575 1.37992CPK2.CPK 15 1.68037 0.0493821 0.222222 1.64576Pooled 30 1.53327 0.0604895 0.245946 1.50664Difference between Means=-0.294
26、206 Conf. Interval For Diff. in Means: (Equal Vars.)Sample 1-Sample 2 (Unequal Vars.)Sample 1-Sample 295Percent -0.47821-0.11020228 D.F. -0.47849-0.10992227.1 D.F.Ratio of Variances=1.44983 Conf. Interval for Ratio of Variances: 0 Percent Sample 1 v Sample 2Hypothesis Test for H0:Diff=0 vs Alt:NE at Alpha = 0.05Computed t statistic = -3.27599 Sig. Level = 2.80739E-3 so reject H0. 十七、结论： 由再现性结果判断第二阶段所求得之参数最佳组合,可将此产品之cpk由1.24343提升至1.5568,不良率由2083ppm降至58ppm,并提供现场人员有效之作业准则. 此实验虽未将ball shear平均值明显提升,但由于cpk之提升造成后测不良率大幅降低,故ball shear之特性质虽属望大值,但是否可无止境的望大,将是值得探讨.
