I 摘要 近年来，中国经济进入新常态、房地产行业的持续低迷低靡和人力资源成本、原 材料成本大幅上升导致卫浴行业增速明显回落，卫浴企业发展面临着前所未有的困难。 巩固和增加市场份额，是卫浴生产企业要解决的重要问题。而产品质量是这一问题的 关键因素之一。作为传统行业，卫浴行业早期是＂自己自足＂的生产模式，零部件由 企业自己生产、自己组装并销售。而现在，随着工业生产分工越来越细，从专业分工 和成本的角度出发，越来越多的卫浴企业采取了直接从外部采购零件、在企业内进行 组装的方式进行生产。卫浴产品质量的高低很大程度上取决于零件质量水平。同时， 对于卫浴产品来说，零件成本占到产品总成本的 60%以上。因此，外购件质量管理的 重要性不言而喻。本文希望通过对 FB 公司外购件质量管理的研究，达到提高产品质 量、降低成本的目的。 本文以 FB 公司外购件质量管理为研究对象，从外购件供应商的选择、外购件的 认可、外购件来料检验、外购件质量异常处理的现状入手，发现了 FB 公司目前外购 件质量管理存在的问题并运用相关的质量管理理论和方法进行了分析。主要问题包括， 外购件供应商选择把关不严；外购件认可验证不充分；外购件进料检验缺乏有效性； 外购件质量异常处理效率低下。基于现代质量管理理论和方法的应用，本文优化了外 购件选择的流程和方法，对外购件认可过程进行了细化和完善，在外购件进料检验过 程主要完善了检验计划并建立了 FB 公司 IQC 人员考核机制，在外购件质量异常处理 中运行了物料评审委员会机制，同时采用了更为科学的七钻石法规范分析问题的方法， 为 FB 公司外购件质量管理工作提供了完整的改进方案。 论文的研究成果可以为 FB 公司外购件质量管理的改善提供指导，并对其他同行 业类似的企业具有一定参考价值。 关键词，外购件，质量，卫浴产品西安电子科技大学硕士学位论文 IIABSTRACT III ABSTRACT In recent years, with China’s economy entering the “New Normal”, the continuing downturn in the Chinese real estate market and the sharply risen labor cost and raw material cost result in significant drop of growth rate in sanitary products industry. Sanitary Manufacturers are facing unprecedented difficulties. To keep and extend the market share is a vital problem that need to be solved to sanitary manufacturers.Quality is one of the key elements to this problem. As one of triditional industries, the early sanitary manufacturers usually adopt the ‘Self-sufficient’mode，which means producing parts， assemblying parts to finished products and selling products by themselves. Nowdays, considering specialization and cost,more and more sanitary manufacturers purchase parts from outside suppliers and only assembly finished products within their company. The quality of parts plays a very important role in the quality of finished sanitary products.Meanwhile, the cost of parts account for 60%+ total cost of finished sanitary product.The importance of purchased parts’quality management is obvious. This thesis expects to improve the quality of finished sanitary product and lower the cost by studying the quality management of purchased parts in FB company. The thesis takes the quality management of purchased parts in FB company as studying object based on the quality management situations of purchased parts’ supplier selection, purchased parts approval, incoming inspection and quality issue handling.Then, obtained the existing problems and analyzed the causes by quality theories and methods.The problems include:the laxity in supplier selection; insufficient verification in part approval; lack of effectiveness in incoming inspection; low efficiency in quality issue handling. Based on application of modern quality theories and tools，the thesis optmized the workflow and method of supplier selection, refined and improved the process of purchased parts approval; modified the inspection plan and established IQC staff’s performance evaluation method in incoming process; adopted the Material Review Board and GM Seven diamonds method to standardize the process of purchased parts’ quality issue handling. This thesis provides an integrated improvement scheme to purchased part’s quality management in FB company.西安电子科技大学硕士学位论文 IV The thesis is guidance to the improvement of purchased part’s quality manangement in FB company. It also has reference value to similar companies in sanitary industry. Keywords: Purchased Parts, Quality, Sanitary Products插图索引 V 插图索引 图 1. 1 论文结构框架图.......................................................................................................4 图 2. 1 PDCA 循环 .............................................................................................................10 图 2. 2 鱼骨图.................................................................................................................... 11 图 2. 3 通用七钻石法步骤图............................................................................................12 图 3. 1 FB 公司及广州办事处组织架构图.......................................................................13 图 3. 2 FB 公司苏州工厂组织架构图...............................................................................14 图 3. 3 典型的龙头产品分解图........................................................................................15 图 3. 4 龙头生产工艺流程图............................................................................................15 图 3. 5 外购件质量管理分工图........................................................................................16 图 3. 6 某新供应商质量体系审核雷达图........................................................................20 图 3. 7 进料检验流程图....................................................................................................26 图 3. 8 外购件质量异常处理流程图................................................................................27 图 3. 9 2017 年 PPM 责任分布图......................................................................................31 图 3. 10 因果分析结果图..................................................................................................32 图 4. 1 优化后的供应商选择流程图................................................................................39 图 4. 2 层次抽样示意图....................................................................................................47 图 4. 3 对角抽样示意图....................................................................................................47 图 4. 4 物料评审委员会组织架构图.................................................................................49 图 4. 5 每日质量问题追踪记录看板.................................................................................50 图 4. 6 MRB 机制质量异常流程图...................................................................................50 图 5. 1 2018 年 PPM 分布图.............................................................................................56西安电子科技大学硕士学位论文 VI表格索引 VII 表格索引 表 3. 1 供应商基本信息调查表........................................................................................17 表 3. 2 供应商行为准则审核表........................................................................................18 表 3. 3 某新供应商质量体系评估表................................................................................19 表 3. 4 样品外观认可报告................................................................................................21 表 3. 5 样品尺寸认可报告................................................................................................22 表 3. 6 外购件认可提交要求表........................................................................................22 表 3. 7 C=0 抽样方案.........................................................................................................25 表 3. 8 外购件单孔阀体 167215 认可过程进度情况统计表..........................................28 表 3. 9 2017 年 FB 公司外购件已认可物料统计信息......................................................30 表 4. 1FB 公司外购件质量管理改进方案的改进思路 ...................................................36 表 4.2 冲压过程审核表....................................................................................................