SPC及CPK教程(實(shí)戰(zhàn)篇)

1、1SPC及及CPK實(shí)實(shí) 戰(zhàn)戰(zhàn) 篇篇21六西格碼在控制中的應(yīng)用六西格碼在控制中的應(yīng)用廣義的六西格碼是一個(gè)完善的管理工具是品質(zhì)管理系統(tǒng)的一種說法單純的六西格碼控制應(yīng)用是一種質(zhì)量控制的目標(biāo)請(qǐng)看以下說法正確與否? 我公司已經(jīng)實(shí)施了六西格碼管理? 我公司達(dá)到了六西格碼的要求? 通過六西格碼管理公司品質(zhì)上了一個(gè)臺(tái)階一六西格碼一六西格碼32六西格碼與不良率六西格碼與不良率: Kr 百分比(%) 百萬(wàn)分缺點(diǎn)數(shù) 1r 2r 3r 4r 5r 6r 68.26 95.45 99.73 99.9937 99.999943 99.9999998 317400 45500 2700 63 0.57 0.002(規(guī)格中心

2、不偏移規(guī)格中心不偏移)常態(tài)分配常態(tài)分配規(guī)格下限規(guī)格下限規(guī)格上限規(guī)格上限-6r-5r-4r-3r-2r-1r+6r+1r+2r +3r +4r +5rX424 Kr 合格百分比(%) 百萬(wàn)分缺點(diǎn)數(shù) 1r 2r 3r 4r 5r 6r 30.23 69.13 93.32 99.3790 99.97670 99.999660 697700 308700 66810 6210 233 3.4規(guī)格中心值往左、右移動(dòng)規(guī)格中心值往左、右移動(dòng)1.5r常態(tài)分配常態(tài)分配規(guī)格下限規(guī)格下限規(guī)格上限規(guī)格上限-6r-5r-4r-3r-2r-1r+6r+1r+2r +3r +4r +5rX1.5r1.5r435n3控制方式

3、與6控制方式的比較：6? ? ? ? ?兩個(gè)影響量 7二二SPC與與CPK1區(qū)別與聯(lián)系區(qū)別與聯(lián)系CPK判定短期的制程能力可以用來(lái)解析目前的制程能力或用來(lái)檢驗(yàn)制程能力是否在管制狀況下SPK長(zhǎng)期的制程能力主要用在制程管制上。兩者配合使用應(yīng)該做到短期=長(zhǎng)期82影響量影響量-標(biāo)準(zhǔn)差標(biāo)準(zhǔn)差Sigma樣173.673.672.076.576.872.076.873.673.673.673.673.670.470.472.0272.073.673.675.273.673.672.076.876.878.472.073.670.470.472.0 UCL UCLCLLCLLCL本376.875.272.076

4、.876.873.676.878.476.878.473.675.270.472.073.676.774.171.471.4測(cè)4 UCL UCLCLLCLLCL222.4 222.4 217.6 228.5 227.2 219.2 225.6 228.8 227.2230.4219.2 222.4211.2212.8217.66.62.60.00.074.174.172.576.275.773.175.276.375.776.873.174.170.470.972.5X=X=4.81.61.61.63.21.64.84.83.24.81.61.60.01.61.6R=R=X=R=1.960.6

5、90.85製 品名 稱TRX-7規(guī)格標(biāo)準(zhǔn)溫度時(shí)間群組數(shù)大小製 造部 門SMT期間49周上限 USL225803管制項(xiàng)目爐溫中心限CL22075總組數(shù)機(jī) 別回焊爐測(cè)溫板TRX-7-1實(shí)板測(cè)量單位&sec下限 LSL2157015測(cè) 定 者姜雲(yún)霞時(shí)時(shí)間間時(shí) 間 管 制日期 2004.11.29時(shí)間1110.838.4R時(shí)間74.12.6 R管制圖C P=預(yù)估不良率 (PPM)製程能力分析時(shí)間 Sigma=CPK=X圖R圖備注備注及原及原因追查因追查1時(shí)間的數(shù)據(jù)離散性較大Sigma=1.96因此要從測(cè)量?jī)x器影響時(shí)間的設(shè)置來(lái)分析解決。時(shí)時(shí)間間X管缺制圖平均0.02.04.06.08.01234

6、56789101112131415UCLCLLCLR69717375777981123456789101112131415UCLCLLCLXUSLLSLSL實(shí)例實(shí)例(Sigma較大離散性問題較大離散性問題)103影響量影響量-中心偏移量中心偏移量11CPK實(shí)例分析實(shí)例分析(離散性較小中心偏移量影響離散性較小中心偏移量影響) 製 品R圖名 稱管制項(xiàng)目測(cè)量單位日期/時(shí)間批號(hào)1234567891011121314151617181920212223242515.8967樣10.1310.1350.1270.1270.1310.1350.1350.1270.1270.1310.1270.1310.13

7、10.1350.1270.1350.1310.1270.1380.1310.1310.1270.1310.1350.1270.241本20.1350.1310.1310.1240.1240.1310.1270.1310.1270.1350.1310.1240.1270.1310.1270.1270.1240.1240.1350.1240.1270.1270.1270.1310.131測(cè)30.130.1270.120.120.1240.1310.1270.1240.1240.1270.1310.1270.1240.1270.120.120.120.1240.1310.1270.1270.1240

8、.120.1310.131定40.1270.1270.1240.1310.1270.1350.1310.120.120.1270.1270.1310.1270.1310.120.1240.1240.1270.1270.1310.130.1270.1240.120.124值50.1240.1310.1240.1270.120.1270.1240.1160.120.120.1240.1270.1240.1240.120.130.1240.1240.120.1270.1310.1270.1240.1270.1310.6440.6510.6260.6290.6260.6590.6440.6180.61

9、80.640.640.640.6330.6480.6140.6330.6230.6260.6510.640.6470.6320.6260.6440.6440.1290.130.1250.1260.1250.1320.1290.1240.1240.1280.1280.1280.1270.1296 0.1230.1270.1250.1250.130.1280.1290.1260.1250.1290.1290.0110.0080.0110.0110.0110.0080.0110.0150.0070.0150.0070.0070.0070.0110.0070.0150.0110.0030.0180.0

10、070.0040.0030.0110.0150.0070.1272R=0.0101中心偏移量為0.0072Sigma值為0.0024通過計(jì)算SPC的管制范圍為0.011可見控制范圍已經(jīng)相當(dāng)小說明每次測(cè)量的數(shù)據(jù)都集中在一個(gè)區(qū)域波動(dòng)很小。因此CPK值十分合理為1.812但管制上下限均在規(guī)格中心到規(guī)格上限的范圍內(nèi)且管制下限還沒有達(dá)到規(guī)格中心?？梢钥紤]調(diào)整規(guī)格并作進(jìn)一步跟蹤。 R管制圖 Sigma= 0.0024CPK= 1.8112備註及原因追查: CP = 2.8242R 平平 均均X管制圖預(yù)估不良率 (PPM)製程能力分析 25合計(jì)量測(cè)數(shù)值的判定條件 USL 藍(lán)色1.67屬于制程能力充分的狀態(tài)下

11、231.3計(jì)算管制上下限上管制界限:UCL= Xbar +3*Sigma=0.139832+3*0.00312=0.149192下管制界限:LCL= Xbar - 3*Sigma =0.139832-3*0.00312=0.1304722412345678910111213141516171819202122232425USL0.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.16UCL0.1490.1490.1490.1490.1490.1490.1

12、490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.149SL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14Xi0.1430.140.1420.140.1450.1430.140.140.1350.1410.1370.140.1330.140.1360.1440.1370.140.140.1430.1370.1420.

13、1430.1420.1352CL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14LCL0.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.130LSL0.120.120.120.120.120.120.120.120.120.120.120.120.120

14、.120.120.120.120.120.120.120.120.120.120.120.120.110.130.150.1712345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25USLUCLSLXiLCLLSLCL1.4管制圖251.5解析管制上下限上管制界限:UCL= 0.149192實(shí)際管制上限= 0.150 在實(shí)際解析中如果測(cè)量的點(diǎn)比較分散可以適當(dāng)放寬解析上限再定期檢討縮緊管制上限到理論值。下管制界限:LCL= 0.130472實(shí)際管制下限= 0.130在實(shí)際解析中如果測(cè)量的點(diǎn)比較分散可以適當(dāng)放寬解析下限再定期檢討縮緊管制下限到

15、理論值。262SPC管制 將CPK解析的管制上下限作為SPC的管制上下線 定時(shí)對(duì)生產(chǎn)制程進(jìn)行量測(cè)這個(gè)時(shí)間可以是每天或每班 檢查每次的量測(cè)結(jié)果是否在管控范圍內(nèi) 量測(cè)點(diǎn)超出管控線需要立即檢討制程尋找出原因 定期(每月或每周)對(duì)近期的控制圖進(jìn)行分析檢查是否有不收控制的趨勢(shì)(如周期變動(dòng)連續(xù)7點(diǎn)連續(xù)11點(diǎn)等)。270.1250.1300.1350.1400.1450.1500.1551/11/21/31/41/51/61/71/81/91/101/111/121/131/141/151/16異常異常1/11/21/31/41/51/61/71/81/91/101/111/121/131/141/150.

16、1480.140.1480.1440.1370.140.1320.1480.1370.1350.1490.1440.1440.1440.1370.1440.1330.1220.140.1390.1360.1550.140.140.1370.1330.1330.1330.1280.1330.1420.1390.1520.140.1370.140.1290.1440.1330.1290.1370.1440.140.1530.1440.140.1370.140.140.1480.1230.1410.1430.1370.1560.1430.1400.1410.1370.1400.1370.1270.1

17、400.1410.1370.1530.0080.0070.0110.0150.0110.0150.010.0150.0070.0050.007Date/Shift14235XR2.1SPC管制圖282.2管制圖的難點(diǎn) CPK解析時(shí)存在中心偏移量較大的情況 CPK解析時(shí)數(shù)據(jù)離散性較大Sigma較大 SPC管制時(shí)管制上下限太嚴(yán)導(dǎo)致經(jīng)常跑出管制線 量測(cè)點(diǎn)都在管制界限內(nèi)是否代表制程良好293SPC & CPK管制的步驟管制的步驟四個(gè)步驟3.1 CPK改進(jìn)3.2 CPK解析3.3SPC管制及改進(jìn)3.4PDCA303.1CPK改進(jìn)-中心偏移量1234567891011121314151617181

18、9202122232425USL0.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.17UCL0.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.149SL0.150.150.150.150.150.150.150.150.150.150.150.150.150.

19、150.150.150.150.150.150.150.150.150.150.150.15Xi0.1430.140.1420.140.1450.1430.140.140.1350.1410.1370.140.1330.140.1360.1440.1370.140.140.1430.1370.1420.1430.1420.1352CL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14LCL0.1300.1300.1300.1300.1300.13

20、00.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.130LSL0.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.150.1712345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25USLUCLSLXiLCLLSLCLSLCLCP=2.13675K

21、=0.5084CPK=1.05313.1CPK解析-消除中心偏移量0.110.130.150.1712345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25USLUCLSLXiLCLLSLCL12345678910111213141516171819202122232425USL0.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.16UCL0.1490.1490.1490.1490.1490.149

22、0.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.149SL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14Xi0.1430.140.1420.140.1450.1430.140.140.1350.1410.1370.140.1330.140.1360.1440.1370.140.140.1430.1370.14

23、20.1430.1420.1352CL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14LCL0.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.130LSL0.120.120.120.120.120.120.120.120.120.120.120.120.

24、120.120.120.120.120.120.120.120.120.120.120.120.12CL SLCP=2.13675K=0.0084CPK=2.1188323.1CPK解析-消除中心偏移量（圖）SL333.2CPK解析-穩(wěn)定性離散性原則CPK解析時(shí)Sigma較大 CP 2 CPK 1.67具體解析過程可以用Xbar-R 管制分析法難難343.2CPK解析-Xbar-R 分析步驟 1計(jì)算XbarRXbar.barRbar 2計(jì)算R的管控線并判斷 3剔除異常的點(diǎn)(超出規(guī)格的)查找異常的原因 4重復(fù)123步驟直到全部在管控范圍內(nèi) 5計(jì)算Xbar的管控線并判斷 6剔除異常的點(diǎn)(超出規(guī)格的

25、)查找異常的原因 7重復(fù)1到6步驟直到全部在管控范圍內(nèi) 8落實(shí)查找出來(lái)的改善措施 9再次復(fù)驗(yàn)。35n1計(jì)算XbarRXbar.barRbarR.UCL=D4*R.bar =2.12*0.0127=0.02694R.LCL=D3*R.bar =0*0.013=0NA2d2D4D321.881.133.27031.021.692.58040.732.062.28050.582.332.1201234567891011121314151617181920212223242510.1370.1190.1370.1330.1580.140.1480.1440.1370.1440.1440.1230.13

26、30.140.1330.140.1440.1290.1370.140.140.1440.1370.1330.13320.1440.1490.1480.1370.1510.1440.140.1330.1480.1480.1480.1280.1480.1480.1370.1480.140.140.1440.1370.1480.1510.1330.1370.13730.1510.1220.1440.140.1550.1480.1330.1370.1480.1510.1440.120.1480.1440.1370.140.1370.1440.1370.1440.140.140.1370.1330.14

27、40.1370.1240.140.1370.1490.140.1370.1330.1510.14830.1330.1310.1370.1370.1330.1370.1290.140.1330.140.1370.1440.140.1370.15150.140.1310.1440.140.1480.1440.140.1440.1480.1370.1440.1190.140.1370.140.1330.1370.140.140.1480.1480.1440.1440.140.144Xbar0.1420.1290.1430.1370.1520.1430.1400.1380.1460.1460.1430

28、.1240.1410.1410.1360.1400.1370.1390.1380.1420.1430.1450.1380.1360.141R0.0140.0300.0110.0070.0100.0080.0150.0110.0140.0140.0150.0120.0150.0110.0070.0150.0150.0150.0110.0110.0110.0110.0110.0070.018USL=CP=Rbar=Sigma=0.00545Rbar=0.16SL=0.14LSL=0.120.139970.0130.01271R.UCL=0.026942Xbar.bar=R.LCL=036n2計(jì)算R

29、的管控線此時(shí)的X.bar圖0.000.010.010.020.020.030.030.0412345678910111213141516171819202122232425UCLRLCL異常點(diǎn)UCL0. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 156USL0. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 160

30、0. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 160SL0. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 140Xbar0. 1420. 1290. 1430. 1370. 1520. 1430. 1400. 1380. 1460. 146

31、0. 1430. 1240. 1410. 1410. 1360. 1400. 1370. 1390. 1380. 1420. 1430. 1450. 1380. 136LSL0. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 120LCL0. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 124

32、0. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1150. 1350. 15512345678910111213141516171819202122232425USLSLXbarLSLUCLLCL37n3重新計(jì)算-剔除R圖中的不合格點(diǎn)(第2點(diǎn))134567891011121314151617181920212223242510.1370.1370.1330.1580.140.1480.1440.1370.1440.1440.1230.1330.140.1330.140.1440.1

33、290.1370.140.140.1440.1370.1330.13320.1440.1480.1370.1510.1440.140.1330.1480.1480.1480.1280.1480.1480.1370.1480.140.140.1440.1370.1480.1510.1330.1370.13730.1510.1440.140.1550.1480.1330.1370.1480.1510.1440.120.1480.1440.1370.140.1370.1440.1370.1440.140.140.1370.1330.1440.1370.140.1370.1490.140.1370.1

34、330.1510.14830.1330.1310.1370.1370.1330.1370.1290.140.1330.140.1370.1440.140.1370.15150.140.1440.140.1480.1440.140.1440.1480.1370.1440.1190.140.1370.140.1330.1370.140.140.1480.1480.1440.1440.140.144Xbar0.1420.1430.1370.1520.1430.1400.1380.1460.1460.1430.1240.1410.1410.1360.1400.1370.1390.1380.1420.1

35、430.1450.1380.1360.141R0.0140.0110.0070.0100.0080.0150.0110.0140.0140.0150.0120.0150.0110.0070.0150.0150.0150.0110.0110.0110.0110.0110.0070.018USL=CP=Rbar=Xbar.bar=R.LCL=00.01196R.UCL=0.025348Sigma=0.00505Rbar=0.16SL=0.14LSL=0.120.140430.012剔除后X.bar.bar及R.bar值均發(fā)生變化。R圖符合要求。0.000.010.010.020.020.030.0

36、31345678910111213141516171819202122232425UCLRLCL38n4計(jì)算Xbar的管控線134567891011121314151617181920212223242510.1370.1370.1330.1580.140.1480.1440.1370.1440.1440.1230.1330.140.1330.140.1440.1290.1370.140.140.1440.1370.1330.13320.1440.1480.1370.1510.1440.140.1330.1480.1480.1480.1280.1480.1480.1370.1480.140.1

37、40.1440.1370.1480.1510.1330.1370.13730.1510.1440.140.1550.1480.1330.1370.1480.1510.1440.120.1480.1440.1370.140.1370.1440.1370.1440.140.140.1370.1330.1440.1370.140.1370.1490.140.1370.1330.1510.14830.1330.1310.1370.1370.1330.1370.1290.140.1330.140.1370.1440.140.1370.15150.140.1440.140.1480.1440.140.14

38、40.1480.1370.1440.1190.140.1370.140.1330.1370.140.140.1480.1480.1440.1440.140.144Xbar0.1420.1430.1370.1520.1430.1400.1380.1460.1460.1430.1240.1410.1410.1360.1400.1370.1390.1380.1420.1430.1450.1380.1360.141R0.0140.0110.0070.0100.0080.0150.0110.0140.0140.0150.0120.0150.0110.0070.0150.0150.0150.0110.01

39、10.0110.0110.0110.0070.018USL=CP=Rbar=Xbar.bar=R.LCL=01.312975UCL=0.01196R.UCL=0.0253481.320029K=0.005344CPK=Sigma=0.00505Rbar=0.16SL=0.14LSL=0.120.140430.0120.1252760.155579CL=0.140428LCL=UCL= Xbar.bar+A2*Rbar=0.14043+0.577*0.012=0.147354LCL= Xbar.bar -A2*Rbar =0.14043-0.577*0.012=0.13350639UCL0. 1

40、470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 147USL0. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 160SL0. 1400. 1400. 1400. 14

41、00. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 140Xbar0. 1420. 1430. 1370. 1520. 1430. 1400. 1380. 1460. 1460. 1430. 1240. 1410. 1410. 1360. 1400. 1370. 1390. 1380. 1420. 1430. 1450. 1380. 136LSL0. 1200. 1200. 1200. 1200. 1200. 1200. 1

42、200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 120LCL0. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1150. 1350. 1551345678910111213141516171819202122232425USL

43、SLXbarLSLUCLLCLn5剔除異常的點(diǎn)(超出規(guī)格的)查找異常的原因異常點(diǎn)異常點(diǎn)異常點(diǎn)異常點(diǎn)40n6重新計(jì)算-剔除第512點(diǎn)Xbar.barRbar都需要重新計(jì)算檢查R圖符合要求134678910111314151617181920212223242510.1370.1370.1330.140.1480.1440.1370.1440.1440.1330.140.1330.140.1440.1290.1370.140.140.1440.1370.1330.13320.1440.1480.1370.1440.140.1330.1480.1480.1480.1480.1480.1370.148

44、0.140.140.1440.1370.1480.1510.1330.1370.13730.1510.1440.140.1480.1330.1370.1480.1510.1440.1480.1440.1370.140.1370.1440.1370.1440.140.140.1370.1330.1440.1370.140.1370.140.1370.1330.1510.14830.1330.1370.1370.1330.1370.1290.140.1330.140.1370.1440.140.1370.15150.140.1440.140.1440.140.1440.1480.1370.1440

45、.140.1370.140.1330.1370.140.140.1480.1480.1440.1440.140.144Xbar0.1420.1430.1370.1430.1400.1380.1460.1460.1430.1410.1410.1360.1400.1370.1390.1380.1420.1430.1450.1380.1360.141R0.0140.0110.0070.0080.0150.0110.0140.0140.0150.0150.0110.0070.0150.0150.0150.0110.0110.0110.0110.0110.0070.018USL=XbbCP=UCLRbar=0.1336270.147633CL=0.140630LCL=