Manufacturing Quality Risk Analysis Approach Considering Production Process Scheme Robustness

5M1E(Man, Machine, Material, Method, Measurement, Environment) are the risk sources of the manufacturing quality, and the production process scheme is the kernel and carrier of the method. However, previous studies of manufacturing quality risk mainly focused on the qualified rate of material and degradation state of machine but ignored the influence of the robustness of the process scheme. Therefore, an extended manufacturing system Reliability-process Quality-product Reliability chain (E-RQR) model was proposed to consider the effect of process robustness on manufacturing quality risk. Firstly, the product process scheme and the connotation of manufacturing quality risk are expounded, and the formation mechanism of manufacturing quality risk based on E-RQR chain is proposed. Secondly, through the collection of manufacturing system operation data and product quality data, the manufacturing quality risk of the manufacturing system and the robustness of process scheme were quantified. On this basis, the technical framework of manufacturing quality risk analysis based on E-RQR chain was proposed. Thirdly, to verify the influence of the robustness of product process scheme on manufacturing quality risk, a robust optimization method of process parameters based on Back Propagation(BP) neural network and Taguchi design was proposed, which proved that robust process scheme can significantly improve manufacturing quality risk. Finally, the feasibility of the proposed method was proved by taking a hydraulic pump as the research object.