版權(quán)說明：本文檔由用戶提供并上傳，收益歸屬內(nèi)容提供方，若內(nèi)容存在侵權(quán)，請進行舉報或認領(lǐng)
文檔簡介
ImplementingSixSigmaQualityatBetterBodyManufacturingImplementingSixSigmaQualityCURRENTPERFORMANCEOverviewPROBLEMSTATEMENTABCIncorporated(ABC)isnotachievingSixSigmaqualitylevelsforallcriticalBody-SideSub-Assemblydimensionsasrequestedbytheircustomers.TARGETPERFORMANCEEnsurethatallcriticalbody-sidesubassemblydimensionsarewithinSixSigmaqualitylevelsof<3.4DPM.Cp
32.0andCpk
31.67.RECOMMENDATIONSChangetonnageto>935tocorrectASM_7YandASM_8YSetclamppositiontolocation2forASM_9YandASM_10YRe-machineA-pillardietocorrectA_3YandASM_3YANALYSISDeterminedthecorrelationbetweenbodysideandassemblydimensions.EvaluatedthesignificanceofTonnage>935forASM_7Y&ASM_8Y.ConductedaDOEforClamppositionforASM_9Y&ASM_10Y.CURRENTPERFORMANCEOverviewPROGOALPROBLEMSTATEMENTProblemStatement&TheGoalABCIncorporated’scustomerwantsABCtoapplySixSigmaproblemsolvingmethodologytoinsurethatthebodysidesubassemblyisachievingSixSigmaqualitylevelsoflessthan3.4defectspermillionforallcriticalbodysidesubassemblydimensions.ABCneedsanimprovementstrategythatminimizesthereworkcostswhileachievingthedesiredqualityobjective.ABC’sgoalistoproducemodulesubassembliesthatmeetthecustomerrequirementsandnotnecessarilytoinsurethateveryindividualstampedcomponentwithintheassemblymeetsitoriginalprintspecifications–sub-systemoptimizationsvs.localoptimization.++A-PillarReinforcementB-PillarReinforcementBodySideOuter++A-PillarReinforcementB-PillarReinforcementBodySideOuterDDefineGOALPROBLEMSTATEMENTProblemSKEYPROCESSINPUTVARIABLESKEYPROCESSOUTPUTVARIABLESMeasurePhaseKeyVariables: Assemblyprocessvariables:WeldPattern(density),ClampLocation,andClampWeldPressureStampingprocessvariables(bodyside):PressTonnage,DieCushionPressure,MaterialThickness
BodyAssemblyDimensionsASM_1YthroughASM_10YMMeasureAssemblyDimensionswithHighestDefectsKEYPROCESSINPUTVARIABLESKEYResolutionalternatives(baseduponpastexperience):1.Makeadjustmentstoassemblyprocesssettings2.Reducevariationofcomponentsthroughbettercontrolofstampingprocessinputvariables3.ReworkstampingdiestoshiftcomponentmeandeviationthatisofftargetandcausingassemblydefectsTargetPerformanceLevel:AlltencriticalassemblydimensionsatSixSigmaqualitylevelof￡3.4DPM.
Cp
32.0andCpk
31.67FishBoneandP-Diagrams:Understandingpotentialcausesofdefects.FromthiswepicktheassemblyandcomponentdimensionsthatrequirefurtheranalysisAnalyzePhaseAAnalyzeResolutionalternatives(basedForouranalysiswewilldoaDOEtocheckforlevelsthatcontributetobetterqualityproduct.FISHBONEDIAGRAMWeldPattern(density)ClampLocationOperatorMachineMaterialsMethodsClampWeldPressurePressTonnageDieCushionPressureMaterialThicknessTrainingYieldStrengthElasticLimitEnvironmentTemperatureHumidityQualityComponentVariabilityInspectionProcessGageR&RBodyAssemblyAnalyzePhaseAAnalyzeP-DIAGRAMBodySideSub-AssemblyStampingProcessOutputsBodySideSub-AssembliesatSixSigmaqualitylevelsControlVariablesClampLocationPressTonnage
WeldDensityDiePressureClampPressureErrorStatesDimensionaldefectsNoiseVariablesEnvironment
InherentVariationInputsMaterialThicknessYieldStrengthForouranalysiswewilldoaAnalysisofASM_7YandASM_8YAnalyzePhaseAAnalyzeConclusion:BS_7YandASM_7Yarefollowingasimilartrend.Acorrelationcharttostudythisfurthershowshighcorrelation.(Pearsoncorrelation,Rof0.701).AnalysisofASM_7YandASM_8YAnalyzePhaseAAnalyzeCapabilityofB_7Y698416DPM0DPMConclusion:B_7Yhas0ppmcomparedto~700KDPMinBS_7Y.Furthermore,BS_7YshowsstrongcorrelationondimensionASM_7Y.(Pearsoncorrelation,Rof0.786).CapabilityofBS_7YAnalyzePhaseAAnalyzeCapabiliXYPlotofTonnagevs.BS_7YConclusion:Tonnagevaluesabove935greatlyimprovesBS_7Yandbringsitclosertothemean.Let’sseewhatimpactthishasonASMdimensions7Y,8Y,9Y,and10YbycreatingasubsetofthedatalookingonlyatTonnage>935.AnalyzePhaseAAnalyzeXYPlotofTonnagevs.BS_7YCoAnalyzePhaseAAnalyzeConclusion:SettingTonnagetogreaterthan935resultedinASM_7YandASM_8Ymeetingthegoalof<3.4DPM.ASM_9YandASM_10Yrequirefurtheranalysis.ImpactthishasonASMdimensions7Y,8Y,9Y&10YonTonnageAnalyzePhaseAAnalyzeConclusiDOEforResponseVariableASM_9YDOEfactorialanalysisshowsClampPositionistheonlysignificantfactorin
determiningASM_9Ydimension
DOEResponseOptimizationforASM_9YSetClampPositiontoLocation2(level1)OptimizerrecommendssettingWeldDensityto1.33weldperinch(level1),
butthisappearstobearobustparameter,whichcouldbechangedforthebenefit
ofprocesswithoutreducingqualityifprocessingtimeorcostshowsabenefit.OptimizerrecommendssettingClampPressureto2100psi(level1),butthis
appearstobearobustparameter,whichcouldbechangedforthebenefitofprocess
withoutreducingqualityifprocessingtimeorcostshowsabenefit.RunadditionaltestsatrecommendedsettingstoconfirmresultsWeldDensityandClampPressurearerobustparametersandcanbesettooptimize
theprocesscapabilitytomaximumlevelandlowestcost.AnalyzePhaseAAnalyzeDOEforResponseVariableASM_AnalyzePhaseAAnalyzeDOEforResponseVariableASM_10YDOEfactorialanalysisshowsClampPositionisalsotheonlysignificant
factorindeterminingASM_10Ydimension
DOEResponseOptimizationforASM_10YSettingclamptolocation2alsoimprovesASM_10YRecommendsamesettingsusedtoimproveASM_9Ytoimproveprocess
capabilitywhichalsoallowsfornochangestomachinesetupandhelpsreduce
possibleprocessconcernsRunadditionaltestsatrecommendedsettingstoconfirmresultsWeldDensityandClampPressurearerobustparametersandcanbesettooptimize
theprocesscapabilitytomaximumlevelandlowestcost.AnalyzePhaseAAnalyzeDOEforDOEforResponseVariableASM_3YDOEfactorialanalysisshowsthatnofactorsaresignificantResponseOptimizationshowsnosolutionforresponseoptimizerObserveProcessCapabilityofA_3YandBS_3YASM_3YandA_3Yhaveasimilarmeanshiftinthe-YdirectionCorrelationofOutputVariablesNodimensionalcorrelationsappeartoexistbetweenASM_3Yand
A_3YorBS_3YStepwiseRegressionAnalysisofBS_3YTonnageandDiePressureappeartobesignificantindetermining
dimensionBS_3YTonnagevalues<920mayimproveBS_3YDiePressureappearstohavenoclearcorrelationtoBS_3YAnalyzePhaseAAnalyzeDOEforResponseVariableASM_ProcessCapabilityofBS_3YandASM_3YatTonnage<920CreatedsubsetofbodydatalookingonlyatdimensionswithTonnage<935Tonnage<920appearstoimprovethemeanofBS_3Yslightly,buthasno
impactonimprovingthemeanofASM_3Y.CapabilityofA_3YandASM_3Ywith+0.80mmmeanoffset
ManipulatedataforA_3YandASM_3Yby+0.80mmtosimulatere-machiningProcesscapabilityshows0defectsforA_3YandASM_3YwiththismeanoffsetAnalyzePhaseAAnalyzeProcessCapabilityofBS_3YaAnalyzePhaseAAnalyzeConclusionsFromtheanalysisofASM_7YandASM_8Ywecanconcludethat:Settingtonnage>935resultsinASM_7YandASM_8YmeetingthegoalAnalyzingASM_9YandASM_10Yhelpsdeterminethat:Settingclamppositiontolocation2,welddensityto1weldevery1.33”
andclamppressureto2000psihelpswithdimensionsASM_9Yand
ASM_10YAnalyzingASM_3Yhelpsusconcludethat:Re-machineA-PillardietomoveA_3Ytonominal–whichcouldcause
BS_3Ytoshifttowardsnominal–effectivelyshiftingASM_3YtonominalAnalyzePhaseAAnalyzeConclusiWiththerecommendedchangestheprocessperformancewillimprovesignificantlyAAnalyzeAnalyzePhaseWiththerecommendedchangestRecommendationsforimprovingtheprocess:SetTonnagetoabove935toimproveASM_7Y&ASM_8YSetClamptoLocation2toimproveASM_9Y&ASM_10YRe-machinetheA-PillardietomovethemeanofA_3YtonominalwhichinturnwillmoveASM_3Ytonominal
Implementtheaboverecommendationsandrunadditionalsamplestoverifyresults.IImproveImprovePhaseRecommendationsforimprovingControlPhaseCControlRecommendedcontrols:ImplementagaugeonthebodysidecomponentpresstomonitortonnageImplementanalarmandshut-offfeatureonthebodysidepressiftonnage
fallsbelow935tonsImplementpoke-yokeclampingfixturethatensuresclampisalwaysin
Position2Establishanaffordablecontrolplanforongoingmonitoringofthe10
criticalassemblydimensions.
ControlPhaseCControlRecommendSummaryPROBLEMSTATEMENTABCIncorporatedisnotachievingSixSigmaqualitylevelsforallcriticalBody-SideSub-Assemblydimensionsasrequestedbytheircustomers.BBMneedstoapplySixSigmaproblemsolvingmethodologytoestablishanimprovementstrategythatminimizesreworkcosts,yetachievesthedesiredqualityobjective.RECOMMENDEDCONTROLS
ImplementagaugeonthebodysidecomponentpresstomonitortonnageImplementanalarm&shut-offfeatureonbodysidepressiftonnagefallsbelow935Implementpoke-yokeclampingfixturethatensuresclampisalwaysinPosition2Establishcontrolplanforongoingmonitoringofthe10criticalassemblydimensions.ANALYSIS&RECOMMENDATIONS
SetTonnagetoabove935toimproveASM_7Y&ASM_8YSetClamptoLocation2toimproveASM_9Y&ASM_10YRe-machinetheA-PillardietomovethemeanofA_3YtonominalTARGETPERFORMANCEBringthekeyprocessoutputvariableswithinSixSigmaqualitylevelof<3.4DPM.
Cp
32.0andCpk
31.67SummaryPROBLEMSTATEMENTABCInImplementingSixSigmaQualityatBetterBodyManufacturingImplementingSixSigmaQualityCURRENTPERFORMANCEOverviewPROBLEMSTATEMENTABCIncorporated(ABC)isnotachievingSixSigmaqualitylevelsforallcriticalBody-SideSub-Assemblydimensionsasrequestedbytheircustomers.TARGETPERFORMANCEEnsurethatallcriticalbody-sidesubassemblydimensionsarewithinSixSigmaqualitylevelsof<3.4DPM.Cp
32.0andCpk
31.67.RECOMMENDATIONSChangetonnageto>935tocorrectASM_7YandASM_8YSetclamppositiontolocation2forASM_9YandASM_10YRe-machineA-pillardietocorrectA_3YandASM_3YANALYSISDeterminedthecorrelationbetweenbodysideandassemblydimensions.EvaluatedthesignificanceofTonnage>935forASM_7Y&ASM_8Y.ConductedaDOEforClamppositionforASM_9Y&ASM_10Y.CURRENTPERFORMANCEOverviewPROGOALPROBLEMSTATEMENTProblemStatement&TheGoalABCIncorporated’scustomerwantsABCtoapplySixSigmaproblemsolvingmethodologytoinsurethatthebodysidesubassemblyisachievingSixSigmaqualitylevelsoflessthan3.4defectspermillionforallcriticalbodysidesubassemblydimensions.ABCneedsanimprovementstrategythatminimizesthereworkcostswhileachievingthedesiredqualityobjective.ABC’sgoalistoproducemodulesubassembliesthatmeetthecustomerrequirementsandnotnecessarilytoinsurethateveryindividualstampedcomponentwithintheassemblymeetsitoriginalprintspecifications–sub-systemoptimizationsvs.localoptimization.++A-PillarReinforcementB-PillarReinforcementBodySideOuter++A-PillarReinforcementB-PillarReinforcementBodySideOuterDDefineGOALPROBLEMSTATEMENTProblemSKEYPROCESSINPUTVARIABLESKEYPROCESSOUTPUTVARIABLESMeasurePhaseKeyVariables: Assemblyprocessvariables:WeldPattern(density),ClampLocation,andClampWeldPressureStampingprocessvariables(bodyside):PressTonnage,DieCushionPressure,MaterialThickness
BodyAssemblyDimensionsASM_1YthroughASM_10YMMeasureAssemblyDimensionswithHighestDefectsKEYPROCESSINPUTVARIABLESKEYResolutionalternatives(baseduponpastexperience):1.Makeadjustmentstoassemblyprocesssettings2.Reducevariationofcomponentsthroughbettercontrolofstampingprocessinputvariables3.ReworkstampingdiestoshiftcomponentmeandeviationthatisofftargetandcausingassemblydefectsTargetPerformanceLevel:AlltencriticalassemblydimensionsatSixSigmaqualitylevelof￡3.4DPM.
Cp
32.0andCpk
31.67FishBoneandP-Diagrams:Understandingpotentialcausesofdefects.FromthiswepicktheassemblyandcomponentdimensionsthatrequirefurtheranalysisAnalyzePhaseAAnalyzeResolutionalternatives(basedForouranalysiswewilldoaDOEtocheckforlevelsthatcontributetobetterqualityproduct.FISHBONEDIAGRAMWeldPattern(density)ClampLocationOperatorMachineMaterialsMethodsClampWeldPressurePressTonnageDieCushionPressureMaterialThicknessTrainingYieldStrengthElasticLimitEnvironmentTemperatureHumidityQualityComponentVariabilityInspectionProcessGageR&RBodyAssemblyAnalyzePhaseAAnalyzeP-DIAGRAMBodySideSub-AssemblyStampingProcessOutputsBodySideSub-AssembliesatSixSigmaqualitylevelsControlVariablesClampLocationPressTonnage
WeldDensityDiePressureClampPressureErrorStatesDimensionaldefectsNoiseVariablesEnvironment
InherentVariationInputsMaterialThicknessYieldStrengthForouranalysiswewilldoaAnalysisofASM_7YandASM_8YAnalyzePhaseAAnalyzeConclusion:BS_7YandASM_7Yarefollowingasimilartrend.Acorrelationcharttostudythisfurthershowshighcorrelation.(Pearsoncorrelation,Rof0.701).AnalysisofASM_7YandASM_8YAnalyzePhaseAAnalyzeCapabilityofB_7Y698416DPM0DPMConclusion:B_7Yhas0ppmcomparedto~700KDPMinBS_7Y.Furthermore,BS_7YshowsstrongcorrelationondimensionASM_7Y.(Pearsoncorrelation,Rof0.786).CapabilityofBS_7YAnalyzePhaseAAnalyzeCapabiliXYPlotofTonnagevs.BS_7YConclusion:Tonnagevaluesabove935greatlyimprovesBS_7Yandbringsitclosertothemean.Let’sseewhatimpactthishasonASMdimensions7Y,8Y,9Y,and10YbycreatingasubsetofthedatalookingonlyatTonnage>935.AnalyzePhaseAAnalyzeXYPlotofTonnagevs.BS_7YCoAnalyzePhaseAAnalyzeConclusion:SettingTonnagetogreaterthan935resultedinASM_7YandASM_8Ymeetingthegoalof<3.4DPM.ASM_9YandASM_10Yrequirefurtheranalysis.ImpactthishasonASMdimensions7Y,8Y,9Y&10YonTonnageAnalyzePhaseAAnalyzeConclusiDOEforResponseVariableASM_9YDOEfactorialanalysisshowsClampPositionistheonlysignificantfactorin
determiningASM_9Ydimension
DOEResponseOptimizationforASM_9YSetClampPositiontoLocation2(level1)OptimizerrecommendssettingWeldDensityto1.33weldperinch(level1),
butthisappearstobearobustparameter,whichcouldbechangedforthebenefit
ofprocesswithoutreducingqualityifprocessingtimeorcostshowsabenefit.OptimizerrecommendssettingClampPressureto2100psi(level1),butthis
appearstobearobustparameter,whichcouldbechangedforthebenefitofprocess
withoutreducingqualityifprocessingtimeorcostshowsabenefit.RunadditionaltestsatrecommendedsettingstoconfirmresultsWeldDensityandClampPressurearerobustparametersandcanbesettooptimize
theprocesscapabilitytomaximumlevelandlowestcost.AnalyzePhaseAAnalyzeDOEforResponseVariableASM_AnalyzePhaseAAnalyzeDOEforResponseVariableASM_10YDOEfactorialanalysisshowsClampPositionisalsotheonlysignificant
factorindeterminingASM_10Ydimension
DOEResponseOptimizationforASM_10YSettingclamptolocation2alsoimprovesASM_10YRecommendsamesettingsusedtoimproveASM_9Ytoimproveprocess
capabilitywhichalsoallowsfornochangestomachinesetupandhelpsreduce
possibleprocessconcernsRunadditionaltestsatrecommendedsettingstoconfirmresultsWeldDensityandClampPressurearerobustparametersandcanbesettooptimize
theprocesscapabilitytomaximumlevelandlowestcost.AnalyzePhaseAAnalyzeDOEforDOEforResponseVariableASM_3YDOEfactorialanalysisshowsthatnofactorsaresignificantResponseOptimizationshowsnosolutionforresponseoptimizerObserveProcessCapabilityofA_3YandBS_3YASM_3YandA_3Yhaveasimilarmeanshiftinthe-YdirectionCorrelationofOutputVariablesNodimensionalcorrelationsappeartoexistbetweenASM_3Yand
A_3YorBS_3YStepwiseRegressionAnalysisofBS_3YTonnageandDiePressureappeartobesignificantindetermining
dimensionBS_3YTonnagevalues<920mayimproveBS_3YDiePressureappearstohavenoclearcorrelationtoBS_3YAnalyzePhaseAAnalyzeDOEforResponseVariableASM_ProcessCapabilityofBS_3YandASM_3YatTonnage<920CreatedsubsetofbodydatalookingonlyatdimensionswithTonnage<935Tonnage<920appearstoimprovethemeanofBS_3Yslightly,buthasno
impactonimprovingthemeanofASM_3Y.CapabilityofA_3YandASM_3Ywith+0.80mmmeanoffset
ManipulatedataforA_3YandASM_3Yby+0.80mmtosimulatere-machiningProcesscapabilityshows0defectsforA_3YandASM_3YwiththismeanoffsetAnalyzePhaseAAnalyzeProcessCapabilityofBS_3YaAnalyzePhaseAAnalyzeConclusionsFromtheanalysisofASM_7YandASM_8Ywecanconcludethat:Settingtonnage>935resultsinASM_7YandASM_8YmeetingthegoalAnalyzingASM_9YandASM_10Yhelpsdeterminethat:Settingclamppositiontolocation2,welddensityto1weldevery1.33”
andclamppressureto2000psihelpswithdimensionsASM_9Yand
ASM_10YAnalyzingASM_3Yhelpsusconcludethat:Re-machineA-PillardietomoveA_3Ytonominal–whichcouldcause
BS_3Ytoshifttowardsnominal–effectivelyshiftingASM_3YtonominalAnalyzePhaseAAnalyzeConc
溫馨提示
- 1. 本站所有資源如無特殊說明，都需要本地電腦安裝OFFICE2007和PDF閱讀器。圖紙軟件為CAD,CAXA,PROE,UG,SolidWorks等.壓縮文件請下載最新的WinRAR軟件解壓。
- 2. 本站的文檔不包含任何第三方提供的附件圖紙等，如果需要附件，請聯(lián)系上傳者。文件的所有權(quán)益歸上傳用戶所有。
- 3. 本站RAR壓縮包中若帶圖紙，網(wǎng)頁內(nèi)容里面會有圖紙預覽，若沒有圖紙預覽就沒有圖紙。
- 4. 未經(jīng)權(quán)益所有人同意不得將文件中的內(nèi)容挪作商業(yè)或盈利用途。
- 5. 人人文庫網(wǎng)僅提供信息存儲空間，僅對用戶上傳內(nèi)容的表現(xiàn)方式做保護處理，對用戶上傳分享的文檔內(nèi)容本身不做任何修改或編輯，并不能對任何下載內(nèi)容負責。
- 6. 下載文件中如有侵權(quán)或不適當內(nèi)容，請與我們聯(lián)系，我們立即糾正。
- 7. 本站不保證下載資源的準確性、安全性和完整性, 同時也不承擔用戶因使用這些下載資源對自己和他人造成任何形式的傷害或損失。
最新文檔
- 母嬰店打工合同范本
- 職業(yè)暴露防護理
- 管網(wǎng)改造施工合同范本
- 2025至2030年中國木雕線條數(shù)據(jù)監(jiān)測研究報告
- 2025至2030年中國復膜膠數(shù)據(jù)監(jiān)測研究報告
- 2025至2030年中國埋入式旋轉(zhuǎn)接頭數(shù)據(jù)監(jiān)測研究報告
- 2025年中國高速肉丸打漿機市場調(diào)查研究報告
- 二零二五年度電子商務(wù)領(lǐng)域競業(yè)協(xié)議敬業(yè)保證合同
- 2025年度籃球賽事贊助商責任免除合同
- 2025年度自愿離婚協(xié)議及子女撫養(yǎng)與監(jiān)護協(xié)議
- 地理-天一大聯(lián)考2025屆高三四省聯(lián)考（陜晉青寧）試題和解析
- 醫(yī)療衛(wèi)生系統(tǒng)招聘考試（中醫(yī)學專業(yè)知識）題庫及答案
- 小巴掌童話課件
- 教科版六年級科學下冊全冊教學設(shè)計教案
- 部編版小學五年級下冊《道德與法治》全冊教案含教學計劃
- 2024年青島遠洋船員職業(yè)學院高職單招語文歷年參考題庫含答案解析
- 8款-組織架構(gòu)圖(可編輯)
- 四年級下冊綜合實踐活動教案 跟著節(jié)氣去探究 全國通用
- 領(lǐng)導干部道德修養(yǎng)1
- Chapter-1-生物信息學簡介
- 中國郵政銀行“一點一策”方案介紹PPT課件
評論
0/150
提交評論