SPC進(jìn)階培訓(xùn)教材

SPC進(jìn)階培訓(xùn)

課程一Module1課程二::內(nèi)內(nèi)容Module2::Agenda統(tǒng)計(jì)技術(shù)術(shù)重溫StatisticsReview新統(tǒng)計(jì)技技術(shù)概念念NewStatisticalConcept直方圖Histograms正態(tài)分布布NormalDistributions控制限及及規(guī)格限限ControlLimitsandSpecificationLimits流程能力力ProcessCapability流程穩(wěn)定定及能力力ProcessStabilityandCapability統(tǒng)計(jì)技術(shù)術(shù)重溫StatisticsReview中心趨向向---平均均Centraltendency---Average典形數(shù)值值的位置Thelocationofthetypicalvalue流程設(shè)定定Processsetting平均值A(chǔ)verage統(tǒng)計(jì)技術(shù)術(shù)重溫StatisticsReview分布Spread極差，標(biāo)標(biāo)準(zhǔn)差Range,standarddeviation((sigma)數(shù)據(jù)相距多遠(yuǎn)遠(yuǎn)，數(shù)據(jù)的的變量程程度Howspreadapartarethedata;;theamountofvariationinthedata極差Range_統(tǒng)計(jì)技術(shù)術(shù)重溫StatisticsReview新統(tǒng)計(jì)技技術(shù)概念念NewStatisticalConcept數(shù)據(jù)的分分布Distributionofthedata某一數(shù)值值出現(xiàn)多多少次howoftencertaindatavaluesoccur數(shù)值在分分布上的的集中程程度theconcentrationofdatavaluesacrossthespread數(shù)據(jù)分布布的形狀狀theshapeofthedataveryshortmediumtallverytallshort練習(xí)---孔孔徑Exercise---HoleDiameters大量數(shù)據(jù)據(jù)!Abunchofdata!!60個(gè)孔徑數(shù)數(shù)值,每每行十個(gè)個(gè)量度數(shù)數(shù)值,按按次序排排列60holediameters---10measurementspercolumn,listedinsequence直方圖Histogram181614121086420孔徑HoleDiameters直方圖-鐘狀曲線線Histogram---Bell-ShapedCurve小樣本數(shù)數(shù)SmallSampleSize較大樣本本數(shù)SlightlyLargerSampleSize多加數(shù)據(jù)據(jù)會(huì)將圖圖形變成成鐘狀A(yù)ddingmoredatatothesampleroundsouttheshapelikeabell!大樣本數(shù)數(shù)LargeSize整體TheWholePopulation正態(tài)分布布NormalDistribution鐘狀曲線線=正態(tài)態(tài)分布Bellcurve=normaldistribution用于Useitto::預(yù)測(cè)predict.計(jì)算事情情發(fā)生的的可能性性(概率率)calculateprobabilitiesofthingshappening.如何制作作?How??將鐘狀曲曲線分開(kāi)開(kāi)為不同同部分,,如切餅餅.Bydividingthebellcurveintoparts---likeslicingapie!正態(tài)分布布NormalDistribution所有鐘狀狀圖可分分作六份份.Allbell-shapedpieshave6slices.各份有多多大?Howbigaretheslices?每一份都都是一樣樣準(zhǔn)差寬寬!Eachsliceisonestandarddeviationwide!6標(biāo)準(zhǔn)差差=整整份的的99..7%..That’s6standarddeviations=99..7%ofthepie.兩邊各有有小“尾尾巴”==0.3%%Weleftafewcrumbsateachedge==..3%..其中:π==3..14159e=2.71828概率密度度函數(shù)：：那一部分分最大?Whicharethebiggestslices?+1s+2s+3s-1s-2s-3s02.2%2.2%.2%.2%13.6%13.6%34.2%34.2%68.3%95.4%99.7%正態(tài)分布布NormalDistribution使用標(biāo)準(zhǔn)準(zhǔn)差決定定控制上上限及下下限,如如鐘狀曲曲線.TodetermineUCL&LCL,usestandarddeviation(s)---justlikethebellcurve!!UCL=Average+3sAverageLCL=Average-3s+3s-3s-3s+3s如何將這這些應(yīng)用用在控制制圖?Howdoesthisrelatetocontrolcharts?設(shè)定控制制限SettingControlLimits將鐘狀曲曲線轉(zhuǎn)90度Flipthebellcurveonit’ssideAverage-3s+3s-2s+2s-1s+1sLCLUCL-3s+3s-2s+2s-1s+1sLCLUCLAverage-3s+3s-2s+2s-1s+1sLCLUCLAverage設(shè)定控制制限SettingControlLimits這是什么么意思??Whatdoesitallmean??UCL=Average+3sLCL=Average-3s-3s+3s-2s+2s-1s+1sAverageLCLUCL控制限---控控制上上,下限限ControlLimits---UCL,,LCL若流程受受到控制制:Ifyourprocessisincontrol:99.7%的數(shù)據(jù)將將會(huì)在控控制上限限及下限限之間..99.7%ofthedatapointswillbebetweentheUCLandLCL.數(shù)據(jù)沒(méi)有有特定的的圖樣,,隨機(jī)的的.Datapointswillshownopattern==random.大部分?jǐn)?shù)數(shù)據(jù)會(huì)趨趨向平均均值.Mostdatapointswillbeclosetotheaverage..數(shù)據(jù)應(yīng)有有一半在在平均值值以上及及一半在在以下..Datapointsbe50/50aboveandbelowaverage.標(biāo)準(zhǔn)差如如何影響響控制上限限及下限限HowStandardDeviationAffectsUCL&LCL將圖1至至圖4與與正確的的標(biāo)準(zhǔn)差差連線那一個(gè)標(biāo)標(biāo)準(zhǔn)差會(huì)會(huì)在控制制圖上定定出最寬寬的控制制限規(guī)格限SpecificationLimits客戶(hù),供供應(yīng)商或或內(nèi)部工工程要求求Customer,supplierorinternalengineeringrequirements包括::Include:目標(biāo)或中中間值((最理想想的)targetornominalvalue((theideal!)在目標(biāo)值值兩旁可可接受的的變異allowablevariationoneithersideofthetargetvalue規(guī)格上限限=目目標(biāo)值值+可可接愛(ài)愛(ài)的變異異USL==target++allowablevariation規(guī)格下限限=目目標(biāo)值值-可可接受受的變異異LSL==target--allowablevariation例子---酸濃濃度Example---AcidConcentration規(guī)格是130克克/升++/-30克升升Specificationis130grams/liter++/-30grams//liter規(guī)格上限限=目標(biāo)標(biāo)值+可可接受的的變量USL==target++allowablevariation130++30==160規(guī)格下限限=目標(biāo)標(biāo)值-可可接受的的變異LSL==target--allowablevariation130--30==100可接受變變異的總總值=規(guī)規(guī)格上限限=規(guī)格格下限Totalallowablevariation=USL-LSL160--100==60我們可以以量度能能力嗎??CanWeMeasureCapability?USLLSL目標(biāo)Target可接受的變異AllowableVariation下圖=規(guī)格Picturebelow=specifications正態(tài)分布(鐘狀曲線)=流程N(yùn)ormaldistribution(bellcurve)=process實(shí)際變異ActualVariation流程中心點(diǎn)ProcessCenterCp必須大于于1CpShouldBeGreaterThan1顯示實(shí)際際變異少少于可接接受變異異Indicatesactualvariationislessthanallowablevariation.LSLUSLLSLUSLLSLUSLCp大于1Cpgreaterthan1Cp=1Cp少于1Cplessthan1Cp---量度流程程分布Cp--MeasuresProcessSpread比較可接接受變異異(T)及實(shí)際變變異(A)Compareallowablevariation((T)toactualvariation((A).T=USL––LSL：給定的技術(shù)要求T(公差)A=6σ：工序自身身實(shí)際存存在的能能力(質(zhì)量水平平)6σCp==T/6σLSLUSLATCp---總結(jié)Cp--Conclusions數(shù)值越大大越好!!Thebiggerthenumber,,thebetter!!Cp的缺點(diǎn)--只能能顯示流流程分布布,但不不能顯示示是否符符合規(guī)格格DeficiencyofCp---Itshowsonlythespreadofprocess,butnotthecompliancetospecification.例子：兩兩流程的的Cp一樣。Example:TwoprocesseswithsameCp..USLLSLTargetUSLLSLTargetCa––準(zhǔn)確度Capabilityofaccuracy想一想:如果T的中心(公差中心心),與6σ之中心不不重合時(shí)時(shí),CP會(huì)是一種怎樣的值,不重合時(shí)CP如何考慮呢?----Cp值是不會(huì)會(huì)發(fā)生變變化的？？Why？偏移量ε=｜X-μ｜如何去表表征這種種情況呢呢？Cpk---量度流程程能力Cpk--MeasuresProcessCapability比較流程程中間值值設(shè)定及及目標(biāo)..Comparessettingofprocesscenter(average)totarget..Cpk==min((USL-X,,X--LSL)3USLLSL目標(biāo)Target流程中間值ProcessCenter偏離中間值OffCenter!!CpkCpk良好GoodCpkCpk差PoorCpkLSLUSLLSLUSL基本定律律:Cpk要求最少少1.33Generalrule---aimforCpkof1.33minimum流程能力力不足的的兩種情情況TwoWaysaProcessIsNOTCapable1.實(shí)實(shí)際流程程變異(A:6)超出右接接受變異異的總值值(B:規(guī)格)Actualprocessvariation((A:sixsigma)exceedstotalallowablevariation((B:spec)TargetBALSLUSL產(chǎn)品不符合規(guī)格Productsoutofspec產(chǎn)品不符合規(guī)格Productsoutofspec流程能力力不足的的兩種情情況TwoWaysaProcessIsNOTCapable2.如如流程表表現(xiàn)不足足處于規(guī)規(guī)格的中中間位置置,并其其中一邊邊的控制制限超越越規(guī)格限限.Ifprocessisnotcenteredproperlyandoneofthecontrollimitsexceedsthespeclimit.LSLUSLLCLUCLTargetAverage產(chǎn)品不能符合規(guī)格Productsoutofspec!產(chǎn)品不是最佳Productsnotthebest.若流程能能力不足足如何辦辦?Whatifaprocessisn’’tcapable?流程需要要改善Theprocessneedsimprovement!首先,采采取改善善行動(dòng),,減少變變異,然然后,按按目標(biāo)值值將流程程表現(xiàn)調(diào)調(diào)至中間間值.First,takeactiontoreducethevariation..Then,,centertheprocessoverthetarget..表現(xiàn)不良Badnews!表現(xiàn)改善Gettingbetter進(jìn)一步改善MuchbetterUSLLSLTargetUSLLSLTargetUSLLSLTarget你需要做做什么??Whatshouldyoudo??USLLSLCp<2andCpk<1.0采取預(yù)防行動(dòng)清除不合格產(chǎn)品

Takeprecautionstoremovenon-conformingproducts

持續(xù)努力減少變異

Continueeffortstominimizevariation將流程表現(xiàn)控制到中間值

Centertheprocess維持流程于控制限內(nèi)

Maintainprocesswithincontrollimits持續(xù)努力減少變異

Continueeffortstominimizevariation將流程表現(xiàn)控制到中間值

CentertheprocessUSLLSLCp<2andCpk>1.0你需要做做什么??Whatshouldyoudo??USLLSLCp<2andCpk>1.33維持流程于控制限內(nèi)

Maintainprocesswithincontrollimits

持續(xù)努力減少變異

Continueeffortstominimizevariation采取預(yù)防行動(dòng)消除不合格產(chǎn)品

Takeprecautionstoremovenon-conformingproducts將流程表現(xiàn)控制到中間值

CentertheprocessUSLLSLCp>2andCpk<1.0你需要做做什么??Whatshouldyoudo??USLLSLCp>2andCpk>1維持流程于控制限內(nèi)

Maintainprocesswithincontrollimits將流程表現(xiàn)控制到中間值

Centertheprocess維持流程于控制限內(nèi)

MaintainprocesswithincontrollimitsUSLLSLCp>2andCpk>1.5穩(wěn)定的流流程StableProcess一致的Consistent可預(yù)測(cè)的的Predictable沒(méi)有特別別原因Nospecialcauses受控的Incontrol有能力的的流程CapableProcess持續(xù)的滿(mǎn)滿(mǎn)足規(guī)格格要求Continuallymeetspecifications.流程穩(wěn)定定及能力力ProcessStability&&Capability流程可以以是受控控,但不不符合規(guī)規(guī)格的.Aprocesscouldbeincontrol,butnotmeetspecifications.重溫---穩(wěn)定定及能力力Recap---Stability&&Capability機(jī)師APilotA機(jī)師BPilotB跑道Landingrunway跑道LandingrunwayBeinginspecisnotsufficient!!只符合規(guī)格是不足夠的！機(jī)師APilotA機(jī)師BPilotB跑道Landingrunway跑道LandingrunwayBeingincontrolisalsonotsufficient!!只是受控也是不足夠的！重溫---穩(wěn)定定及能力力Recap---Stability&&Capability重溫---穩(wěn)穩(wěn)定及能能力Recap---Stability&&Capability流程穩(wěn)定定processstability+流程能力力+processcapability+持續(xù)改善善+continualimprovement_________________________優(yōu)越表現(xiàn)現(xiàn)performanceexcellence受控狀態(tài)InControl符合規(guī)格MeetsspecsCPK與精益6水平關(guān)系系衡量過(guò)程程能力大大小兩種種方式：：1.CPK2.精益6水平陰影部分分即為不合格率率:P=PL+PU=P((X<TL)+P(X>TU)精益6水平—Z值，半個(gè)個(gè)公差范范圍內(nèi)含含有的個(gè)數(shù)（無(wú)無(wú)偏移））。如果加工工中心有有偏移，Z值該如何何計(jì)算？？?jī)煞N方式式來(lái)衡量量過(guò)程能能力!兩種表達(dá)達(dá)方式共共同點(diǎn)是是什么？？CPK與精益6水平關(guān)系系CPK與精益6水平關(guān)系系良率計(jì)算算為99.98%CPK----minitab運(yùn)用實(shí)例例進(jìn)行CPK分析前，，首先檢檢測(cè)數(shù)據(jù)據(jù)是否符符合正態(tài)態(tài)分布。。如果是是非正態(tài)態(tài)數(shù)據(jù)，，計(jì)算CPK時(shí)需將數(shù)數(shù)據(jù)進(jìn)行行正態(tài)轉(zhuǎn)轉(zhuǎn)換。采用正態(tài)態(tài)分布計(jì)計(jì)算的CPK為2.37，PPK為1.15CPK----minitab運(yùn)用實(shí)例例采用組間間/組內(nèi)能力力分布計(jì)計(jì)算的CPK為1.21，PPK為1.15CPK----minitab運(yùn)用實(shí)例例為何這兩兩種計(jì)算算方法存存在差異異？到底底那一種種最合理理？148414841484為何我們們手動(dòng)算算的標(biāo)準(zhǔn)準(zhǔn)差與Minitab運(yùn)算的不不一樣？？課程三Module3課程3:內(nèi)容容Module2::Agenda制作控制制圖ControlChartPreparation制作反應(yīng)應(yīng)計(jì)劃ReactionPlansPreparation解決問(wèn)題題TroubleshootingSPC稽核生產(chǎn)中使使用SPCUsingSPCDuringProduction1.收集數(shù)據(jù)Collectdata3.理解數(shù)據(jù)

Interpretthedata2.在圖上記錄數(shù)據(jù)

Recorddataonchart4.特別成因?SpecialCause?6.采取糾正行動(dòng)

Takecorrectiveaction5.繼續(xù)執(zhí)行流程

Continuetoruntheprocess是Yes否No7.準(zhǔn)備文件

DocumentSPC數(shù)據(jù)收集集記錄CollectionofSPCdata由SPC聯(lián)絡(luò)員按按照要求求收集并并記錄數(shù)數(shù)據(jù)由SPC稽核員將將數(shù)據(jù)錄錄入SPC系統(tǒng)，對(duì)對(duì)SPC圖進(jìn)行判判定。若若判定失失控，需需實(shí)施糾糾正行動(dòng)動(dòng)，則發(fā)發(fā)出失控控反應(yīng)計(jì)計(jì)劃。SPC聯(lián)絡(luò)員填填寫(xiě)《SPC檢查表》并在控制制圖上描描點(diǎn)，若若有控制制點(diǎn)或趨趨勢(shì)圖樣樣滿(mǎn)足判判異條件件時(shí)，應(yīng)應(yīng)在2小時(shí)內(nèi)反反饋工序序主任及及技術(shù)PE。反應(yīng)計(jì)劃劃---偏差差報(bào)告ReactionPlan–DiscrepancyReportPE安排對(duì)失失控點(diǎn)做做初步分分析和原原因排查查,確定是否否為特殊殊原因?qū)?dǎo)致SPC失控，PE需在12小時(shí)以?xún)?nèi)內(nèi)在《SPC檢查表》上填寫(xiě)失失效反應(yīng)應(yīng)計(jì)劃，，并對(duì)制制定的改改善措施施及時(shí)落落實(shí)。SPC管理工程程師對(duì)SPC實(shí)施狀況況進(jìn)行跟跟進(jìn)，跟跟進(jìn)SPC糾正措施施的效果果驗(yàn)證。。控制圖格格式ControlChartFormatPE安排對(duì)失失控點(diǎn)做做初步分分析和原原因排查查什么是解解決問(wèn)題題?WhatisTroubleshooting?找出問(wèn)題題的根本本原因并并采取糾糾正行動(dòng)動(dòng)Lookingfortherootcauseofaproblemandtakingcorrectiveaction.解決問(wèn)題題步驟::Troubleshootingprocess:特別成因因?Specialcause?作反應(yīng)!!按反應(yīng)應(yīng)計(jì)劃采采取糾正正行動(dòng)..React!Followreactionplanforcorrectiveaction.再次量度度.Takeanothermeasurement..記錄于反反應(yīng)計(jì)劃劃及控制制圖.Documentonreactionplanandcontrolchart.解決問(wèn)題題指引TroubleshootingGuidelin