西格瑪改善測量

西格瑪改善測量

SigmaKaizen

Measure

何謂精益西格瑪?

WhatisLeanSigma?改善突破的速度,時效為本的戰(zhàn)略

LeanSigmaisamethodologyalignedwithatime-basedstrategyatthespeedofKaizenBreakthrough

聚焦于縮短前置時間及減少變化

Focusedonlead-time&variabilityreduction

利用六西格瑪及精益生產(chǎn)原理

Utilizesbothsixsigmaandleanprinciples

推動文化變革

Drivesculturalchange

減少不良產(chǎn)品,減少產(chǎn)品及流程變化

LeanSigmareducesdefectsandvariationinproductandprocesses

向3.4PPM不良品邁進(jìn)

Strivesfor3.4defectspermillion

以測量為基礎(chǔ)

Measurementfocused

現(xiàn)場數(shù)據(jù)和歷史數(shù)據(jù)

Liveanddeaddata

財務(wù)效益好,所化時間少BottomLineResultsinSubstantiallyLessTimeSigmaKaizen西格瑪改善精益西格瑪模型

LeanSigmaModelLeanKaizen6Sigma(3.4DPM)5Sigma(233DPM)4Sigma(6,210DPM)3Sigma(66,807DPM)1-2Sigma(308,537DPM)精益西格瑪設(shè)計

DesignforLeanSigma制程能力

ProcessCapability優(yōu)化制程

ProcessOptimization創(chuàng)建流線

CreateFlow消除浪費

WasteElimination邏輯與直覺

Logic&Intuition找出不良品DeterminetheDefectY制定流程表現(xiàn)EstablishProcessPerformanceY評審測量系統(tǒng)EvaluateMeasurementSystemY評審標(biāo)準(zhǔn)化操作EvaluateStandardOperationsY識別根本原因IdentifyRootCausesX’s提出解決方案DevelopSolutionsX’s排列及實施解決方案Prioritize&ImplementSolutions主要的XVitalFewX’s測試解決方案,驗證結(jié)果TestSolutions&VerifyResults主要的XVitalFewX’s完善標(biāo)準(zhǔn)化操作RefineStandardOperations主要的XVitalFewX’s驗證測量系統(tǒng)ValidateMeasurementSystem主要的XVitalFewX’s實施控制系統(tǒng)及評審計劃ImplementControlSystem&AuditPlan主要的XVitalFewX’s確定制程能力DetermineProcessCapabilityY測量Measure分析Analyze改善Improve控制Control精益西格瑪項目階段

LeanSigmaProjectPhases項目實施ProjectImplementation西格瑪改善SM測量階段–5天改善SigmaKaizenSM

MeasurePhase–5dayKaizen第5天Day5第4天Day4第3天Day3第2天Day2第1天Day1精益西格瑪簡介

LeanSigmaOverview

改善突破法

KaizenBreakthroughMethodology

精益西格瑪測量工具

LeanSigmaMeasureTools

識別缺陷、“Y”及項目范圍

Identifydefect,“Y”,&projectscope

詳細(xì)的現(xiàn)場行走示意圖

EnhancedSpaghettiMap

質(zhì)量圖

QualityMap

驗證標(biāo)準(zhǔn)化操作

VerifyStandardOperations

比較分析

ComparativeAnalysis

收集歷史資料

CollectHistoricalData

傳授&行動Teach&Do

傳授&行動Teach&Do

培訓(xùn)&范圍Training&Scope

比較分析

ComparativeAnalysis

測量系統(tǒng)分析

MeasurementSystemAnalysis

必要時,改善測量系統(tǒng)

Improvemeasurementsystem,ifnecessary

確定制程能力

DetermineProcessCapability

收集現(xiàn)場數(shù)據(jù)

CollectLivedata

快速解決

Quickkills

比較分析

ComparativeAnalysis

基本質(zhì)量工具

BasicQualityTools

因果圖

Cause&EffectChart

必要時,收集更多數(shù)據(jù)

GatherAdditionalDataifRequired

測量階段展示

PresentationofMeasurePhase

西格瑪改善實施SigmaKaizenImplementation傳授&行動Teach&Do

項目實施ProjectImplementation精益西格瑪測量回顧

LeanSigmaMeasureReview

用另外收集的數(shù)據(jù)更新資料

UpdateInformationw/AdditionalDataCollection

精益西格瑪分析/改善工具

LeanSigmaAnalyze/ImproveTools

基本分析工具

BasicAnalyticalTools

假設(shè)性試驗

HypothesisTesting

確定根本原因

IdentifyRootCause

觀察工場

ShopFloorObservations

培訓(xùn)&范圍Training&Scope

風(fēng)險評估

RiskAssessment

實施改善

ImplementImprovements

防錯

MistakeProofing

數(shù)據(jù)收集

CollectData

通過假設(shè)性試驗,驗證改善

VerifyImprovementsthroughHypothesisTesting

完善標(biāo)準(zhǔn)化操作

RefineStandardOperations

分析/改善階段展示

PresentationofAnalyze/ImprovePhase

西格瑪改善SM分析/改善階段–5天改善SigmaKaizenSM

Analyze/Improve–5dayKaizen西格瑪改善實施SigmaKaizenImplementation傳授&行動Teach&Do

傳授&行動Teach&Do

傳授&行動Teach&Do

第5天Day5第4天Day4第3天Day3第2天Day2第1天Day1控制（30天跟催)

Control(30dayfollowup)

改善公報

Kaizennewspaper

鑒察使用統(tǒng)計制程控制

Monitorusingstatisticalprocesscontrol

鑒察堅持標(biāo)準(zhǔn)化操作

Monitoradherencetostandardoperations

借力其它地區(qū)

Leveragetootherareas

精益西格瑪辯論

LeanSigmareportout

慶祝項目結(jié)束

Celebrate

項目實施ProjectImplementationPeaseShield定義PeaseShield產(chǎn)品為節(jié)省成本之產(chǎn)品

PositionPeaseshieldproductlinetocontributetobottomline不良品率降低50%50%reductioninqualitydefectsDavidBealArvinPleimaMattGoesling縮水線及模糊Shrinklines&fog預(yù)計Estimated實際Actual$1,050,000開始Started完成Completed實施ImplementedJuly18,2000July21,2000July21,2000LeanSigmaCharter描述Description:業(yè)務(wù)目標(biāo)BusinessObjective:結(jié)果

Deliverable:項目Y/缺陷ProjectY/Defect:財務(wù)效果Financial:時間

Timing:發(fā)起人Sponsors:項目組長ProjectLeader:指導(dǎo)Mentor:流程主人ProcessOwner:精益西格瑪團隊LeanSigmaTeam核心團隊Coreteam對流程有深刻認(rèn)識的人士,例如工人、品質(zhì)工程師、流程工程師、設(shè)計工程師等

Individualswhohaveindepthknowledgeoftheprocess,i.e..operators,qualityengineers,processengineers,designengineers

參加過所有改善活動的人士

Teammembersparticipatethroughoutallthekaizenevents

其它人士Resources需要時才召集的人士

Individualswhoarerequiredonanasneededbasis

改善活動期間或之后動員起來的人士

Mobilizedduringkaizenand/orbetweenkaizenweeks

零件或流程照片PictureofPartorProcess三種圖3

TypesofMaps質(zhì)量圖QualityMap業(yè)務(wù)流程圖BusinessProcessFlow

Map制造Manufacturing業(yè)務(wù)/辦公室Business/Office

詳細(xì)的現(xiàn)場行走示意圖EnhancedSpaghettiMap詳細(xì)的現(xiàn)場行走示意圖EnhancedSpaghettiMap顯示物料流程

Showsmaterialflow

顯示工人流程

Showsoperatorflow

觀察實際布置,找出浪費活動

Aidsinidentifyingwastefulactivitiesbyviewingitfromthebasisofphysicallayout

顯示實際發(fā)生的事與想像會發(fā)生的事

Showswhatisactuallyhappeningversuswhatpeoplethinkhappens

每人都要熟悉流程

Familiarizeseveryonewiththeprocess

找出物料搬運/儲存方面的變化

Identifiesvariationsinmaterialhandling/storage

步驟Step絲攻Tapper玻璃清洗

Glasswasher3． 包裹Wrapper4． 澆注Pourer5． 凝固Cure7． 脫模Demold8．檢驗Inspect問題Problems玻璃不干凈Glassnotclean工模不方,工模準(zhǔn)備Moldnotsquare,moldprep

鎖模位置,移開模鎖,模鎖跌落Clamplocation,clampremoval,clampsfalloff凝固時間、溫度、濕度Celtime,temp.,humidity邊緣/表面干凈Edge/faceclean

澆注Pourer凝固臺CureTable檢驗Inspector脫模DeMolder玻璃清洗GlassWasher黃色絲攻YellowTapper

模具加工MoldMaker包裹Wrapper樹脂防護(hù)罩Resin

Shield送生產(chǎn)部To

Production開始Start結(jié)束EndLTW Revised:7/01 ?2001TBMConsultingGroup,Inc.AllRightsReserved.詳細(xì)的現(xiàn)場行走示意圖EnhancedSpaghettiMap質(zhì)量圖QualityMap確定流程之所有步驟

Identifiesallthestepsintheprocess

清楚顯示每個步驟之所有規(guī)格

Clearlyshowsallspecificationsofeachstep

確定每個步驟所用之測量儀器。用測量系統(tǒng)分析來測試這些系統(tǒng)

Identifiesthemeasurementdevicesusedineachstep.Thesesystemswillbetestedusingameasurementsystemsanalysis.

流程控制的理解與實際變得顯然

Perceptionofthecontrolversustherealityofthecontrolbecomesapparent

全力以赴于一個變革步驟,找出已知問題

Totalfocusononetransformationsteptoidentifyknownproblems

質(zhì)量圖產(chǎn)品流程日期流程步驟規(guī)格/質(zhì)量標(biāo)準(zhǔn)測量控制方法模具/工夾具發(fā)現(xiàn)缺陷/已知問題缺陷原因差距分析質(zhì)量圖QualityMap流程步驟規(guī)格/質(zhì)量標(biāo)準(zhǔn)測量控制方法模具/工夾具發(fā)現(xiàn)缺陷/已知問題缺陷原因差距分析后拉伸生產(chǎn)線3后拉伸生產(chǎn)線1輸送帶末端寬167mm拉伸機出口寬164mm收縮率一般8~11%,無規(guī)格;寬都變化+/-3%,有規(guī)格張力控制:7每1,200英尺測量一次10英寸針孔記號測量線性收縮;鋼尺測量產(chǎn)品寬都5分鐘后,10英寸樣板變成8.5”;寬度為170mm產(chǎn)品在直帶上往一個方向彎曲,在另一直帶上往相反方向彎曲產(chǎn)品應(yīng)力;方在聚脂薄膜上時會彎曲冷卻槽溫度差異;水沒有冷卻;沒有壓滾機;張力為7正確嗎?產(chǎn)品在鼓輪上還在收縮;產(chǎn)品明顯彎曲,但無法測量輸送帶末端寬170mm拉伸機出口寬169mm收縮率一般2%,無規(guī)格;無規(guī)格每1,200英尺測量一次張力控制:7輸送帶在運轉(zhuǎn)時測量為10”10英寸針孔記號測量線性收縮;鋼尺測量產(chǎn)品寬都最后線性長度收縮只有0.2”質(zhì)量圖QualityMap流程步驟工具加工前加工后管尾張開表示工具完全插入;滿足回程彎曲插入之設(shè)計標(biāo)準(zhǔn)圖紙上的設(shè)計規(guī)格張開工具長度不等,張開不對稱工人變化性張開大小無測量數(shù)據(jù);沒有最打最小管長小于張開尺寸;可用紅色工具定義長度規(guī)格/質(zhì)量標(biāo)準(zhǔn)測量控制方法模具/工夾具發(fā)現(xiàn)缺陷/已知問題缺陷原因差距分析柏拉圖Pareto比較原因出現(xiàn)頻率,按照遞降順序排列

Compareshowfrequentlydifferentcausesoccurandputsthemindecreasingorderofoccurrence

過濾資料,重點改善

Usedtofilterdatatofocusimprovementefforts

柏拉圖原理ParetoPrinciple:20%的原因造成80%的問題20%ofthecausesaccountfor80%oftheproblem數(shù)量柏拉圖標(biāo)簽_1喉管泄漏接線錯誤臟污其它零件損壞擦傷樹脂防護(hù)罩歷史資料

HistoricalDatacollectedonResinShield數(shù)量柏拉圖缺陷數(shù)量缺陷柏拉圖收縮模糊氣泡比例累計%何謂測量系統(tǒng)分析?

WhatisMeasurementSystemAnalysis“MSA”?識別測量系統(tǒng)變量,量化如何影響流程

Itidentifiesandquantifieshowmuchoftheoverallprocessvariabilityisduetothemeasurementsystem

測量數(shù)據(jù)是測量過程的輸出,可能發(fā)生變化

Measurementsareoutputsofameasurementprocess,whicharesubjecttovariation.

離散型

/特征型數(shù)據(jù)

Discrete/AttributeData

專家重評

ExpertReevaluation

鑒定人同意

AppraiserAgreement連續(xù)性數(shù)據(jù)

ContinuousData儀器重復(fù)性及再現(xiàn)性

GageR&R

立即評估測量變異,確定如何影響流程Measurementvariationmustbeassessedimmediatelytodetermineimpactonprocess連續(xù)性數(shù)據(jù)ContinuousData規(guī)格下限LSL規(guī)格上限USL流程變異ProcessVariation流程變異ProcessVariationX1X2X3…Xn測量過程變異MeasurementProcessVariation儀表變異Gage

Variation鑒定人變異Appraiser

VariationX1X2X3…Xn重復(fù)性Repeatability校對Calibration穩(wěn)定性Stability線性度Linearity靈敏度Discrimination再現(xiàn)性Reproducibility鑒定人AAppraiser

A鑒定人CAppraiser

C鑒定人BAppraiser

B由不同鑒定人使用同一測量系統(tǒng)對同一項目進(jìn)行測量之平均測量值差異 Variationintheaverageofthemeasurementsmadebydifferentappraisersusingthesamemeasuringsystemwhenmeasuringtheidenticalcharacteristiconthesameitem測量系統(tǒng)導(dǎo)致的差異Variationduetothemeasuringsystem

重復(fù)性Repeatability由同一鑒定人使用同一測量裝置對同一項目之同一特性進(jìn)行多次測量之測量值差異Thevariationinmeasurementsobtainedwithonemeasurement

devicewhenusedseveraltimesbyanappraiserwhilemeasuringthesamecharacteristiconthesameitem第1次測量Measurement

1第3次測量Measurement

3第2次測量Measurement

2測量設(shè)備導(dǎo)致的差異Variationduetothemeasuringdevice儀器重復(fù)性及再現(xiàn)性GageR&R規(guī)格Spec規(guī)格上限USL規(guī)格下限LSL差異Variability一般經(jīng)驗RuleofThumb:<15%,可以接受 Under15% Acceptable15~30%,有疑問 15–30% Questionable>30%,不接受,必須改善 Over30% Reject–ImprovementMandatory貴司的原則是什么??)Whatareyourcompany’sguidelines??(GRR%)儀器差異X100總差異數(shù)據(jù)世界DataWorlds不良品: 不能滿足客戶要求的產(chǎn)品 Defective: Theuniteithermeetsordoesnot meetcustomerrequirements不良次數(shù) 一個產(chǎn)品不能滿足客戶要求的次數(shù) Defect: Thenumberoftimesaunitfailsto meetrequirements連續(xù)性 能夠呈現(xiàn)任何數(shù)值的可測量特性 Continuous: Ameasurablecharacteristicthat cantakeonanyvalue數(shù)據(jù)世界決定所用的分析工具TheDataWorlddictateswhatanalyticaltoolstouse制程能力ProcessCapability將制程能力、平均偏差及標(biāo)準(zhǔn)偏差與Relateprocesscapability,meanandstandarddeviation…

制程能力ProcessCapabilityZ值ZValue規(guī)格極限相聯(lián)系,用一個Z值即西格瑪值來表示…tospecificationlimitsandexpressthemasasingleZvaluea.k.a.SigmalevelZ值ZValue溫度制程能力ProcessCapabilityforTemperature制程能力ProcessCapability流程數(shù)據(jù)規(guī)格下限規(guī)格上限(長期能力)潛在/短期能力短期能力長期能力觀測到的性能期望的短期性能期望的長期性能制程能力ProcessCapability不良次數(shù)概率“p(d)”:ProbabilityofaDefect“p(d)”:不良產(chǎn)品次數(shù)與總產(chǎn)品數(shù)之比;即在一次運作里可能發(fā)現(xiàn)不良品次數(shù)之百分比。Theratioofthenumberofbadunitstothetotalunits;itisthepercentageofdefectiveunitsyouwouldexpecttofindwithinarun.

不良產(chǎn)品次數(shù)產(chǎn)品生產(chǎn)總數(shù)制程能力ProcessCapability好零件Good不良品Bad

產(chǎn)品一次通過率“FTY”:產(chǎn)品不出現(xiàn)缺陷而通過一次運作之比例

FirstTimeYield“FTY”:thepercentageofunitsthatpassthroughan

operationwithoutanydefects

例如:一天內(nèi)測試了1,056個洗碗機Example: 1056dishwashersweretestedinoneday924個通過,132個由于各種原因不通過924passedand132failedforvariousreasons

不通過產(chǎn)品數(shù)量+通過產(chǎn)品數(shù)量=產(chǎn)品總數(shù)#ofbadunits+#ofgoodunits=TotalNo.ofunits

不通過的產(chǎn)品數(shù)可以表達(dá)為不良品概率p(d):#ofbadunitscanbeexpressedasaprobablyofadefective,p(d):

制程能力ProcessCapability每個產(chǎn)品不良次數(shù)“DPU”:

總不良次數(shù)與總產(chǎn)品數(shù)之比,即每個產(chǎn)品可能發(fā)生不良之次數(shù)。DefectsPerUnit“Dpu”:Theratiooftotaldefectstototalunits,defectsperunit,istheaveragenumberofdefectsyouwouldexpecttofindoneachunit.

每個產(chǎn)品不良次數(shù)用DPU表示,公式如下:Defectsperunitisdenotedbydpuandtheformulaisdefinedas:

XXokok總不良次數(shù)產(chǎn)品總數(shù)根本原因RootCause(s)質(zhì)量工具/假設(shè)性試驗QualityToolsHypothesisTesting比較分析ComparativeAnalysis(在魚骨圖上圈出最可能原因)(circlethemostlikely

onthefishbone)因果法Cause&Effect柏拉圖Pareto質(zhì)量圖Quality

Map質(zhì)量系統(tǒng)分析MSA現(xiàn)場行走示意圖Spaghetti

Map標(biāo)準(zhǔn)化運作Standard

Ops商業(yè)流程圖BusinessProcessFlowMap根本原因流程RootCauseProcess用數(shù)據(jù)來證實這些可以解決的根本原因Validatesthemanageablefew“root”causeswithdata過濾所有可能原因,找出可以解決的原因Filtersall

possiblecauses

toamanageablefew識別各種事件及可能原因Identifiesnumerousissuesandpossible

causes在魚骨圖上寫出所有可能原因Allpossiblecausesputonfishbone集思廣益與因果法BrainstormingandCause&Effect目的Purpose:針對特定事件,快速收集數(shù)據(jù)

Togathermanyideasquicklyforagivenissue

利用比較分析,找出潛在差異

Tousewiththecomparativeanalysisforpotentialdifferences

原則Rules:所有組員,了解問題

Everyoneintheteamneedstounderstandtheissueforbrainstorming不下結(jié)論,不作討論,只可澄清

Nojudgingordiscussion;onlyclarification

在便條上或活頁紙上,列出建議

ListideasonPostItTMnotesorflipchartastheyaregiven

利用因果法,拓寬集思廣益思路UseCause&Effecttooltobroadenbrainstormingexploration因果法類別Cause&EffectCategories測量Measurements測量設(shè)備Measurementdevises數(shù)據(jù)捕獲系統(tǒng)Dataacquisitionsystems校對Calibration靈敏度Discrimination物料Materials原料Rawmaterials零部件Parts/components人力Manpower培訓(xùn)Training人事問題Personnelissues機器Machines設(shè)備Equipment保養(yǎng)Maintenance整體設(shè)備效率OEE方法Methods標(biāo)準(zhǔn)化操作Standardoperations非增值活動Nonvalueaddedactivities計劃Scheduling

環(huán)境Environment溫度Temperature濕度Humidity建筑物Buildings空間Space制造–五個M一個EManufacturing(5M’s&E)因果圖CauseandEffectDiagram縮水線ShrinkLines(威爾伯)(Wilbur)機器

Machine環(huán)境Environment材料Material人力ManPower方法

Method鎖模位置ClampLocation脫模前太快Toosoonbeforedemold開鎖ClampRemoval模鎖跌落ClampFallingOff模具準(zhǔn)備MoldPrep經(jīng)驗不足Experience脫模步驟DemoldSteps模具不方正MoldNotSquare凝膠時間過快GelTimeFast樹脂模ResinPat邊緣/表面清潔Edge/FaceClean新員工NewEmployees濕度Humidity溫度Temperature臟污Contamination何謂比較分析?WhatisaComparativeAnalysis?著重尋找數(shù)據(jù)

Amethodoffocusingthesearchfordata

系統(tǒng)化找出正、負(fù)偏差原因

AsystematicprocessforfindingthecauseofaNegativeorPositivedeviation

團隊分析問題

Ateambasedproblemanalysistool

DecorativelitesShrinklinesDemold,Swiggle,Conveyor,Consumer,Retail,Distributor,BettyNexttoedgeorcamingline1994Randomly:GreaterMonday,TuesdaythanWednesday,ThursdayWithinfirstweekafterlaunchAbout5%1–20.1to24"longhair?to2"wideApprox.7.5%ofproductionJanuarythrumid-April,then5%mid-Aprilthroughmid-JulyClearlaminates,123’sShortShot,Swirly,BadMix,DelaminationUnitlineOncamingline,withouttouchingandedgeorcamingedgeDuringprototyping@Supplier,Onnewmolds(Allp/ns)Withinfirstfewcycles5%,increasingnordecreasingSomanythatyoucannotseethroughglass<.1nor>24”Increasingordecreasingwithinthetimebuckets接觸空氣,不夠樹脂,樹脂,比例,模鎖,凝膠時間,固化時間,模具烘焙頻率,剛性與柔性,澆注時堵塞;表面條件,混合條件,加料條件Exposuretoair,lessresin,resin,ratio,nomoldforlams,clamps,geltime,curetime,rigidvs.pliable,tapedborders,sealedatpour;Treatedasgold,verylowdemand,frequencyofmoldbaking;Surfacevs.Mixorfillcondition教育

Education接觸空氣,烘焙部當(dāng),粘合力差,臟污,充料不勻,邊緣而非中間黑污Aircontact,improperlycured,poorcohesion,contamination,unevensaturation,blotonedgenotincenter.人,凝膠時間People,

curetime工模設(shè)計,苯乙烯堆積

Molddesign,styrenebuild-up周末模具沒有通風(fēng)

Moldsetsoverweekendwithoutventilation模具內(nèi)苯乙烯堆積Styrenebuild-upon