扭矩保證程序培訓(xùn)

1、整理課件Torque Integrity Assurance Program Training扭矩保證程序培訓(xùn)AP&A Manufacturing Quality5/19/2006 Rev 2整理課件Preparing your plant for TIAP工廠準備工廠準備Set up a Fastening System Control Team建立扭力控制小組 Identify a champion (Final Area Manager)確定一名領(lǐng)導(dǎo)(總裝區(qū)域經(jīng)理) Identify a supervisor or team leader (Torque expert or en

2、gineer)確定一名主管或小組組長(扭矩專家或工程師) Identify other team members and functions (Torque auditors, power tool repairmen and TPPS personnel)確定其他多功能成員(扭矩審核員,工具維修人員和TPPS人員)Read procedures & standards (VOPFAN241, PT-3, PT-5) Located in AP&A e-room閱讀程序和標準(VOPFAN241, PT-3, PT-5)Develop computerized list of

3、torque tools with calibration requirements建立軟拷貝的扭矩清單(包含校準要求)Develop a documented audit route 開發(fā)書面的扭力檢查路線Develop files to keep records and reports used to manage your torque program建立專用文件夾來保存扭力控制的記錄和報告.Perform torque assurance self assessment執(zhí)行扭矩保證自我評估.整理課件What is Torque?什么是扭矩什么是扭矩? Simply stated, to

4、rque is the force that turns a threaded fastener (screw, nut, bolt).簡單地說,扭矩就是旋轉(zhuǎn)有螺紋的堅固件(螺栓,螺母,螺釘)力矩 The primary function of these fasteners is to hold or clamp parts together.緊固件的主要作用是連接或夾緊零件. It is important that adequate clamp load exist. 足夠的剪切力很重要. Clamp Load is difficult to measure in a productio

5、n environment, it is done in a laboratory by在生產(chǎn)環(huán)境中剪切力的測量是很困難的, 在實驗室可由以下方式測得: Measuring the length of the fastener 測量緊固件的長度 Using a load cell in the joint有接合處用一個負載元件 Using strain gauges on the fastener在堅固件上用張力量具 Using ultrasonic measurements用超聲波測量 The best we can do is measure Torque工廠最好辦法就是測量扭矩工廠最好辦

6、法就是測量扭矩.整理課件How Do We Measure Torque?我們該如何測量扭矩我們該如何測量扭矩?Dynamic torque is electronically measured with a transducer during the securing process of a fastener. (Setting Torque)動態(tài)扭矩是在旋緊緊固件過程中通過傳感器自動測量(設(shè)定扭矩值) It does not take into account changes that occurs to joint clamp load after processing point.

7、它不會考慮裝配后接合處扭矩的變化. It is used to center a tool at the mean of the torque specification (setting torque) and to monitor the process.將扭力工具設(shè)定在規(guī)范的中間值(設(shè)定扭力),以監(jiān)控扭緊過程.Residual torque is measured through minimal rotation, in the tightening direction of a secured fastener. (Breakaway or Static)殘余扭矩是沿緊固件旋緊方向通過

8、測量最小旋轉(zhuǎn)力(分離或靜態(tài)) It is the torque left in the joint after fastener installation. 它是在緊固件裝配后殘留在接合處的扭矩. Measurement is made by rotating the fastener a few degrees more in the tightening direction with a hand-held torque wrench.測量是用手持扭力扳手在緊固件沿緊固方向旋轉(zhuǎn),緊固件剛旋轉(zhuǎn)時測量的扭力值.整理課件How to Determine Residual Limits?如何確定殘

9、余扭力的控制限如何確定殘余扭力的控制限? Residual limits are determined by performing a Torque Process Potential Study (TPPS) on the operation. 殘余扭力的限值是通過實施扭力過程潛在研究確定的. TPPS dynamically centers the tool at the specification mean, determines its process potential (Pp & Ppk), measures the resulting residual torque va

10、lue. TPPS是將工具設(shè)定在規(guī)范中值,確定它的初始過程能力(PP&PPK),測量產(chǎn)生的殘余扭矩值 The analysis of the residual data determines the inspection limits for that process. 分析殘余扭力值確定扭力監(jiān)控的限值.整理課件How to Determine Capability of a Torque Process?如何確定扭矩過程能力如何確定扭矩過程能力? 3 Basic Methods: Torque Process Potential, Process Prove out, and Pro

11、cess Capability 3種基本方法:扭力過程潛在研究,過程輸出,和過程能力 TPPS is required for all Mandatory and Significant Operations (Delta Safety CCs and SCs). Full study which records Dynamic and residual torque, dynamic Pp and Ppk data is used to report capability of a process and residual is used to determine audit limits

12、during surveillance. 對所有法規(guī)強制要求的和重要的扭力(三角符號涉及安全的CC項和SC項)應(yīng)實施復(fù)雜的TPPS .復(fù)雜的TPPS應(yīng)記錄動態(tài)和殘余扭矩,動態(tài)扭力的pp和PPk數(shù)據(jù)用來報告一個過程的能力,殘余扭力用來確定日常扭力監(jiān)督過程中檢查控制限. Torque Prove-out is a short study which records 20 consecutive values and is used to center the tool output to the mean of the dynamic torque and verifies process is

13、within Engr. specification.扭矩過程輸出:是短期研究.記錄20個連續(xù)值,并將工具設(shè)定在動態(tài)扭矩值的中間值,確認過程滿足工程規(guī)范的要求. Torque Process Capability is continuous data collecting in subgroups of 5 values at predetermined intervals used for x-bar-r control charts and Cp and Cpk values.扭矩過程能力:按規(guī)定的時間間隔,連續(xù)測量1個子組5件產(chǎn)品的扭力,用來做Xbar-R圖及計算Cp和Cpk值.整理課件

14、What is TPPS?什么是什么是TPPSTorque Process Potential Study (TPPS) is a process for examining threaded fastener operations. It aligns an operation to the dynamic mean specification, and to establish residual torque limits for monitoring that operation.扭矩過程潛在研究是檢查緊固件緊過程,確保生產(chǎn)過程達到動態(tài)扭力中間值,并建立過程監(jiān)控的殘余扭矩限值. Full

15、 TPPS requires a minimum of three (3) separate subgroups of 20 data values of both dynamic and residual 復(fù)雜的TPPS 要求最少3個子組,每個子組至少連續(xù)20個數(shù)據(jù),包括測量動態(tài)和殘余扭矩值.Mini TPPS has the same definition as the Torque Process Potential Study listed above with exception of the sample size taken.簡單的TPPS 除了抽取樣本的大小不同,其他與上面提到

16、的TPPS相同. Mini TPPS is a short study which records 30 consecutive torque values. 簡單的TPPS是短期過程研究,它只記錄30個連續(xù)的扭矩值. If this study indicates that either the dynamic or the residual data cannot be contained within the Engineering Specification Range, a longer study is required 如果簡單的TPPS研究顯示,動態(tài)或殘余數(shù)據(jù)不能滿足工程規(guī)范要

17、求,就需要進行長期的研究.整理課件When is TPPS Required?實施實施TPPS的時間的時間New Critical (Safety) operations require a full TPPS completed within 3 months of Job#1 or the “Effected In” date of the engineering change.新的關(guān)鍵的(安全的)扭力項目,復(fù)雜TPPS要求在JOB 1#或工程變更生效日之后3個月內(nèi)完成.New Significant operations require a full TPPS completed wit

18、hin 6 months of Job#1 or the “Effected In” date of the engineering change.新的重要扭力項目,復(fù)雜TPPS要求在JOB 1#或工程變更生效日之后6個月內(nèi)完成.New Other (not designated Critical/Mandatory or Significant) operations require a MINI TPPS completed within 12 months of Job#1 or the “Effected In” date of the engineering change.新的其他的

19、(非關(guān)鍵的/強制的或重要的)扭力項目，簡單TPPS要求在JOB 1#或工程變更生效日之后12個月內(nèi)完成。NOTE: Temporary additional teams members may be added during launch and funded by launch budget. Once a TPPS has been completed on each threaded fastener operation, a new TPPS will only be required if there is a change to the joint composition or f

20、astening process such as: Fastener finish, Fastener change, Joint component change and Torque value is different than process sheet value.注意注意:在試生產(chǎn)過程中應(yīng)增加臨時的在試生產(chǎn)過程中應(yīng)增加臨時的TPPS小組成員和相應(yīng)的預(yù)算小組成員和相應(yīng)的預(yù)算.當(dāng)扭力的當(dāng)扭力的TPPS完成后完成后,僅在接合部件或緊固過程變更發(fā)生時才被要求重新實施該特性的僅在接合部件或緊固過程變更發(fā)生時才被要求重新實施該特性的TPPS，如：緊固件變更、接合，如：緊固件變更、接合部件變更、

21、扭矩值與過程規(guī)定不同部件變更、扭矩值與過程規(guī)定不同.整理課件Setting Up Operations作業(yè)準備作業(yè)準備獲得經(jīng)過檢定的動力工具確認正確的工具安裝適宜的空氣壓力或控制動態(tài)中值規(guī)范1、正確的工具安裝？2、正確的已調(diào)整的及有功能的潤滑系統(tǒng)？3、正確的空氣壓力設(shè)置？4、接口和鉆頭是否完好？重新分配或安裝過程變更形式新車型轉(zhuǎn)到：新車型程序（僅為“C”或“S”運行工程變更或由空氣轉(zhuǎn)為直流電采集10個殘余讀數(shù)采集20個殘余讀數(shù)是否有讀數(shù)在低于規(guī)范？是否有讀數(shù)在低于規(guī)范？轉(zhuǎn)到：糾正措施轉(zhuǎn)到：糾正措施A、TTPS優(yōu)先整理課件New Model Programs新車型程序新車型程序主要的新車型程序（

22、關(guān)鍵的和重要的操作）JOB 1#之前JOB 1#之前或之后JOB 1#之后用電動工具緊固，在接合模擬器上設(shè)置動態(tài)中值用定扭力扳手確認扳手響之前，緊固件是否發(fā)生旋轉(zhuǎn)識別緊固件為第2 優(yōu)先識別緊固件為第一優(yōu)先跟蹤第一優(yōu)先發(fā)生的趨勢測量殘余扭矩以確定最小值識別問題并文件化糾正措施寫PSO 以繼續(xù)進行100%手工扭矩100%的手工扭矩運行后開始有規(guī)律的扭矩監(jiān)視第一優(yōu)先或第二優(yōu)先緊固件停止手工操作開始有規(guī)律的監(jiān)控優(yōu)先TPPS轉(zhuǎn)到：運行準備第一步整理課件Steps to Conducting a TPPS執(zhí)行執(zhí)行TPPS的步驟的步驟 Attachments within training package

23、outlines steps to conducting a TPPS study 本培訓(xùn)包的附件明確了執(zhí)行TPPS的步驟整理課件How to Collect the data?如何收集數(shù)據(jù)如何收集數(shù)據(jù)Collecting actual data for TPPS為TPPS收集實際數(shù)據(jù)Sample 66 units for both dynamic (dynamic data only) and residual torque for Full TPPS. The object is to get 60 useable samples of dynamic torque and 60 of r

24、esidual torque 復(fù)雜的TPPS，需要抽樣66臺車的動態(tài)（僅動態(tài)數(shù)據(jù)）和殘余扭矩值。其目的是為了獲得60個可用的動態(tài)扭矩和60個殘余扭矩的樣本值。Take a sample set of 22 units and analyze the sample, both the dynamic and residual values should be taken from the same fastener抽取22臺車為一組樣本測量動態(tài)和殘余扭矩值并分析，動態(tài)和殘余扭矩值應(yīng)測量同一個緊固件。Before taking the second and third sample sets, c

25、heck that the process has not changed (i.e. tool, air pressure, etc. have not been changed). After taking the first 10 samples in each set, check that the mean is close to the original setting在取得第二組和第三組樣本之前，檢查過程沒有變更（如，工具，空氣壓力等未發(fā)生變更），在取得每組前10個樣本后，檢查均值是否靠近初始設(shè)定值。Take the second sample set of 22 units o

26、n the following shift and the final sample set of 22 units on the next shift by alternate technician在隨后的班次采集第二樣本組的22個車，最后一個樣本組的22個車可由輪班技師在下一個班次抽取。Sample 30 units for both dynamic and residual torque on a single shift for Mini TPPS對于簡單的TPPS ，在一個班中抽取30個車測量動態(tài)和殘余扭矩Multiple fasteners perform full TPPS fo

27、r each fastener多個緊固件時，為每一個緊固件實施復(fù)雜的TPPSMultiple stations perform full TPPS on one station and remaining you mean center the tool and determine Ppk based on 30 samples多個工作站情況下，每一個工作站執(zhí)行復(fù)雜的TPPS，并且設(shè)定工具中間值及確定在30個樣本的PPK。整理課件How to Analyze the data?如何分析數(shù)據(jù)如何分析數(shù)據(jù) Print Datamyte reports and graphs, review dyna

28、mic and residual data打印數(shù)據(jù)報告和圖形，評審動態(tài)和殘余數(shù)據(jù) Dynamic histogram should show normal distribution and Pp/Ppk should be greater than 1.33動態(tài)柱狀圖應(yīng)顯示正態(tài)分布并且PP/PPK值應(yīng)大于1.33 The objective for operations with new components and tooling is a minimum Ppk of 1.67. For “critical” operations that have a Ppk less than 1.3

29、3, initiate 100% click wrench checking until the process is proven capable新零件和工具的過程能力目標為新零件和工具的過程能力目標為PPK最小最小為為1.67。 對于關(guān)鍵特性其對于關(guān)鍵特性其PPK值小于值小于1.33的情況下，用的情況下，用100%定扭扳手定扭扳手檢查，只到其過程證明有能力。檢查，只到其過程證明有能力。 Residual histogram should show normal distribution and stable individual moving range charts殘余扭力柱狀圖應(yīng)顯示過

30、程是正態(tài)分布并且極差圖顯示過程穩(wěn)定。整理課件Torque Surveillance扭力監(jiān)視扭力監(jiān)視Torque Surveillance is the monitoring of threaded fastener operations to assure that they remain within specification and in control. This monitoring may give the first indication that the process is changing or that a concern exists. 扭力監(jiān)控就是檢查緊固件操作以確保

31、它們滿足規(guī)范之內(nèi)并且受控，扭力監(jiān)控可以在最快的時間內(nèi)發(fā)現(xiàn)過程改變或存在的問題。 Monitoring involves taking (5) torque data samples (dynamic or residual) and making contact with the operator for comments on any detected changes.扭力監(jiān)控是檢查5個扭矩樣本(動態(tài)或殘余),對發(fā)生的任何變化應(yīng)與操作者溝通。 Critical Item (5) samples twice per shift關(guān)鍵項目，每班兩次，每次5個樣本。 Significant Item

32、s (5) samples once per shift重要項目每班一次,每次5個樣本 Sampling rate on other operations or low volume (7 fewer jobs per hour) are at Assembly plant discretion非重要特性或低產(chǎn)量（每小量少于7臺）的抽樣標準由裝配工廠自己判定. High Torque (check or adjust tooling, notify production with concern） notice for further actions實測扭矩高于控制線（檢查或調(diào)整工具，使用TC

33、N）,確定下一步措施. Low Torque (mark unit, notify production with concern notice and go into corrective action mode實測值低于控制線（標記問題車輛，使用TCN并采取糾正措施).整理課件Torque Surveillance制造部門確認過程工具或正確的程序正在被使用維修已標識部件緊固系統(tǒng)控制C項目S項目每班兩次，每次5個樣本每班一次，每次5個樣本對于低數(shù)量操作的抽樣頻率和數(shù)量，參見本文件的“監(jiān)控內(nèi)容”值在規(guī)范限之外?用扭矩問題通知通知制造部門，參見文字的詳細內(nèi)容高或低檢查工具，與操作者進行評審用TC

34、N通知制造部門和FSC協(xié)調(diào)員下載數(shù)據(jù)到計算機下載數(shù)據(jù)到扭矩檢查和研究系統(tǒng)標識車輛用TCN通知制造部門轉(zhuǎn)到糾正措施生成要求的報告整理課件Corrective Action糾正行動糾正行動 If low torque is identified in second 5 sample units如果第二次重新采樣的5個樣本中,發(fā)現(xiàn)實測扭力低于控制限 If all the samples are within the residual limits (residual data), take five (5) torque samples every hour for the next two (2)

35、 hours. If no other out-of-specification samples occur, return to normal sampling 如果所有樣本都在殘余控制限內(nèi)（殘余數(shù)據(jù)），在接下來的2個小時內(nèi)，每小時采集5個扭力樣本，。如果沒有超出規(guī)范，回到正常抽樣狀態(tài)。 When a torque concern has been confirmed by one reading in a second sample of five, Production Supervisor and/or Auditor will immediately call the Quality

36、 Manager, or designee with the torque concern information. The Quality Manager will instruct the Pre-Delivery Supervisor to stop shipping all vehicles如果第二組抽樣中,發(fā)現(xiàn)扭力超出控制線，生產(chǎn)主管和/或?qū)徍藛T立即通知質(zhì)量經(jīng)理或相關(guān)人員。質(zhì)量經(jīng)理通知車輛發(fā)運主管停止發(fā)運所有車輛。 Correct all plant controllable causes 糾正所有現(xiàn)場可控制的原因 Campaign downstream units with a c

37、licker wrench set at the minimum torque, to the last sampled unit or until all units not shipped are checked 將扭力扳手設(shè)定在扭規(guī)范的下限,對所有已生產(chǎn)的車輛進行全部檢查,直到上次抽樣合格的車輛或所有未發(fā)運車輛被全部檢查為止。整理課件Corrective Action Mode制造部門/預(yù)交付緊固系統(tǒng)控制抽取6個以上讀數(shù)從扭力監(jiān)控僅關(guān)鍵的項目停止發(fā)運100%手工檢查招回系統(tǒng)驗證糾正的工具和過程更新TCN，通知主管增加檢查糾正過程問題解決寫CR/CR保留糾正日志新零件發(fā)出QR值低于最小扭力值低于最小扭力根本原因工廠可控制的問題增加檢查到每小時5件，隨后2小時手工檢查，直到過程被糾正，設(shè)置定扭扳手為最小扭力值召回行動用設(shè)置了最小扭力的定扭扳手進行手工扭力檢查所有車輛整理課件Tool Calibration Frequency工具校準頻次工具校準頻次 Develop tool calibration list with frequency, tool