摘 要
2011 年 6 月，为了增强在风电市场中的竞争力，YSM 公司引进一场称为“必赢”战役。
全球机舱工厂参与的大项目有两个：精益生产和六西格玛。质量关键点中的改善发电机和
齿轮箱对齐调整的质量水平被提为六西格玛项目。目前，YSM 公司的发电机和齿轮箱调整
对齐的质量水平为二西格玛左右，调整时间长，且调整结果不稳定。客户对 YSM 公司的这
一项质量指标的满意度不高，甚至有时需要 YSM 公司派出维护人员，在客户风场中的几十
米高空上的风机上去返工。
为了增强顾客满意度，响应总部的号召，减少不良成本,YSM 公司决定决定采用六西格
玛的方法，研究发电机和齿轮箱调整对齐的质量改进。
YSM 公司按六西格玛已经成形的 DMAIC 模式进行分析、论证、研究这一课题。首先，
界定研究的范围，识别同课题相关的关键过程；然后，明确并量化关键过程的输出，制定
改进目标；接着，使用鱼骨图等，推测影响过程失效的因素，再基于过程流程图，对过程
进行分析，利用过程潜在失效模式和后果分析工具筛选出影响过程输出的主要因素；紧接
着，消除或减少这些假设的主要因素的影响，运行过程并验证假设；最后，如果改进方法
有效，对改善的过程流程进行文件化，编写控制计划，并对过程进行统计控制，以保持改
进的成果。在研究这一课题的过程中，我们使用了大量的工具、图形和图表，如流程图，
鱼骨图，因果矩阵，过程潜在失效模式和后果分析，Minitab 软件等。
YSM 公司通过六西格玛方法，最终找到了提高发电机和齿轮箱调整对齐质量水平的方
法，能够将这一过程的质量水平由原来的二西格玛提高到六西格玛，且缩短了调整时间。
如果按此优化的流程操作的话，将大大降低生产成本和质量成本，并提高工作效率。在研
究和实践的过程中，我们逐渐掌握了六西格玛的 DMAIC 方法，熟悉了测量系统分析，控制
图，过程失效模式及后果分析，Minitab 软件等工具，并在项目的团队活动中增强了团队
的协作能力。
关键词：质量水平, 统计控制，发电机的调整对齐，六西格玛，DMAIC 模式
ABSTRACT
In June 2011, In order to be more competitive in wind power market, a battle called “MUST
WIN” was introduced to YSM company. There are two big projects involved at Nacelle PBU:
lean production and six sigma. One of the critical to quality point that improve the alignment
quality level of generator and gear box is implemented as six sigma project. Currently, YSM
quality level of aligning generator and gear box is about two sigma and it takes a lot of time, and
adjusting results is instability. Customers are not satisfied with the quality level, and sometimes
YSM has to send maintenance personnel to rework it in wind turbine which stands tens of meters
high on field.
YSM company decides to adopt six sigma methods to study quality improvement of the
aligning generator and gearbox in response to the call of headquarter and to enhance customer
satisfaction and to reduce non-conformity costs.
YSM analyzes and demonstrates and researches on the subject by six sigma DMAIC mode.
First, define the scope of the study, identify process related with the subject; second, clarify and
measure the critical outputs of process, and set goals; then, use the fishbone diagram to presume
the factors causing the process failure, analyze the process base on the flowchart and select the
major input factors by tool of process potential failure mode and effects analysis; the forth,
remove or reduce these major factors and run process to verify the assumption; finally, if the
corrective method is effective, revise the process documents and implement statistical process
control to keep the improvement achievement. During the research on the subject, we used a lot
of tools and graphics and charts, such as flowcharts, fishbone diagram, cause and effect matrix,
process potential failure mode and effects analysis, Minitab software etc.
YSM company ultimately finds a method to improve the aligning quality level of generator
and gearbox through six sigma methodology, and reduce the time of adjust. Now the quality
level of aligning becomes from six sigma to four sigma. If our people work according to the
optimized process and methods, then it will greatly reduce the production cost and
non-conformity cost, improve work efficiency. In the meantime of research and practice, we
gradually understand the six sigma DMAIC methodology, and familiar with the MSA, control
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chart, PFMEA, Minitab and other tools，the project team activities also enhance our team
collaboration.
KEY WORDS：quality level，statistical control，generator alignment，six sigma，dmaic