六西格瑪測(cè)量解讀課件

1、 Measure PhaseGB Mod #8Continuous Improvement Road MapImprove改進(jìn)Control控制Define CTQ 定義關(guān)鍵質(zhì)量特性Determine Current State 確定當(dāng)前水平Determine Key Input / Output Variables 確定 關(guān)鍵輸入/輸出 變量Perform MSA 進(jìn)行測(cè)量系統(tǒng)分析Calculate initial process capabilities 計(jì)算初始過(guò)程能力Measure 測(cè)量Verify Effects of Key inputs with DOEs使用試驗(yàn)設(shè)計(jì)來(lái)驗(yàn)證關(guān)鍵輸

2、入的影響Determine Optimum Settings 優(yōu)化關(guān)鍵輸入的了水平Update Control Plan 更新控制計(jì)劃Verify Improvement驗(yàn)證改進(jìn)的 結(jié)果Analyze 分析Evaluate Existing Control Plan 評(píng)估當(dāng)前的控制計(jì)劃Using statistical methods to determine potential key inputs 使用統(tǒng)計(jì)方法篩選潛在關(guān)鍵輸入Prioritize key input variables確定各關(guān)鍵輸入的 影響大小NDefine 定義測(cè)量階段 制定項(xiàng)目計(jì)劃識(shí)別關(guān)鍵輸入和關(guān)鍵輸出驗(yàn)證測(cè)量系統(tǒng)確定

3、初始過(guò)程能力測(cè)量 - 工具箱過(guò)程流程圖測(cè)量系統(tǒng)分析/ 量具重復(fù)性再現(xiàn)性過(guò)程能力分析CPK(連續(xù)型變量）DPMO(計(jì)數(shù)型變量）課程目的 理解數(shù)據(jù)類型連續(xù)型變量計(jì)數(shù)型變量能夠畫(huà)出過(guò)程流出圖，并識(shí)別出過(guò)程的輸入輸出理解測(cè)量系統(tǒng)誤差的要素理解過(guò)程能力Process Mapping Suppliers供應(yīng)商Business企業(yè)Customers客戶塊狀圖少量的細(xì)節(jié)輸入-輸出圖詳細(xì)的隨著逐層分解一步步細(xì)化過(guò)程流程圖非常詳細(xì)Process Mapping Levels of detail 詳細(xì)的過(guò)程圖是一種描述Y=F(X）的關(guān)系的結(jié)構(gòu)化的方法使用按部就班的7步法 團(tuán)隊(duì)合作一個(gè)人不知道所有的過(guò)程In a pl

4、ant project:制造工程師操作人員生產(chǎn)線主管維修人員詳細(xì)的過(guò)程圖詳細(xì)流程圖的輸入頭腦風(fēng)暴現(xiàn)場(chǎng)觀察作業(yè)指導(dǎo)書(shū)工程標(biāo)準(zhǔn)操作者的經(jīng)驗(yàn)人，機(jī)，料，法，環(huán)Step 1定義項(xiàng)目團(tuán)隊(duì)需要關(guān)注的過(guò)程范圍。過(guò)程范圍應(yīng)在可操作的水平。準(zhǔn)備反應(yīng)堆氧化穩(wěn)定完成裝上融化的蠟放進(jìn)規(guī)定的點(diǎn)放進(jìn)規(guī)定的點(diǎn)檢查噴嘴型號(hào)達(dá)到反應(yīng)溫度每小時(shí)取樣緩慢減少壓力監(jiān)視 酸度監(jiān)視溫度監(jiān)視外觀DPU = 0.05DPU = 0.02DPU = 0.01DPU = 0.11CT = 45 secCT = 30 secCT = 5 secCT = 21 secCOPQ = ?COPQ = ?COPQ = ?COPQ = ?放進(jìn)規(guī)定的點(diǎn)Ste

5、p 2記錄產(chǎn)生一個(gè)合格的產(chǎn)品或服務(wù)需要的所有的作業(yè)（如果可能的話在每一個(gè)工序記錄缺陷數(shù)據(jù)，節(jié)拍，成本，等等）。另外，所有的檢驗(yàn)，返工，運(yùn)輸?shù)牟襟E應(yīng)該被識(shí)別出來(lái)。Prepare Reactor準(zhǔn)備反應(yīng)堆Oxidize氧化穩(wěn)定完成裝上融化的蠟放進(jìn)規(guī)定的點(diǎn)放進(jìn)規(guī)定的點(diǎn)檢查噴嘴型號(hào)達(dá)到反應(yīng)溫度每小時(shí)取樣緩慢減少壓力監(jiān)視 酸度監(jiān)視溫度監(jiān)視外觀DPU = 0.05DPU = 0.02DPU = 0.01DPU = 0.11CT = 45 secCT = 30 secCT = 5 secCT = 21 secCOPQ = ?COPQ = ?COPQ = ?COPQ = ?Prepare Reactor準(zhǔn)備反

6、應(yīng)堆Oxidize氧化穩(wěn)定完成裝上融化的蠟放進(jìn)規(guī)定的點(diǎn)放進(jìn)規(guī)定的點(diǎn)檢查噴嘴型號(hào)達(dá)到反應(yīng)溫度每小時(shí)取樣緩慢減少壓力監(jiān)視 酸度監(jiān)視溫度監(jiān)視外觀DPU = 0.05DPU = 0.02DPU = 0.01DPU = 0.11CT = 45 secCT = 30 secCT = 5 secCT = 21 secCOPQ = ?COPQ = ?COPQ = ?COPQ = ?Step 3記錄每一個(gè)操作是增值的還是不增值的。增值的操作是：客戶認(rèn)可的改變了產(chǎn)品的法律法規(guī)或合同的要求，或出于安全環(huán)保的考慮NVANVAVAVA在每一個(gè)步驟列出內(nèi)部和外部的YS 內(nèi)部的YS是對(duì)下道工序很關(guān)鍵的輸出 外部的YS是對(duì)顧

7、客很關(guān)鍵的輸出Step 4Output準(zhǔn)備時(shí)間Prepare Reactor酸值粘性Charge melted wax反應(yīng)堆溫度Bring to reaction temp溫度輪廓HT coeff氧化時(shí)間Oxidize酸值顏色Put in set points粘性Sample hourly反應(yīng)堆溫度Monitor acid number溫度輪廓廢氣流廢氣比較HT coeff反應(yīng)時(shí)間Output穩(wěn)定時(shí)間Stabilize酸值顏色Put in set points粘度Slowly reduce press反應(yīng)堆溫度Monitor temp溫度輪廓廢氣流廢氣比較HT coeffFinish time

8、Finish酸值顏色Check nozzle type粘性Put in set points滴落點(diǎn)Monitor appearance硬度小球外觀1234識(shí)別Ys我們希望當(dāng)產(chǎn)品離開(kāi)本道工序時(shí)應(yīng)處于怎樣的狀況下？在進(jìn)入下道工序前什么樣的關(guān)鍵尺寸需要被滿足？什么樣的關(guān)鍵特性需要被滿足？這些特性是對(duì)內(nèi)部客戶很重要還是對(duì)外部客戶很重要？Step 4Step 55).列出每一過(guò)程的內(nèi)部和外部輸入外部輸入是原材料的關(guān)鍵特性 內(nèi)部輸入是過(guò)程本身的變差I(lǐng)nputAgit speedTemperaturePressureAir flow% O2 in airAir temp帶速帶溫流動(dòng)率噴嘴型號(hào)空洞尺寸室溫?cái)噭?dòng)

9、速度桶溫OutputStab timeStabilizeAcid numberColorPut in set pointsViscositySlowly reduce pressReactor tempMonitor tempTemp profile Off gas flowOff gas compHT coeffFinish timeFinishAcid numberColorCheck nozzle typeViscosityPut in set pointsDrop PointMonitor appearanceHardnessPellet appearOutputPrep timePr

10、epare ReactorAcid numberViscosityCharge melted waxReactor tempBring to reaction tempTemp profileHT coeffOxid timeOxidizeAcid numberColorPut in set pointsViscositySample hourlyReactor tempMonitor acid numberTemp profileOffgas flowInput蠟級(jí)Amt 蠟裝料率攪動(dòng)速度Rxn 溫度壓力氣流% O2 in air粘性蠟溫酸值目標(biāo)攪動(dòng)速度 *溫度 *壓力*氣流% O2 in

11、air空氣溫度空氣濕度Offgas compHT coeffResp timeXs 識(shí)別XS什么輸入/變量/因素會(huì)影響過(guò)程的YS哪些因素可能影響識(shí)別的YS達(dá)到標(biāo)準(zhǔn)使用頭腦風(fēng)暴以及人機(jī)料法環(huán)分類法篩選潛在的輸入Step 5Step 6將所有的Xs分為以下的一種或幾種類別控制因素(C) ：那些在過(guò)程運(yùn)行過(guò)程中可以控制調(diào)整的輸入。(如：速度、進(jìn)給率、溫度、壓力等）標(biāo)準(zhǔn)化作業(yè)：通常人們認(rèn)為應(yīng)該執(zhí)行的合理的基本操作。這里的目的是確保我們記錄真實(shí)的流程（如清潔、安全、裝零件，作業(yè)準(zhǔn)備等）。噪音因子：由于太困難或成本原因而無(wú)法控制的因素 （如環(huán)境溫濕度，作業(yè)員培訓(xùn)等）Step 6InputTypeOutpu

12、tAgit speedContrStab timeTemperatureContrStabilizeAcid numberPressureContrColorAir flowContrPut in set pointsViscosity% O2 in airNoiseSlowly reduce pressReactor tempAir tempContrMonitor tempTemp profile Off gas flowOff gas compHT coeffBelt speedContrFinish timeBelt tempContrFinishAcid numberFlow rat

13、eContrColorNozzle typeContrCheck nozzle typeViscosityHole sizeContrPut in set pointsDrop PointRoom tempNoiseMonitor appearanceHardnessAgit speedContrPellet appearTank tempContrInputTypeOutputWax grade控制Prep timeAmt waxContrPrepare ReactorAcid numberCharge rateContrViscosityAgit speedContrCharge melt

14、ed waxReactor tempRxn tempContrBring to reaction tempTemp profilePressureContrHT coeffAir flowContr% O2 in air噪音ViscosityNoiseWax tempNoiseAN targetContrOxid timeAgit speed *ContrOxidizeAcid numberTemperature *ContrColorPressure *ContrPut in set pointsViscosityAir flow *ContrSample hourlyReactor tem

15、p% O2 in airNoiseMonitor acid numberTemp profileAir tempContrOffgas flowAir humidityNoiseOffgas compHT coeffResp timeStep 7識(shí)別你現(xiàn)在的數(shù)據(jù)采集點(diǎn)以及你可能需要采集數(shù)據(jù)的位置。這些區(qū)域可以被稱為記錄點(diǎn)Tally Point 1Tally Point 2OutputPrep timePrepare ReactorAcid numberViscosityCharge melted waxReactor tempBring to reaction tempTemp profile

16、HT coeffOxid timeOxidizeAcid numberColorPut in set pointsViscositySample hourlyReactor tempMonitor acid numberTemp profileOffgas flowInputWax gradeAmt waxCharge rateAgit speedRxn tempPressureAir flow% O2 in airViscosityWax tempAN targetAgit speed *Temperature *Pressure *Air flow *% O2 in airAir temp

17、Air humidityOffgas compHT coeffResp timeInputAgit speedTemperaturePressureAir flow% O2 in airAir tempBelt speedBelt tempFlow rateNozzle typeHole sizeRoom tempAgit speedTank tempOutputStab timeStabilizeAcid numberColorPut in set pointsViscositySlowly reduce pressReactor tempMonitor tempTemp profile O

18、ff gas flowOff gas compHT coeffFinish timeFinishAcid numberColorCheck nozzle typeViscosityPut in set pointsDrop PointMonitor appearanceHardnessPellet appearProcess Map Example CAB Brazing Exercise Example!在你工廠內(nèi)選擇一個(gè)過(guò)程畫(huà)出他的過(guò)程流程圖可以是制造過(guò)程或管理過(guò)程For ExampleFloat Bracket CuttingVinyl LayupBilling ProcessWork

19、order creationYet another Example!分成小組畫(huà)出午飯過(guò)程的過(guò)程流程圖識(shí)別出關(guān)鍵輸入和輸出準(zhǔn)備好在課堂上報(bào)告你的過(guò)程流程圖Expanding the Detailed Process Map測(cè)量系統(tǒng)輸入和輸出是如何測(cè)量的標(biāo)準(zhǔn)上規(guī)格限，期望值，下規(guī)格限種類可控制，噪音，標(biāo)準(zhǔn)化作業(yè)，原材料Notice how much information you have about the process in a very simple format!Example of Detailed Map用Excel可以輕松的完成Uses for the Detailed Proce

20、ss Map必須有一個(gè)準(zhǔn)確的流程圖來(lái)代表真實(shí)的過(guò)程，它為以下的工作提供了關(guān)鍵的輸入因果矩陣的輸入因子的最初的評(píng)估的輸入過(guò)程輸出的評(píng)估測(cè)量階段的基礎(chǔ)當(dāng)可疑的因素被排除和新的因素被發(fā)現(xiàn)以后，應(yīng)該更新詳細(xì)的過(guò)程流程圖。Next StepsDetailed Process Map 詳細(xì)過(guò)程流程圖Cause and Effects Matrix 因果矩陣OUTPUTSINPUTSTypes of Data數(shù)據(jù)類型你想知道什么？信息來(lái)源單詞圖文字描述數(shù)字1)你想知道什么？2)你想通過(guò)怎樣的方式看到你想知道的事？3)什么樣的工具會(huì)幫你展現(xiàn)是你想要看到的事。4)對(duì)于選定的工具需要什樣的數(shù)據(jù)類型5)你可以從何處

21、獲得需要的數(shù)據(jù)CriticalQuestionsPlanExecute數(shù)據(jù)本身不提供任何信息，你必須“拷問(wèn)”數(shù)據(jù)來(lái)獲得信息，而“拷問(wèn)”的方法就是統(tǒng)計(jì)技術(shù)類別測(cè)量離散連續(xù)名稱排序l間隔比例Discrete Vs. Continuous DataFAILPASS電子電路離散拒絕通過(guò)QTYUNITDESCRIPTION TOTAL1$10.00$10.003$1.50$4.5010$10.00$10.002$5.00$10.00SHIPPING ORDERERROR 錯(cuò)誤$TEMPERATUREThermometer 溫度Time 時(shí)間連續(xù)Caliper 卡尺$Example分成小組列一張的各種數(shù)據(jù)

22、清單，并加以分類準(zhǔn)備好匯報(bào)小組發(fā)現(xiàn)連續(xù)型離散型$信息稀少富含信息連續(xù)型數(shù)據(jù)的優(yōu)點(diǎn)獲得關(guān)于過(guò)程的相同程度的理解必須注意離散型數(shù)據(jù)與連續(xù)性數(shù)據(jù)的區(qū)別CPK, PPM,DPMOMSASPC,P , C, Xbar-Rbar假設(shè)檢驗(yàn)：T，ANOVA， Chi-quarePareto, Histogram概率分布概率分布（一般簡(jiǎn)稱為分布）是一種能夠用來(lái)預(yù)測(cè)隨機(jī)事件的方法有很多種“標(biāo)準(zhǔn)”分布能夠幫助我們建立真實(shí)變差的模式。標(biāo)準(zhǔn)分布屬性數(shù)據(jù)二項(xiàng)泊松變量數(shù)據(jù)正態(tài)對(duì)數(shù)正態(tài)T 分布F 分布指數(shù)Discrete (Attribute)Continuous (Variable)Continuous(Variable)

23、Discrete(Attribute)輸出輸入Chi-squareAnalysis of VarianceDiscriminate AnalysisLogistic regressionCorrelationMultiple Regression選擇統(tǒng)計(jì)工具統(tǒng)計(jì)工具可以覆蓋各種數(shù)據(jù)類型組合。These are some of the statistical techniques that you will use to drive Process Improvement分析指導(dǎo)Y X Continuous 連續(xù)Discrete 離散 (Proportions)Discrete 離散 (“Gro

24、ups”)Continuous 連續(xù)Chi-Square卡方檢驗(yàn)t-test Paired t-test ANOVALogistic Regression邏輯回歸Regression回歸分析We are in the region of greatest statistical power!Chi-Squared Test 卡方檢驗(yàn)no 2 or moreyes2-sample t-testZ-testAre XsDiscrete?no continuousRegressionno Y is discreteChi-Squaredyesno 2 or moreANOVA (test for e

25、qual Variances)no comparing twoindependent groupsPaired t-testAre YsContinuous?2 groupsonly?Are Y1sMatched toY2syesSample size30 and known?ComparingvariancesyesANOVA no meansOne or twogroupsProportion testyesyesyesno only 11-sample t-testyesnoAttribute Terminology 屬性數(shù)據(jù)術(shù)語(yǔ)Attribute Data: Qualitative (

26、go / no go) data that can be tallied for recording and analysis. 屬性數(shù)據(jù)：可記錄和分析的定性數(shù)據(jù).Attribute Measurement System: A measurement system that compares each part to a standard and accepts the part if this standard is met. 定性的測(cè)量系統(tǒng): 將每一個(gè)零件與標(biāo)準(zhǔn)比較,如果達(dá)到標(biāo)準(zhǔn)則放行,這樣的測(cè)量系統(tǒng)叫定性測(cè)量系統(tǒng).Screen: 100% evaluation of product us

27、ing inspection techniques (an attribute measurement system). 篩選: 對(duì)產(chǎn)品的100%檢驗(yàn)(定性的測(cè)量系統(tǒng)).Screen Effectiveness: The ability of the attribute measurement system to properly discriminate good from bad. 篩選有效性: 定性測(cè)量系統(tǒng)從不合格零件中區(qū)分合格的零件的能力.Customer Bias: Operator has a tendency to hold back good product. 客戶傾向: 操作

28、人員傾向報(bào)廢合格的產(chǎn)品.Producer Bias: Operator has a tendency to pass defective product. 生產(chǎn)者傾向: 操作人員傾向放行不合格產(chǎn)品過(guò)程表現(xiàn)的評(píng)價(jià)指標(biāo)CONTINUOUSDATA 連續(xù)SHORT-TERMCPCPKPPPPKDPODPUPPMYRTDPMO數(shù)據(jù)類型數(shù)據(jù)歷史評(píng)價(jià)指標(biāo)的種類統(tǒng)一的評(píng)價(jià)指標(biāo)DISCRETEDATA 離散LONG-TERMLONG-TERMDATASigma Scale SIGMA 水平選擇合適的控制圖類型Statistical Process Control Reference Manual, page iiUse c or uchartNoNoYesNoYesYesNoYesYesNoYesYesYesNoNoNoYes確定要控制的特性用p圖是不合格品數(shù)嗎？是否性質(zhì)相同或不利于子組取樣-如化學(xué)溶液，油漆等？是計(jì)量型數(shù)據(jù)嗎？用np圖或p圖用u圖用c圖或u圖樣本大小是不變的嗎？計(jì)算子組均值方便嗎？用單值控制圖用中值控制圖用均值-極差圖用均值-極差圖是否有