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StatisticalTechniqueto6-SigmaQuality6-sigmatrainiing(六西格碼培訓(xùn)資料)-文檔資料StatisticalTechniqueto6-SigmaQuality1ABOUTINSTRUCTORCurrentposition:Sr.Officer,LCMEng.Dept MPhif.(EE),BEng(Hons)Eng.Pastworkingexperience:HKUST:TofabricateOLEDanddesigntherelateddrivingcicruits.CityU:TofabricatePolymericOptoWaveguidesPhilips:TodevelopLCMincludingB/W,ColorSTN,TFTandPLEDSolomonSystech:TodevelopthedriverICforB/W,ColorSTN,TFTandPDAproducts.2COURSEABSTRACTThiscourseistointroducethewaysofProcessControlSystemtargetingto6-sigmaQualityinthemanufacturingareas.ThebenchmarkofSixSigmawillbesharedduringthecourse.Inordertoachieveit,seriesofmeasurementsystemcapabilities,performancemetricsandprocesscontrolmethodologywillbediscussed.3愛情1StatisticalTechniqueto6-SigABOUTINSTRUCTORCurrentposition:Sr.Officer,LCMEng.Dept MPhif.(EE),BEng(Hons)Eng.Pastworkingexperience:HKUST:TofabricateOLEDanddesigntherelateddrivingcicruits.CityU:TofabricatePolymericOptoWaveguidesPhilips:TodevelopLCMincludingB/W,ColorSTN,TFTandPLEDSolomonSystech:TodevelopthedriverICforB/W,ColorSTN,TFTandPDAproducts.2ABOUTINSTRUCTORCurrentpositiCOURSEABSTRACTThiscourseistointroducethewaysofProcessControlSystemtargetingto6-sigmaQualityinthemanufacturingareas.ThebenchmarkofSixSigmawillbesharedduringthecourse.Inordertoachieveit,seriesofmeasurementsystemcapabilities,performancemetricsandprocesscontrolmethodologywillbediscussed.3COURSEABSTRACTThiscourseisCOURSEOBJECTIVES

Participantswilllearn:-*WhatissixSigma*ControlPlanningandMethodology*Measurementsystemcapability*ProcessCapabilityMetrics*ContinuousProcessImprovement4COURSEOBJECTIVESParticipantsTraditionalProcessCapability*99.73%ofthetotalareawithinspec.limits.Defectratewillbe2,700PPM.*Only93.32%oftheareaunderthecurveanddefectrateis66,000PPM.5TraditionalProcessCapabilitySixSigmaCapability*Defectrate-0.002PPM*Defectrate-3.4PPM6SixSigmaCapability6?

OutputVariablesManagetheoutputs.ATraditionalViewSalesGrowthMarketShareProfitability7?OutputVariablesManagetheo?

OutputVariables?

InputVariablesManagetheinputs;respondtotheoutputs.ANon-traditionalViewSalesGrowthMarketShareProfitabilityCustomerSatisfactionProductQualityOn-TimeDeliveryCOQCreditTermsRelationshipsServiceCustomerTraining8?OutputVariables?InputVariWhatis6-SigmaMotorola’stermtoexpressaprocesscapabilitythatproducesonly0.002defectspereachmillionunitsmanufacturedwhentheprocessiscentered,oramaximumofonly3.4defectsforeachmillionunitswhentheprocessshiftsupto1.5sigmatooneside.Theterm“6sigma”isbecomingsynonymouswith“QualityExcellence”.9Whatis6-Sigma9

TheConceptof"SixSigma"DifferentnumbersofOpportunities...ManufacturingProcessesCustomersorSuppliersAdministrativeAreas6=Astructuralapproachtocontinuousimprovement1-Identifytheproductorserviceyouprovide2-Identifyyourcustomers&theirrequirements3-Determineyourneeds&suppliers4-Definetheprocessfordoingwork5-Eliminatedefectsources/optimizetheprocess6-ContinuouslyimprovetheSigmalevel(or“Sixstepstowardexcellence”)

ABitofStatistics...-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0upperspeclimitLowerspeclimit+1.5Sigma-1.5Sigma3.4ppm

orZero+10TheConceptof"SixSigmaCENSOREDNormalDistribution-GaussianCurveSigma==Deviation

(Squarerootofvariance)-7-6-5-4-3-2-101234567AxisgraduatedinSigma68.27%95.45%99.73%99.9937%99.999943%99.9999998%result:317300ppmoutside(deviation)45500ppm2700ppm63ppm0.57ppm0.002ppm

between+/-1between+/-2between+/-3between+/-4between+/-5between+/-6=11CENSOREDNormalDistribution-SixSigma...AndtheStatistics

-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0+1.5Sigma-1.5Sigma3.4ppmorZeroUpperspec.limitLowerspec.limit

Reducethevariation:when

<=Designspecificationwidth/12

Stabilizetheprocess,withoutaffectingthevariance,tolimitthemaximumprocessshiftto+/-1.5

Undertheseconditions,andintheworstcase,therewillbenomorethana3.4ppmdefect(reject)level,withspecificationlimitsat4.5ononesideand7.5ontheother.

Note:Onecanseethatthepointcorrespondingto6onthegraduatedperformancescaleaboveismeasuredin”Sigma’s”(with6correspondingtoa3.4ppmdefectlevel).

Cp>=2andCpk>=1.5Cp>=212SixSigma...AndtheStatisticsSixSigma...AndCapabilityCp=Designspecificationwidth63Cpk=Min.

Mean-SpecLimitWithamaximumprocessshiftof+/-1.513SixSigma...AndCapabilityCp-CustomersorSuppliers:Oneopportunityperproductdeliveredorpercomponentpurchased.-Manufacturingprocess:Opportunitiesateachprocessstep)-Administrativeareas:NumberofopportunitiesforerrorforeachactivityperformedTheOpportunities...14-CustomersorSuppliers:OneSomeExamplesofOpportunityCustomerPerspective:1opportunityperproductdeliveredex.1regulator=1opportunity1controller=1opportunity

Productionlines:Regulator=160opportunitiesController=1200opportunitiesForm(Payment,PurchaseOrder,..):Numberoffields

Expedite/Delivery:1opportunity/packagingunit15SomeExamplesofOpportunityCuAqualitylevelof"6"correspondstolessthan3.4defectspermillionOpportunities(i.e.,correct99.99966%ofthetime)

NumberofDefectsNumberofUnits=

D.P.U

D.P.Ux1000000NumberofOpportunities

=D.P.M.Op.SigmaandOpportunities1Opportunity=D.P.M.Op16Aqualitylevelof"6"corresAUniversalMeasurementScale...345676681062102333.4SigmaDPMOpOnonecondition:Calculatethedefectsandestimatetheopportunitiesinthesameway...17AUniversalMeasurementScaleMeasurementWithSIGMAIsSimple!!!EstimatetheOpportunitiesCountthe

Defects

FollowtheIndicator:Defects

permillionOpportunitiesConversioninto"Sigma"canbeaccomplishedwiththehelpofastatisticaltable.

6=3.4dpmo18MeasurementWithSIGMAIsSimpConvertingDefectLevelsto.....Sigma!175defectsareidentifiedwhileproducing5000controllersThemanufactureofonecontrollerallowsfor1367defectopportunities.D.P.Op=0.035/1367=0.0000256AnExample:D.P.U=175/5000=0.035

D.P.M.Op=25.6

"Sigma"level:5.5519ConvertingDefectLevelsto...SixSigma:AnAmbitiousObjective??Accurateto99.99966%(lessthan3.4defectsforeachmillionopportunities)couldappearexcessive....!

99.9%isalreadyVERYGOOD!

Butwhatcouldhappenataqualitylevelof99.9%(i.e.,1000ppm),

inoureverydaylives(about4.6)?

?4000wrongmedicalprescriptionseachyear?Morethan3000newbornsaccidentallyfalling

fromthehandsofnursesordoctorseachyear?TwolongorshortlandingsatAmericanairportseachday?400lettersperhourwhichneverarriveattheirdestination20SixSigma:AnAmbitiousObjectTheImpactofQuality:“6SigmaSuppliers”13wrongdrugprescriptionsperyear10newbornbabiesdroppedbydoctors/nursesperyearTwoshortorlonglandingsperyearinalltheairportsintheU.S.Onelostarticleofmailperhour21TheImpactofQuality:“6SigmDefectReduction:“PeelingtheOnion”?ActionNameDateACTIONPLANPROCEDURECONTINUOUSIMPROVEMENTMODELTRENDCHARTGOALTIME100%BRAINSTORMING/PARETOANALYSIS/ROOTCAUSEIDENTIFICATIONRESULTSANDINSTITUTIONALIZEMEASUREANALYZEPROBLEMSOLVEProcessstep1Processstep3Processstep2????SUPPLIERSUPPLIERSUPPLIERCUSTOMERCUSTOMERCUSTOMERRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTS22DefectReduction:“PeelingtheMeasurementSystemsCapabilityThecapabilityofthemeasurementsystemmustbeensuredbeforethesystemisusedforprocesscontrolorformeasurementsusedincapabilitystudies.GageRepeatability&Reproducibility(R&R):isastatisticalstudytoinvestigatethegage’sabilitytorepeatameasurementonthesamepart(repeatability)andtheabilitytogivethesamereadingonthesamepartwhenusedbydifferentpeople(reproducibility).Under10%-acceptable10%-30%-Maybeacceptabledependingonapplication. Effortshouldbemadetoimprovethegagacapability.Over30%-Notsuitabletouse.23MeasurementSystemsCapabilityGageR&R24GageR&R24ProcessPerformanceCapabilityTomeasuretheabilityofamachineorprocesstoproduceaproductwithinspecification.PotentialProcessCapabilityIndex(Cp):-Ratioofspecificationwidthovertheprocessspread

SpecWidth Cp= ProcessSpread

USL-LSL = 6-Sigma25ProcessPerformanceCapabilityProcessPerformanceCapabilityProcessCapabilityIndex(CpK):-anoff-targetprocessshouldbe“penalized”forshiftingfromwhereitshouldbe.CpKistheindextomeasurethisrealcapabilitywhentheoff-targetpenaltyistakenintoconsideration.

Target-ProcessMean Penalty/Correctionfactor,k= 1/2SpecificationWidth

Mean-Closerspeclimit Cpk=Cp(1-k)= 3sigma26ProcessPerformanceCapabilityProcessPerformanceCapability27ProcessPerformanceCapabilityProcessPerformanceCapability*Maximumcustomersatisfactionisachievedonlywhentheproductisrightontarget.

28ProcessPerformanceCapabilityProcessPerformanceCapability29ProcessPerformanceCapabilityTotalProcessControlSystem1.Process/ProductFailureModeandEffectsAnalysis(FMEA)Ananalyticaltechniqueaimedatproblempreventionthroughidentificationofpotentialproblems.Foreachfailuremode,theeffectonthetotalsystemisstudiedandactionstominimizetheprobabilityoffailuresareplanned.FMEAwillserve:a)Identifiesknownorpotentialprocessfailuremodesb)Assessesthepotentialriskeffectsofthefailurestothecustomerc)Identifiesthepotentialproductormanufacturingprocesscausesandcontrolactionsd)Identifiessignificantprocessvariablestofocuscontrolsfordetectingandreducingsimilarfailures30TotalProcessControlSystem30FMEA31FMEA31TotalProcessControlSystem2.ProcessControlPlanAsummarydescriptionoftheproceduresforcontrollingallsignificantcharacteristicsoftheprocessesusedtomanufactureafamilyofsimilarproducts.Itidentifiestheimportantprocessesusedtoproduceaproduct,thesignificantcharacteristicsassociatedwitheachprocessandhowtocontroleachofthosesignificantcharacteristics.ControlPlanconsists:a)Processb)Equipmentc)Significantcharacteristicsd)Measurementmethode)Minimumsamplesizeandfrequencyf)Analysismethodg)Outofcontrolaction32TotalProcessControlSystem32ControlPlan33ControlPlan33TotalProcessControlSystem3.TotalControlMethodologyAsetofdocumentsprovidingallnecessaryinstructionsonhowtocontroleachsignificantvariableinaprocess.ATotalControlMethodologyisusedattheindividualprocesslevel,whileaControlPlanisusedforaproductlinethatcontainsseveralprocesses.TotalControlMethodologyconsists:a)PositrolPlanb)PositrolLogchecklistc)ControlChartsd)Out-of-ControlActionPlan(OCAP)e)Process/MachineSetupCheckListf)P/MScheduleandChecklistg)P/Mprocedures34TotalProcessControlSystem34AttributeControl35AttributeControl35VariableControl36VariableControl36StatisticalTechniqueinElectricalTestArea37StatisticalTechniqueinElectContinuousImprovement38ContinuousImprovement38ContinuousImprovement39ContinuousImprovement39ContinuousImprovement40ContinuousImprovement40=Astructuredapproachtocontinuousimprovement1-Identifytheproductorserviceyouprovide2-Identifythecustomer&theirrequirements3-Determineyourneeds&suppliers4-Definetheprocessfordoingwork5-Eliminatedefectsources/optimizetheprocess6-ContinuouslyimprovetheSigmalevel(or”Sixstepstowardexcellence")SixSigmaandContinuousImprovementSupplierCustomerEnterNeeds

ExitProduct/ServiceProcessActivity123456Feedback41=Astructuredapproachtocon感謝觀賞感謝觀賞StatisticalTechniqueto6-SigmaQuality6-sigmatrainiing(六西格碼培訓(xùn)資料)-文檔資料StatisticalTechniqueto6-SigmaQuality1ABOUTINSTRUCTORCurrentposition:Sr.Officer,LCMEng.Dept MPhif.(EE),BEng(Hons)Eng.Pastworkingexperience:HKUST:TofabricateOLEDanddesigntherelateddrivingcicruits.CityU:TofabricatePolymericOptoWaveguidesPhilips:TodevelopLCMincludingB/W,ColorSTN,TFTandPLEDSolomonSystech:TodevelopthedriverICforB/W,ColorSTN,TFTandPDAproducts.2COURSEABSTRACTThiscourseistointroducethewaysofProcessControlSystemtargetingto6-sigmaQualityinthemanufacturingareas.ThebenchmarkofSixSigmawillbesharedduringthecourse.Inordertoachieveit,seriesofmeasurementsystemcapabilities,performancemetricsandprocesscontrolmethodologywillbediscussed.3愛情43StatisticalTechniqueto6-SigABOUTINSTRUCTORCurrentposition:Sr.Officer,LCMEng.Dept MPhif.(EE),BEng(Hons)Eng.Pastworkingexperience:HKUST:TofabricateOLEDanddesigntherelateddrivingcicruits.CityU:TofabricatePolymericOptoWaveguidesPhilips:TodevelopLCMincludingB/W,ColorSTN,TFTandPLEDSolomonSystech:TodevelopthedriverICforB/W,ColorSTN,TFTandPDAproducts.44ABOUTINSTRUCTORCurrentpositiCOURSEABSTRACTThiscourseistointroducethewaysofProcessControlSystemtargetingto6-sigmaQualityinthemanufacturingareas.ThebenchmarkofSixSigmawillbesharedduringthecourse.Inordertoachieveit,seriesofmeasurementsystemcapabilities,performancemetricsandprocesscontrolmethodologywillbediscussed.45COURSEABSTRACTThiscourseisCOURSEOBJECTIVES

Participantswilllearn:-*WhatissixSigma*ControlPlanningandMethodology*Measurementsystemcapability*ProcessCapabilityMetrics*ContinuousProcessImprovement46COURSEOBJECTIVESParticipantsTraditionalProcessCapability*99.73%ofthetotalareawithinspec.limits.Defectratewillbe2,700PPM.*Only93.32%oftheareaunderthecurveanddefectrateis66,000PPM.47TraditionalProcessCapabilitySixSigmaCapability*Defectrate-0.002PPM*Defectrate-3.4PPM48SixSigmaCapability6?

OutputVariablesManagetheoutputs.ATraditionalViewSalesGrowthMarketShareProfitability49?OutputVariablesManagetheo?

OutputVariables?

InputVariablesManagetheinputs;respondtotheoutputs.ANon-traditionalViewSalesGrowthMarketShareProfitabilityCustomerSatisfactionProductQualityOn-TimeDeliveryCOQCreditTermsRelationshipsServiceCustomerTraining50?OutputVariables?InputVariWhatis6-SigmaMotorola’stermtoexpressaprocesscapabilitythatproducesonly0.002defectspereachmillionunitsmanufacturedwhentheprocessiscentered,oramaximumofonly3.4defectsforeachmillionunitswhentheprocessshiftsupto1.5sigmatooneside.Theterm“6sigma”isbecomingsynonymouswith“QualityExcellence”.51Whatis6-Sigma9

TheConceptof"SixSigma"DifferentnumbersofOpportunities...ManufacturingProcessesCustomersorSuppliersAdministrativeAreas6=Astructuralapproachtocontinuousimprovement1-Identifytheproductorserviceyouprovide2-Identifyyourcustomers&theirrequirements3-Determineyourneeds&suppliers4-Definetheprocessfordoingwork5-Eliminatedefectsources/optimizetheprocess6-ContinuouslyimprovetheSigmalevel(or“Sixstepstowardexcellence”)

ABitofStatistics...-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0upperspeclimitLowerspeclimit+1.5Sigma-1.5Sigma3.4ppm

orZero+52TheConceptof"SixSigmaCENSOREDNormalDistribution-GaussianCurveSigma==Deviation

(Squarerootofvariance)-7-6-5-4-3-2-101234567AxisgraduatedinSigma68.27%95.45%99.73%99.9937%99.999943%99.9999998%result:317300ppmoutside(deviation)45500ppm2700ppm63ppm0.57ppm0.002ppm

between+/-1between+/-2between+/-3between+/-4between+/-5between+/-6=53CENSOREDNormalDistribution-SixSigma...AndtheStatistics

-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0+1.5Sigma-1.5Sigma3.4ppmorZeroUpperspec.limitLowerspec.limit

Reducethevariation:when

<=Designspecificationwidth/12

Stabilizetheprocess,withoutaffectingthevariance,tolimitthemaximumprocessshiftto+/-1.5

Undertheseconditions,andintheworstcase,therewillbenomorethana3.4ppmdefect(reject)level,withspecificationlimitsat4.5ononesideand7.5ontheother.

Note:Onecanseethatthepointcorrespondingto6onthegraduatedperformancescaleaboveismeasuredin”Sigma’s”(with6correspondingtoa3.4ppmdefectlevel).

Cp>=2andCpk>=1.5Cp>=254SixSigma...AndtheStatisticsSixSigma...AndCapabilityCp=Designspecificationwidth63Cpk=Min.

Mean-SpecLimitWithamaximumprocessshiftof+/-1.555SixSigma...AndCapabilityCp-CustomersorSuppliers:Oneopportunityperproductdeliveredorpercomponentpurchased.-Manufacturingprocess:Opportunitiesateachprocessstep)-Administrativeareas:NumberofopportunitiesforerrorforeachactivityperformedTheOpportunities...56-CustomersorSuppliers:OneSomeExamplesofOpportunityCustomerPerspective:1opportunityperproductdeliveredex.1regulator=1opportunity1controller=1opportunity

Productionlines:Regulator=160opportunitiesController=1200opportunitiesForm(Payment,PurchaseOrder,..):Numberoffields

Expedite/Delivery:1opportunity/packagingunit57SomeExamplesofOpportunityCuAqualitylevelof"6"correspondstolessthan3.4defectspermillionOpportunities(i.e.,correct99.99966%ofthetime)

NumberofDefectsNumberofUnits=

D.P.U

D.P.Ux1000000NumberofOpportunities

=D.P.M.Op.SigmaandOpportunities1Opportunity=D.P.M.Op58Aqualitylevelof"6"corresAUniversalMeasurementScale...345676681062102333.4SigmaDPMOpOnonecondition:Calculatethedefectsandestimatetheopportunitiesinthesameway...59AUniversalMeasurementScaleMeasurementWithSIGMAIsSimple!!!EstimatetheOpportunitiesCountthe

Defects

FollowtheIndicator:Defects

permillionOpportunitiesConversioninto"Sigma"canbeaccomplishedwiththehelpofastatisticaltable.

6=3.4dpmo60MeasurementWithSIGMAIsSimpConvertingDefectLevelsto.....Sigma!175defectsareidentifiedwhileproducing5000controllersThemanufactureofonecontrollerallowsfor1367defectopportunities.D.P.Op=0.035/1367=0.0000256AnExample:D.P.U=175/5000=0.035

D.P.M.Op=25.6

"Sigma"level:5.5561ConvertingDefectLevelsto...SixSigma:AnAmbitiousObjective??Accurateto99.99966%(lessthan3.4defectsforeachmillionopportunities)couldappearexcessive....!

99.9%isalreadyVERYGOOD!

Butwhatcouldhappenataqualitylevelof99.9%(i.e.,1000ppm),

inoureverydaylives(about4.6)?

?4000wrongmedicalprescriptionseachyear?Morethan3000newbornsaccidentallyfalling

fromthehandsofnursesordoctorseachyear?TwolongorshortlandingsatAmericanairportseachday?400lettersperhourwhichneverarriveattheirdestination62SixSigma:AnAmbitiousObjectTheImpactofQuality:“6SigmaSuppliers”13wrongdrugprescriptionsperyear10newbornbabiesdroppedbydoctors/nursesperyearTwoshortorlonglandingsperyearinalltheairportsintheU.S.Onelostarticleofmailperhour63TheImpactofQuality:“6SigmDefectReduction:“PeelingtheOnion”?ActionNameDateACTIONPLANPROCEDURECONTINUOUSIMPROVEMENTMODELTRENDCHARTGOALTIME100%BRAINSTORMING/PARETOANALYSIS/ROOTCAUSEIDENTIFICATIONRESULTSANDINSTITUTIONALIZEMEASUREANALYZEPROBLEMSOLVEProcessstep1Processstep3Processstep2????SUPPLIERSUPPLIERSUPPLIERCUSTOMERCUSTOMERCUSTOMERRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTS64DefectReduction:“PeelingtheMeasurementSystemsCapabilityThecapabilityofthemeasurementsystemmustbeensuredbeforethesystemisusedforprocesscontrolorformeasurementsusedincapabilitystudies.GageRepeatability&Reproducibility(R&R):isastatisticalstudytoinvestigatethegage’sabilitytorepeatameasurementonthesamepart(repeatability)andtheabilitytogivethesamereadingonthesamepartwhenusedbydifferentpeople(reproducibility).Under10%-acceptable10%-30%-Maybeacceptabledependingonapplication. Effortshouldbemadetoimprovethegagacapability.Over30%-Notsuitabletouse.65MeasurementSystemsCapabilityGageR&R66GageR&R24ProcessPerformanceCapabilityTomeasuretheabilityofamachineorprocesstoproduceaproductwithinspecification.PotentialProcessCapabilityIndex(Cp):-Ratioofspecificationwidthovertheprocessspread

SpecWidth Cp= ProcessSpread

USL-LSL = 6-Sigma67ProcessPerformanceCapabilityProcessPerformanceCapabilityProcessCapabilityIndex(CpK):-anoff-targetprocessshouldbe“penalized”forshiftingfromwhereitshouldbe.CpKistheindextomeasurethisrealcapabilitywhentheoff-targetpenaltyistakenintoconsideration.

Target-ProcessMean Penalty/Correctionfactor,k= 1/2SpecificationWidth

Mean-Closerspeclimit Cpk=Cp(1-k)= 3sigma68ProcessPerformanceCapabilityProcessPerformanceCapability69ProcessPerformanceCapabilityProcessPerformanceCapability*Maximumcustomersatisfactionisachievedonlywhentheproductisrightontarget.

70ProcessPerformanceCapabilityProcessPerformanceCapability71ProcessPerformanceCapabilityTotalProcessControlSystem1.Process/ProductFailureModeandEffectsAnalysis(FMEA)Ananalyticaltechniqueaimedatproblem

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