白车身关键分总成合格率提升流程

林建辉　蒋伟光

摘 要：汽车白车身是由100多个分总成拼接而成，其中关键分总成大约有20多个，这些关键分总成作为白车身重要组成部分，同时也是底盘及各种功能零件关键安装点的集中区域，分总成的焊接质量，尺寸状态与白车身三坐标合格率、总装装配精度等有密不可分的联系，进而影响整车各项性能表现，所以分总成尺寸合格率控制是白车身制造技术的重要环节。本文通过PDCA循环质量提升方法，包含现状调查、原因分析、措施制定、效果检查等相关内容以及在提升过程中夹具调试技巧分析相关内容，提升分总成合格率，确保白车身满足各项功能要求。

关键词：关键分总成 PDCA 夹具调试 尺寸合格率

The Process of Improving the Qualification Rate of the Key Sub-assembly of the Body-in-white

Lin Jianhui Jiang Weiguang

Abstract：The car body-in-white is composed of more than 100 sub-assemblies， of which there are about 20 key sub-assemblies. These key sub-assemblies are an important part of the body-in-white， as well as the key installation of the chassis and various functional parts. The point concentration area， the welding quality of the sub-assembly， and the size state are inextricably linked with the three-coordinate qualification rate of the body-in-white， and the assembly accuracy of the final assembly， etc.， affects the performance of the entire vehicle， so the sub-assembly size qualification rate control is an important part of the body-in-white manufacturing technology. This article uses the PDCA cycle quality improvement method， including status investigation， cause analysis， measure formulation， effect inspection and other related content， as well as fixture debugging skills analysis related content in the upgrading process， to improve the sub-assembly qualification rate and ensure that the white body meets various functional requirements

Key words：key sub-assembly， PDCA， fixture debugging， dimensional qualification rate

1 引言

白车身主要有前大梁总成、下安装板总成、前围板总成、侧围分总成、后车架总成，顶盖总成、地板总成以及门盖总成等关键零部件总成拼接而成，如图1。白车身是汽车框架最重要的部分，它是底盘关键件、发动机以及其他总装件安装的载体。所以白车身质量控制是能否造好车的基础，而质量好的白车身，零部件质量控制是关键。影响分总成合格率数据的因素众多，涉及产品设计、冲压成型、焊接夹具、焊接变形和操作过程等多方面，因此如何快速提升分总成试制环节合格率需要一套流程作为指导。

2 分总成合格率提升流程准备工作

现场合格率提升过程前先要对以下几项关键信息进行准备和掌握：（1）熟悉零件的产品结构及……