Red_X_一天教材.ppt

1、Page 1,Statistical Engineering Red X Strategy Overview,Page 2,Learning Objectives 學(xué)習(xí)目標(biāo),At the end of this course the learner will understand: 本課程結(jié)束的時(shí)候，學(xué)習(xí)者應(yīng)了解以下幾個(gè)方面： Red X Terms “Red X” 專業(yè)術(shù)語(yǔ) The Importance of Strategic Thinking “Red X” 策略想法的重要性 How to Use the following Red X Techniques: Strategy Diag

2、ram Component Search Group Comparison Tolerance Parallelogram Note: Red X Strategies now includes over 30 techniques.,Page 3,History Overview 發(fā)展歷史概括,Dorian Shainin (1940s),Shainin Consulting (1970s),GM you only need to find out what drives the contrast 不要試圖了解所有的事情，只需要找到誰(shuí)引起的變化 Understand that there i

3、s always going to be “noise”,2-24,Using “Red X Strategy” to Find the Cure for Smallpox,Page 41,X to Y Thinking X 到 Y的思索,Scientific Method 科學(xué)的方法 Strategy: Make a change (X) and wait to see if the problem (Y) gets better. 策略：通過(guò)改變一個(gè)或者使更多的原因(X) 來(lái)確 定它們是否會(huì)使結(jié)果(Y)變好。 This is a Guessing Strategy. If we do no

4、t guess what the Root Cause is, we will never fix the problem. 這是一個(gè)假設(shè)的策略。如果我們不假定根本原因的話，我們可能永遠(yuǎn)也解決不掉問(wèn)題。 Assumption: I know the relationship between cause and effect 假定：已經(jīng)知道了原因與結(jié)果之間的關(guān)系,Page 42,Y to X Thinking Y 與 X 的思索,Red X Strategies Select BOBs and WOWs at opposite extremes of the Green Y Distributi

5、on. Within these samples we will have captured extremes of the Red X. 在Green Y兩個(gè)極端處選擇BOB和WOW，通過(guò)這些樣本，我們可以抓出極端的Red X Eliminate what is the same and focus on what is different. 排除掉相同的因素而關(guān)注于差異 The more Contrast we have, the easier it will be to identify the Red X. 差異越大越容易找出Red X來(lái) Assumption: I can under

6、stand the physics by observing the extremes 假設(shè)：通過(guò)對(duì)極端的觀察，可以了解其原理,Page 43,Y to X Relationship,Page 44,Strategy Diagram 策略圖,Where can I observe the most contrast? 我在哪里可以觀測(cè)到最大的差異？,Page 45,Strategy Diagrams 策略圖,What is a Strategy Diagram? 什么是策略圖？ Strategy diagram is an organized list of Contrast opportun

7、ities. 策略圖是列出所有可能產(chǎn)生差異因素的清單。 Generally, the WOW condition is known and clearly identified. However there are many opportunities for selecting the BOB. 通常，WOW很容易識(shí)別，然而，BOB時(shí)常會(huì)有很多的選項(xiàng)，比較難以選擇。 Contrast choices are arranged from Smallest (Feature/Defect/Event) to Biggest (Time). 差異項(xiàng)選擇按照從小到大排列 The smallest s

8、trategy choice that shows the largest Contrast is usually the best strategy to use. 差異越大而體現(xiàn)差異的因素項(xiàng)越小，策略圖越有效。 The first contrast choice is always a question of the measurement/evaluation system. You cannot proceed with another strategy choice if you do not have a repeatable failure mode or measurement

9、 system. 第一個(gè)差異項(xiàng)總是詢問(wèn)測(cè)量評(píng)估系統(tǒng)。如不能重現(xiàn)失效或沒(méi)有可重復(fù)測(cè)量系統(tǒng)，就不能再進(jìn)行其他的策略。 The last contrast choice is Time. This could include: Shift to Shift, Day to Day, Month to Month, etc. 最大的差異項(xiàng)是時(shí)間。有可能是班組和班組、天與天、月與月等的對(duì)比。,Page 46,Strategy Diagrams 策略圖,Strategy Diagrams cannot be completed at your desk. 策略圖不是在辦公桌上完成的 Strategy Di

10、agrams should be developed while you are experiencing the failure mode. 策略圖應(yīng)該是在體驗(yàn)到失效之后而發(fā)展進(jìn)行的 Evaluate Strategy Choices with results from Concentration Diagram, Multi-Vari, and other relevant observations. 評(píng)估策略選項(xiàng)應(yīng)根據(jù)集中圖、多邊差和其它相關(guān)的觀測(cè)。 Vehicle to Vehicle is the most popular strategy choice; however, it i

11、s often not the best choice. 車與車之間的對(duì)比是最通用的策略選項(xiàng)，卻不一定是最好的選項(xiàng)。 Remember the Physics of Failure and look for creative Contrast opportunities (Region to Region, Side to Side, Model to Model, etc) 記住失效的原理和創(chuàng)造性地選擇差異項(xiàng)(區(qū)域?qū)^(qū)域、邊對(duì)邊、類型對(duì)類型等),Page 47,Measurement System Contrast,The first Strategy Choice that we must

12、 evaluate is “do we have a repeatable measurement system?” This is true for all types of problems. We cannot proceed with any other Strategy if our measurement system is not repeatable.,Feature If we measure the same part multiple times, do we get similar readings? Defect If we evaluate a BOB vehicl

13、e a 2nd time is it still BOB? If we evaluate a WOW vehicle a 2nd time is it still WOW? Event Is the Failure mode intermittent? Is a BOB vehicle always BOB? Is a WOW vehicle always WOW?,Page 48,Feature Strategy Diagrams 特征策略圖,How can I observe contrast with a Feature type failure? 通過(guò)失效類型的特征，如何觀測(cè)差異？,P

14、age 49,Hood Fit Inconsistent Gap to Fender,Observed Clue List: Feature is repeatable. Measurement System passes Isoplot. Hood to fender gaps are always parallel. No “A” or “V” Gaps. Some cars = Big Left Tags can fall off and pen marks wear off 用蝕刻的方式作標(biāo)記，因?yàn)闃?biāo)簽可能脫落，用筆作的標(biāo)記也可能會(huì)被磨損消蝕掉 Use the actual assem

15、bly process as close as possible 拆解過(guò)程要和實(shí)際裝配過(guò)程盡量接近 Remember to swap assemblies, not every nut, bolt, spring 記住交換的是個(gè)集合，不是每個(gè)螺母、螺釘、彈簧 Be aware that thread integrity on aluminum blocks and cases is an important issue 注意在鋁塊上的線的完整性以及案例是比較重要的問(wèn)題。,Page 75,Component Search NCC 736 Component Search Stage I & II

16、 Data 階段一和階段二的數(shù)據(jù)匯總,Original,Disassembly / Reassembly #1,Disassembly / Reassembly #2,Disassembly / Reassembly #3,Pump, Valve Body, & Channel Plate Only,Driven Sprocket Support Only (Pump, VB, CP put back),Reverse Clutch Housing Only (DSS put back),Original,Original,Disassembly / Reassembly #1,Disasse

17、mbly / Reassembly #2,Disassembly / Reassembly #3,Pump, Valve Body, & Channel Plate Only,Driven Sprocket Support Only (Pump, VB, CP put back),Reverse Clutch Housing Only (DSS put back),Original,308,310,200,299,319,309,310,307,308,203,WOW Transmission,Green Y,Neutral to Reverse,Shift Delay (ms),199,20

18、2,208,205,BOB Transmission,Green Y,Neutral to Reverse,Shift Delay (ms),196,199,Page 76,The larger the group size, the lower the risk. 組越大，風(fēng)險(xiǎn)越低 The recommended group size is 4, 4. 推薦的組的大小是4,4。 Stage 1 rules - Complete separation - Stage 2 Decision Limits,Search Algorithm Factors 搜索算法系數(shù),Component Sear

19、ch,Risk FactorI,Risk FactorII,(Product Variation Risk FactorI x Process Variation),(Decision Limits = Median + Risk FactorII x Average Range),Page 77,Component Search,Passing Rules,Rule 1: Complete separation must exist between BOB and WOW values (no touching/overlap) 規(guī)則1 ：BOB和WOW取值必須完全分離（沒(méi)有接觸及重疊） R

20、ule 2: The difference between the medians must be greater than the average range times a risk factor 兩者的中數(shù)之差必須大于極值平均值與風(fēng)險(xiǎn)系數(shù)的乘積,RBOB and RWOW must be small,DY must be big,Page 78,Component Search,Decision Limits 決策界限 Purpose of the Decision Limits 設(shè)定決策界限的目的 To statistically calculate your limits of pr

21、ocess variation 用統(tǒng)計(jì)的方法計(jì)算過(guò)程差異的界限,Page 79,Page 80,Page 81,Component Search Exercise 元件查找練習(xí),Page 82,Group Comparison 分組和配對(duì)對(duì)比,Which component feature is driving the Green Y failure? 哪一個(gè)元件失效導(dǎo)致了Green Y的失效？,Page 83,Group Comparison 分組和配對(duì)對(duì)比,What is a Group Comparison? 什么是分組與配對(duì)對(duì)比？ It is a powerful clue gener

22、ation tools used when the “dictionary” can no longer be split into smaller components. 當(dāng)“字典”不能被拆分為更小的元件時(shí)，“分組和配對(duì)對(duì)比”可以被用作有力的線索產(chǎn)生工具。 It is a tool that can quickly identify potential Red X candidates! “分組和配對(duì)對(duì)比”是能夠很快識(shí)別出潛在的Red X 候選者的工具。,Page 84,Group Comparison 分組與配對(duì)對(duì)比,In a Group Comparison, the character

23、istics or features measured between BOBs and WOWs are rank ordered. Then, Tukeys End Count is used to identify Red X candidates. 在分組對(duì)比中， 在BOB和WOW之間測(cè)量到的特征或特性是按從最好到最差的順序排列的，然后用圖基計(jì)算終值方法識(shí)別Red X 的候選者。 Group Comparison requires only the collection of a group of BOB and WOW assemblies to identify the diffe

24、rence between the groups. It does not have the ability to see the small Red X feature differences like the Paired Comparison. 分組對(duì)比只需要收集一個(gè)組中BOB和WOW的集合來(lái)辨別組之間存在的差異。但不能象配對(duì)對(duì)比那樣可以識(shí)別細(xì)微的Red X特征的差異。,Page 85,Group Comparison Rules: 分組對(duì)比原則：,Select a minimum of 5 BOBs and 5 WOWs (recommended 8). 最少選擇5對(duì)BOB和WOW配對(duì)

25、樣本（推薦8組）。 Measure any pertinent characteristic. Dont be too restrictive, but remember the physics! 測(cè)量每一個(gè)相關(guān)的特征。不要太過(guò)苛刻，但要記住所要測(cè)量的物理性質(zhì)。 Be aware of measurement variation when checking different dimensions. 在核對(duì)不同的尺寸時(shí)，應(yīng)該考慮到測(cè)量的偏差。 Stage 0 Analysis is recommended for estimating Delta M 。 推薦進(jìn)行0階段分析來(lái)估計(jì)M 的值。 D

26、etermine the end count for each feature following the guidelines of Rank Order ANOVA. Use Table 5.5 from Red X Strategies Pocket Guide to determine the minimum end count requirements for identifying Red X candidates. 根據(jù)ANOVA的排序指導(dǎo)確定每一個(gè)特征的計(jì)算終值。使用源自RED X策略指導(dǎo)手冊(cè)的表5.5確定用以識(shí)別Red X 候選者所需的最小計(jì)算終值。,Page 86,Grou

27、p Comparison Rules: 分組對(duì)比原則：,Update solution tree with the appropriate splits and identify the Red X candidate. Proceed with the Confirmation phase. 通過(guò)適當(dāng)?shù)牟鸾夂妥R(shí)別Red X 候選者的方法來(lái)修正問(wèn)題解決樹(shù)。并且繼續(xù)進(jìn)入到確認(rèn)階段。,Page 87,Group Comparison Table Required End Count 分組對(duì)比表所必需的計(jì)算終值,*This is not a statistical confirmation test

28、 這不是一個(gè)統(tǒng)計(jì)學(xué)驗(yàn)證試驗(yàn),Page 88,It is a good idea to include an illustration of the features and dimensions you are measuring! 為你正在測(cè)量的特征和尺寸加上說(shuō)明是好的想法。,It is a good idea to include the original Green Y measurements for the BOB and WOW groups. 對(duì)BOB和WOW分組中包括原始的Green Y的測(cè)量是個(gè)好主意,Determine the features or dimensions

29、to be measured between the BOBs and WOWs. 在BOB和WOW之間確定將要測(cè)量的特征或尺寸。,Worksheet for Group Comparison 分組對(duì)比作業(yè)單,Steps . . . . 步驟,Page 89,Determine the “end count” for each measured dimension. 為每一測(cè)量尺寸確定終值。,Rank order each dimension and indicate if the measurement is from a BOB or WOW. 將每一尺寸從好到壞進(jìn)行排列，同時(shí)指出該測(cè)量是

30、出自BOB還是WOW。,The dimension(s) that meet the minimum end count requirement is the Red X candidate(s)! 大于或等于所需最小終值的尺寸就是RED X的候選者。,Worksheet for Group Comparison (continued) 分組對(duì)比作業(yè)單（續(xù)）,Page 90,Page 91,Notes,Page 92,Tolerance Parallelogram 允許度平行四邊形法則,Page 93,X-Y Scatter Plot Patterns,Page 94,Tolerance Pa

31、rallelogram 允許度平行四邊形法則,What is Tolerance Parallelogram? 什么是允許度平行四邊形法則？ Tool used to show the relationship between a Red X and the Green Y. 能夠體現(xiàn)Red X和Green Y關(guān)系的工具。 Why do we need it? 為什么需要用這種工具？ Show the relationship between the Red X and Green Y. 能夠顯示Red X和Green Y的關(guān)系。 Determination of realistic tole

32、rances. 決定現(xiàn)存的允許度。,Page 95,Plot points from previously collected data to show the relationship between the Red X and the Green Y. 將先前所收集的Green Y 和對(duì)應(yīng)的Red X數(shù)據(jù)用點(diǎn)的形式表示出來(lái)。 Red X control limits must be selected such that customer enthusiasm is always achieved. Red X控制線的選擇必須與客戶接受度有關(guān)。,Tolerance Parallelogram

33、 Real World Relationship,Page 96,Tolerance Parallelogram 允許范圍的平行四邊形法則,Page 97,1. Plot the Red X relative to the Green Y (obtain 30 points from previous and/or current data collection) 畫(huà)出Green Y及相對(duì)應(yīng)的Red X為坐標(biāo)的點(diǎn)(從先前或是現(xiàn)在所獲得的數(shù)據(jù)取30 個(gè)點(diǎn)),Draw in a regression line that reflects a mid position of the distribu

34、tion. 畫(huà)一條能夠反映這些點(diǎn)分布的中間位置的恰當(dāng)線。,Building A Tolerance Parallelogram 確定允許范圍的平行四邊形,Page 98,Eliminate the furthest point from the regression line. Draw in the limit line parallel to the regression line and passing through the second furthest point from the line. Draw in the opposite limit line parallel to,

35、 yet opposite the regression line. 去掉距離這條恰當(dāng)線最遠(yuǎn)的一個(gè)點(diǎn)。通過(guò)距離第二遠(yuǎn)的點(diǎn)做一條與恰當(dāng)線平行的直線。同時(shí)以恰當(dāng)線為中心，向另一面做鏡射，這樣就得到了與恰當(dāng)線距離相等的兩條平行線。,Building A Tolerance Parallelogram(Cont) 確定允許范圍的平行四邊形(續(xù)),Page 99,4. Draw in the upper and lower control limits on the Green Y with horizontal lines. Connect the upper limit to the upper limit line and the lower limit to the lower limit line. 用水平線標(biāo)出Green Y上下控制線(客戶接受度)。如右圖所示通過(guò)上控制線與上平行線的交點(diǎn)向下引一條垂線；同樣，通過(guò)下控制線與下平行線的交點(diǎn)也做一條垂線。 Reminder: Top to Top Bottom to Bottom 提示：頂