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1、Process Management过程管理,Class Objective学习目的,To familiarize operators with the process使操作者熟悉过程To have the ability to trouble shoot the parts and machine具有解决零件及机器问题的能力To reduce Scrap and Downtime减少废料及停机时间To improve productivity提高生产率,What is Process什么是过程？,DefinitionA定义A A series of steps,actions,or oper
2、ations 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。,DefinitionB定义BA 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,Ninety percent of all defects are made because of reason
3、s 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 t
4、o 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。One 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 m
5、achine.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 a
6、bout 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 Ma
7、nagement过程管理,First 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），
8、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
9、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,What will happen if one of
10、 these steps does not occur?如果其中一个步骤并未进行会发生什么事？_ 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,The cycle will stop.停止压铸。Therefore 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
11、 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,Machine cycle will stop.机器停止运行。Cycle 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。Possible scrap,Dies may have chance to cool o
12、ff.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
13、 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。,Proc
14、ess 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 your
15、e 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
16、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,To often the process sheet is taken as a joke.Lets take some time and review a sheet.If you feel that the sheet on
17、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
18、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 i
19、s 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
20、 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
21、，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 harde
22、st 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,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 S
23、hot 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,Sh
24、ot 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
25、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,So
26、on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
27、 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
28、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
29、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 NotGiven 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 M
30、anagement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
31、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-tin
32、gs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
33、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,Pot level液面高度Tube Temp充液管温度Metal Temp
34、金属温度Is the end of the tube clean导管末端是否洁净Did the metal flow from the tube miss the sleeve.充料时没有对准料缸Condition 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
35、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
36、部解决。,Process Management过程管理,Most 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 met
37、al 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 attribu
38、ted 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 r
39、esult 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
40、of one of the following,有裂缝的零件通常是由以下某原因造成的：too much pressure during intensification增压过程中太多压力the part sticking to the die零件难以与模具脱离poor intensification hold持压时间不足the 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。These are not all of the scrap related problem
41、s 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,it 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。we are able to compensate for many
42、 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 a
43、nd 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。,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 worked on similar problems either got
44、 help from another person,made lots of scrap or got incredibly lucky.The best thing that you can do to help yourself trouble shoot a problem is to look at the problem from a simplistic point of view,如果你不能够正确处理某个问题，不要害怕去问别人。任何人在处理类似的问题时都是要么向别人寻求帮助，要么生产出很多废件，要么就是出奇地好运。你能够帮助自己预见问题的最好的办法就是从最简单的角度去看问题。as
45、k yourself some basic questions when you think that you are ready to make a change only do one at a time,wait at least three shots before evaluating the success or failure of the change,some changes such as die or metal temp may take several shots to realize the full effect.last of all record what y
46、ou did the prior set point and the new one.当你自己认为你已经做好准备可以变更(参数)的时候，问你自己 一些最基础的问题，然后等待。等机器再做三次压射之后再评估到底你的变更是正确的还是错误的。有些变更，例如模具或金属温度，有可能需要等压射好几次之后才能够意识到变更所带来的全部效果，最后将变更前的设置及变更后的设置分别记录下来。,Process Management过程管理,If successful then make a note somewhere that if it should happen again you have a referenc
47、e guide that may be of some help.如果更改成功，你可以做一下记录。等下次发生同样问题时可以作为参考，或许就能帮你解决问题了。To end this topic its is important to understand that we follow a process to eliminate one of the biggest quality related problems there is CONSISTENCY(or lack of),Just like if your machine is constantly starting and stopping your scrap rate is much higher this would be the same if you constantly changed the settings on the machine.在结束我们的课程之前，我们应该明白很重要的一点，就是要了解我们的过程管理应该帮助我们解决最主要的质量问题之一，就是一致性（或缺乏一致性）。就象你的机器如果经常开关，那么你的废件率就非常高。同样，如果你经常更改机器上的设置，那么你的废件率也会很高。,
