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Polyurethane foam is the main production process for the sponge of vehicle seat,which directly determines the quality of the seat sponge. The process involves manydisciplines: mechanical, chemical, automatic control, electronics, and process complexrange of relevant parameters. Currently, the industry generally rely on the experience of theoperator control often cause foaming process instability obvious defects phenomenon, ahigher rate of product rejection. In this paper, based on the theory of probability theory andmathematical statistics6sigma scientific management methods, through the five steps ofthe DMAIC (Define, Measure, Analyze, Improvement, and Control), use some scientificstatistics tools, such as: hypothesis testing, analysis of variance, regression analysis andexperimental design and so on, in-depth study of polyurethane foam technology, to find anassociation between the process parameters in the foaming process and laws, and toprovide guidance to the results of its foaming process.Before the start of the study, collected some seat sponge defect data for five months,and do statistical analysis to the data, to identify the research goals, define the scope of thestudy. According to the characteristics of polyurethane foam technology, and use processflow diagram, C&E Matrix, brainstorming method to identify all the potential impact offactors that may affect the research objectives. Through design of experiments, hypothesistesting, we can get the key key impact factors.Finally, by improving the experimental Optimization the experimental binding theDOE Increasing stars step experimental strategy, using Minitab statistical analysis softwareto indentify the relationship between the response and factor, or the relationship betweenthe factor and the factor. Establish the quantitative mathematical model, Finally, byoptimizing the experimental parameters to optimize the allocation of response optimizer todetermine the mathematical model parameter method, and the use of correlation andregression analysis validated and simplified mathematical model, verification andadjustment in trial production, and ultimately worked out a foaming process parameters ofthe standard form used to guide the actual production.Finally, the research results effectively solve the problem of the actual productionprocess, greatly improving the Company sponge Yield First Time Through, bring someeconomic benefits, and provide some guidance for the entire seat foam sponge industry.
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