《SIGMA黑帶項目》課件

通過6Sigma項目改善提高XB9138系列直通率實施單位：研發(fā)中心中試部實施時間：2006.05---2006.11項目BB：龔一桂6SigmaBB項目2/18/20241精選課件ppt定義階段DMAIC2/18/20242精選課件ppt項目選定背景客戶對此款攪拌水壺產(chǎn)品需求量大,品質(zhì)要求嚴.同行業(yè)產(chǎn)品價格競爭激烈外部環(huán)境XB9138系列攪拌式水壺現(xiàn)時直通率為78.5%客戶要求1.產(chǎn)品需求量大(30萬/年)2.品質(zhì)要求嚴提升直通率提升品質(zhì)DMAIC<現(xiàn)象><要求><結(jié)果>2/18/20243精選課件ppt項目選定背景內(nèi)部環(huán)境1.2006年1-4月成品直通率低,為78.5%2.成品合格率低，2005年QA驗貨合格率為86.2%3.劣質(zhì)成本高，占銷售額的比例大。檢查工序水溫檢測功能檢測耐壓測試外觀檢測總裝直通率單站直通率88.9%98.6%96.4%92.9%78.5%DMAIC2006年1-4月產(chǎn)品直通率2/18/20244精選課件ppt顧客及CTQ直通率低DMAIC外部顧客銷售/客服要求提升產(chǎn)品品質(zhì)/低廉的價位/較少的維修機會利益獲取更大利潤/節(jié)省維修投入內(nèi)部顧客財務(wù)管理中心/成本核算部要求降低劣質(zhì)成本/一次就做好利益增加利潤VOCCTQ2/18/20245精選課件ppt項目范圍PMC進料成品入倉OQC檢驗IQC檢驗總裝XB9138系列主要生產(chǎn)過程過程范圍DMAIC2/18/20246精選課件ppt項目范圍XB9138系列主要裝配流程（SIPOC)DMAIC拆底座裝腳墊與繞線蓋拆大身上座,裝電源線到底座裝馬達墊裝固定板到電機固定電機到大身插插座引線裝插座到大身壓連接頭,裝開關(guān)焊接引線(一）焊接引線(二）焊接引線(三）固定壓線碼與PCB板接線扎扎帶機身內(nèi)檢吹熱縮管找出影響直通率的關(guān)鍵流程裝裝飾圈2/18/20247精選課件ppt項目范圍XB9138系列主要裝配流程（SIPOC)DMAIC固定大身上下座拆大杯裝手柄蓋與水龍頭壓滾動軸承壓軸承到發(fā)熱盤固定發(fā)熱盤到大杯固定FUSE與溫控器裝腳墊壓插片到杯座，插杯座引線（一）插杯座引線（二）固定杯座裝攪拌刀組件上連接頭水溫測試耐壓測試功率測試清潔機身，繞電源線清潔大杯與杯蓋外觀檢查找出影響直通率的關(guān)鍵流程2/18/20248精選課件ppt戰(zhàn)略分析1.高品質(zhì)生活供應(yīng)商2.質(zhì)量上臺階，管理上層次，滿足客戶要求3.經(jīng)市場為中心，以客戶為中心，以技術(shù)為中心2006集團戰(zhàn)略提高直通率，既降低了劣質(zhì)成本，又降低了制造成本，而且提高了產(chǎn)品品質(zhì)，保證了交期，提高了產(chǎn)品市場競爭力和客戶滿意度。DMAIC2/18/20249精選課件ppt問題綜述DMAIC2/18/202410精選課件ppt總裝一車間XB9138近期直通率走勢圖DMAIC問題綜述2/18/202411精選課件pptY和缺陷定義Y=直通率=Y1*Y2*Y3*Y4

DMAICY1定義:煲水測試合格率Y2定義:耐壓測試合格率Y3定義:功能測試合格率Y4定義:外觀檢查合格率Y的定義缺陷定義2/18/202412精選課件ppt項目目標DMAIC現(xiàn)狀1-5月目標11月78.5%90%2/18/202413精選課件ppt財務(wù)收益預(yù)計改善目標計算工式合計(RMB)年度收益(人工費用x50%+裝配費用0.53x30%+公共費用0.23x100%）x預(yù)計訂單量300,000x直接提高直通率10%=(1.49x50%+0.53x30%+0.23x100%)x300,000x11.5%￥:44365元投入費用改模費用3000+制作夾具費2000=5000元￥:5000元相關(guān)費用1.人工成本：1.49元2.裝配成本：0.53元3.公共費用：0.23元財務(wù)總收益:￥年度預(yù)計收益總值=預(yù)期收益-投入費用=44365-5000=39365元DMAIC無形收益：直通率的提高，同時產(chǎn)能也顯著提高，產(chǎn)品品質(zhì)明顯改善，提高了產(chǎn)品的市場競爭力和客戶滿意度。2/18/202414精選課件ppt項目團隊組織Champion曾展暉BB:龔一桂MBB：肖晨雷有勇楊國銘張術(shù)強品質(zhì)監(jiān)控及檢驗標準的制定現(xiàn)場作業(yè)改善及作業(yè)方式標準化，控制文件。FMEA分析，流程改進，工程優(yōu)化測量系統(tǒng)分析，人員培訓計劃，實驗實施。項目協(xié)調(diào)跟進及MSA、DOE、各階段分析品管部李紅霞工程部周建輝總裝部蘇長富數(shù)據(jù)的收集和改善的實施，生產(chǎn)現(xiàn)場的控制DMAIC2/18/202415精選課件ppt階段6月定義測量分析改進控制5月7月11月內(nèi)容項目進程計劃項目建立，完成定義階段的9個部分Y的確認，數(shù)據(jù)收集，MSA現(xiàn)水平分析C&EMatrix,FMEA數(shù)據(jù)收集，多變量分析主變量確定，方差分析FMEA改善計劃作成確立質(zhì)量改進的持續(xù)有效方案，通過實驗確認工藝，管理標準化，制造系統(tǒng)內(nèi)推廣提交項目報告DMAIC10月9月8月5.6-6.46.6-7.67.7-9.109.11-10.1510.16-11.202/18/202416精選課件ppt溝通方式時間地點參加人員主題周總結(jié)會隔周周五下午16：00中試部小組全體成員工作進度匯報階段總結(jié)會各階段完成時中試部小組全體成員各階段工作總結(jié)溝通協(xié)調(diào)DMAIC2/18/202417精選課件ppt定義階段總結(jié)以VOB、VOC導(dǎo)出CTQ，定義Y.分析內(nèi)外部環(huán)境找到項目范圍確定項目目標和收益估算組建項目團隊、成員角色分工制定項目進程計劃DMAIC2/18/202418精選課件ppt測量階段2/18/202419精選課件pptY′S的確認顧客CTQ品質(zhì)投訴，成本增加項目Y：提高直通率（計量型數(shù)據(jù)）可操作Y’S(計量型數(shù)據(jù)）煲水測試合格率、功能測試合格率耐壓測試合格率、外觀檢查合格率DMAIC2/18/202420精選課件pptY′S的確認Y的問題描述煲水測試☆

不通電☆

反轉(zhuǎn)☆

燈不亮☆

不加熱☆

水龍頭漏水☆

連接頭漏水☆

溫度高或低☆

發(fā)熱盤漏水☆開關(guān)不良耐壓測試☆耐壓不良功能測試☆I(lǐng)NT☆雜音☆功率高或低外觀檢查☆大身刮花☆杯刮花☆機身混色☆絲印不良☆手柄蓋離縫☆大身錯位☆底座錯位☆機內(nèi)異物DMAIC2/18/202421精選課件ppt測量日期：2006.6.12分析人員：雷有勇張術(shù)強

Y的MSA-LQC成品外觀判斷

測試員3名;樣品10個;反復(fù)3次樣品標準測試員A測試員B測試員CⅠⅡⅢⅠⅡⅢⅠⅡⅢ1OKNGNGNGNGNGNGNGNGNG2OKNGNGNGOKOKOKNGNGNG3NGOKOKNGOKOKNGNGNGOK4NGOKOKOKOKNGOKOKOKNG5OKOKOKOKNGNGNGNGNGNG6OKNGNGNGNGOKNGNGNGNG7NGOKOKOKOKOKOKNGNGNG8NGOKNGNGOKNGNGOKOKOK9OKNGNGNGNGNGNGNGNGNG10NGOKOKOKOKOKOKOKOKOKDMAIC2/18/202422精選課件pptLQC成品外觀檢查MSA結(jié)果DMAIC2/18/202423精選課件pptWithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110880.00(44.39,97.48)210660.00(26.24,87.84)310880.00(44.39,97.48)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.7333330.1825744.016630.0000OK0.7333330.1825744.016630.00002NG0.4666670.1825742.556040.0053OK0.4666670.1825742.556040.00533NG0.6825400.1825743.738420.0001OK0.6825400.1825743.738420.0001Kappa值小于0.7,需要改善每個檢查員檢查結(jié)果一致性(重復(fù)性)百分比DMAICLQC成品外觀檢查MSA結(jié)果2/18/202424精選課件pptEachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110110.00(0.25,44.50)210110.00(0.25,44.50)310110.00(0.25,44.50)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent1360.00480.00220.002240.00360.00440.003240.005100.00220.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG-0.6107740.182574-3.345350.9996OK-0.6107740.182574-3.345350.99962NG-0.4774410.182574-2.615050.9955OK-0.4774410.182574-2.615050.99553NG-0.6666670.182574-3.651480.9999OK-0.6666670.182574-3.651480.9999Kappa值小于0.7,需要改善P值大于0.05,說明一致性檢驗結(jié)果不可靠檢驗錯誤次數(shù)每個檢查員檢查結(jié)果與標準一致性(重復(fù)性)百分比DMAICLQC成品外觀檢查MSA結(jié)果2/18/202425精選課件pptBetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI10330.00(6.67,65.25)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.3438910.05270466.524880.0000OK0.3438910.05270466.524880.0000

AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI1000.00(0.00,25.89)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG-0.5849610.105409-5.549421.0000OK-0.5849610.105409-5.549421.0000所有檢驗員檢查結(jié)果）一致性(重復(fù)性）百分比所有檢驗員檢查結(jié)果一致性Kappa小于0.7，需改善所有檢驗員檢查結(jié)果與標準一致性百分比所有檢驗員檢查結(jié)果與標準一致性Kappa小于0.7，需改善DMAICLQC成品外觀檢查MSA結(jié)果2/18/202426精選課件ppt樣品標準測試員A測試員B測試員CⅠⅡⅢⅠⅡⅢⅠⅡⅢ1OKOKOKOKOKOKOKOKOKNG2NGNGNGNGNGNGNGNGNGOK3OKOKOKOKOKOKOKOKOKOK4OKOKOKOKOKOKOKOKOKOK5NGNGNGNGNGNGNGNGNGNG6OKOKOKOKOKOKOKOKOKOK7OKOKOKOKOKOKOKOKOKOK8NGNGNGNGNGNGNGNGNGNG9NGOKOKOKNGNGNGOKOKOK10OKOKOKOKOKOKOKOKOKOKY的MSA-LQC成品功能測試

測試員3名;樣品10個;反復(fù)3次DMAIC2/18/202427精選課件pptLQC成品功能測試MSA結(jié)果DMAIC2/18/202428精選課件pptWithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI11010100.00(74.11,100.00)21010100.00(74.11,100.00)310990.00(55.50,99.75)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG1.000.1825745.477230.0000OK1.000.1825745.477230.00002NG1.000.1825745.477230.0000OK1.000.1825745.477230.00003NG0.850.1825744.655640.0000OK0.850.1825744.655640.0000Kappa值大于0.7,每個檢驗員檢驗結(jié)果一致性可以接受P值小于0.05,說明一致性檢驗結(jié)果可靠LQC成品功能測試MSA結(jié)果每個檢查員檢查結(jié)果一致性(重復(fù)性)百分比DMAIC2/18/202429精選課件pptEachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110990.00(55.50,99.75)21010100.00(74.11,100.00)310880.00(44.39,97.48)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent1125.0000.0000.00200.0000.0000.003125.0000.00110.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.780220.1825744.273440.0000OK0.780220.1825744.273440.00002NG1.000000.1825745.477230.0000OK1.000000.1825745.477230.00003NG0.714590.1825743.913980.0000OK0.714590.1825743.913980.0000檢驗錯誤次數(shù)Kappa值大于0.7,每個檢驗員檢驗結(jié)果與標準一致性可以接受P值小于0.05,說明檢驗員檢驗結(jié)果與標準一致性結(jié)果可靠所有檢查員檢查結(jié)果一致性(重復(fù)性)百分比DMAICLQC成品功能測試MSA結(jié)果2/18/202430精選課件pptBetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI10880.00(44.39,97.48)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.8400770.052704615.93930.0000OK0.8400770.052704615.93930.0000

AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI10880.00(44.39,97.48)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.8316040.1054097.889280.0000OK0.8316040.1054097.889280.0000AttributeAgreementAnalysisKappa值大于0.7，說明所有檢驗員檢驗結(jié)果一致性可靠所有檢驗員檢查結(jié)果一致性(重復(fù)性）百分比所有檢驗員檢查結(jié)果與標準一致性百分比Kappa值大于0.7，說明所有檢驗員檢驗結(jié)果與標準一致性可靠DMAICLQC成品功能測試MSA結(jié)果2/18/202431精選課件pptY的MSA-LQC成品耐壓測試

測試員3名;樣品10個;反復(fù)3次DMAIC2/18/202432精選課件pptY的MSA-LQC成品耐壓測試結(jié)果DMAIC2/18/202433精選課件pptWithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI11010100.00(74.11,100.00)21010100.00(74.11,100.00)31010100.00(74.11,100.00)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG10.1825745.477230.0000OK10.1825745.477230.00002NG10.1825745.477230.0000OK10.1825745.477230.00003NG10.1825745.477230.0000OK10.1825745.477230.0000Kappa值大于0.9,每個檢驗員檢驗結(jié)果一致性非常好P值小于0.05,說明一致性檢驗結(jié)果可靠每個檢查員檢查結(jié)果一致性(重復(fù)性)百分比DMAICY的MSA-LQC成品耐壓測試結(jié)果2/18/202434精選課件pptEachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI11010100.00(74.11,100.00)21010100.00(74.11,100.00)31010100.00(74.11,100.00)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent100.0000.0000.00200.0000.0000.00300.0000.0000.00

#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG10.1825745.477230.0000OK10.1825745.477230.00002NG10.1825745.477230.0000OK10.1825745.477230.00003NG10.1825745.477230.0000OK10.1825745.477230.0000所有檢查員檢查結(jié)果一致性(重復(fù)性)百分比沒有檢驗錯誤Kappa值大于0.9,每個檢驗員檢驗結(jié)果一致性非常好P值小于0.05,說明每個檢驗員檢驗結(jié)果可靠DMAICY的MSA-LQC成品耐壓測試結(jié)果2/18/202435精選課件pptBetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI1010100.00(74.11,100.00)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG10.052704618.97370.0000OK10.052704618.97370.0000AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI1010100.00(74.11,100.00)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG10.1054099.486830.0000OK10.1054099.486830.0000Kappa值大于0.9，說明所有檢驗員檢驗結(jié)果一致性非常好所有檢驗員檢查結(jié)果一致性(重復(fù)性）百分比所有檢驗員檢查結(jié)果與標準一致性百分比Kappa值大于0.9，說明所有檢驗員檢驗結(jié)果與標準一致性非常好DMAICY的MSA-LQC成品耐壓測試結(jié)果2/18/202436精選課件pptY的MSA-LQC成品煲水測試

測試員3名;樣品10個;反復(fù)3次DMAIC2/18/202437精選課件pptY的MSA-LQC成品煲水測試結(jié)果DMAIC2/18/202438精選課件pptWithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110990.00(55.50,99.75)210990.00(55.50,99.75)310990.00(55.50,99.75)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.8564590.1825744.691020.0000OK0.8564590.1825744.691020.00002NG0.8642530.1825744.733710.0000OK0.8642530.1825744.733710.00003NG0.8642530.1825744.733710.0000OK0.8642530.1825744.733710.0000Kappa值大于0.7,每個檢驗員檢驗結(jié)果一致性可以接受P值小于0.05,說明檢驗員檢驗結(jié)果一致性結(jié)果可靠每個檢查員檢查結(jié)果一致性(重復(fù)性)百分比DMAICY的MSA-LQC成品煲水測試結(jié)果2/18/202439精選課件pptEachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110990.00(55.50,99.75)210990.00(55.50,99.75)310990.00(55.50,99.75)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent100.0000.00110.00200.0000.00110.00300.0000.00110.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.9267400.1825745.075960.0000OK0.9267400.1825745.075960.00002NG0.9326600.1825745.108390.0000OK0.9326600.1825745.108390.00003NG0.9326600.1825745.108390.0000OK0.9326600.1825745.108390.0000檢驗結(jié)果本身不一致次數(shù)Kappa值大于0.,每個檢驗員檢驗結(jié)果與標準一致性可以非常好所有檢查員檢查結(jié)果一致性(重復(fù)性)百分比P值小于0.05,說明檢驗員檢驗結(jié)果一致性結(jié)果可靠DMAICY的MSA-LQC成品煲水測試結(jié)果2/18/202440精選課件pptBetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI10770.00(34.75,93.33)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.8623150.052704616.36130.0000OK0.8623150.052704616.36130.0000

AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI10770.00(34.75,93.33)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.9306870.1054098.829270.0000OK0.9306870.1054098.829270.0000Kappa值大于0.7，說明所有檢驗員檢驗結(jié)果一致性可靠Kappa值大于0.9，說明所有檢驗員檢驗結(jié)果與標準一致性非常好DMAICY的MSA-LQC成品煲水測試結(jié)果2/18/202441精選課件ppt1.成品外觀檢查結(jié)果不可以接受，需對檢驗員進行培訓。責任人：蘇長富、李紅霞。培訓結(jié)束后需進行第二次MSA分析。2.成品功能、耐壓、煲水測試結(jié)果可以信賴。MSA結(jié)果分析人員培訓DMAIC2/18/202442精選課件ppt成品外觀檢查培訓DMAIC培訓記錄2/18/202443精選課件pptLQC成品外觀檢查第二次MSA樣品標準測試員A測試員B測試員CⅠⅡⅢⅠⅡⅢⅠⅡⅢ1OKOKOKOKOKOKOKOKOKOK2NGNGOKNGNGNGNGNGNGNG3OKOKOKOKOKOKOKOKOKOK4NGNGNGNGNGNGNGNGNGNG5OKOKOKOKOKOKOKOKOKOK6OKOKOKOKOKOKNGOKOKOK7NGNGNGNGNGNGNGNGNGNG8NGNGNGNGNGNGNGNGOKNG9OKOKOKOKOKOKOKOKOKOK10NGNGNGOKNGNGNGNGNGNG

測試員3名（同第一次）;樣品10個;反復(fù)3次DMAIC2/18/202444精選課件pptLQC成品外觀檢查第二次MSA結(jié)果DMAIC2/18/202445精選課件pptWithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110880.00(44.39,97.48)210990.00(55.50,99.75)310990.00(55.50,99.75)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.7285070.1825743.990200.0000OK0.7285070.1825743.990200.00002NG0.8660710.1825744.743670.0000OK0.8660710.1825744.743670.00003NG0.8660710.1825744.743670.0000OK0.8660710.1825744.743670.0000Kappa值大于0.7,每個檢驗員檢驗結(jié)果一致性可以接受P值小于0.05,說明檢驗員檢驗結(jié)果一致性結(jié)果可靠每個檢查員檢查結(jié)果一致性(重復(fù)性)百分比DMAICLQC成品外觀檢查第二次MSA結(jié)果2/18/202446精選課件pptEachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110880.00(44.39,97.48)210990.00(55.50,99.75)310990.00(55.50,99.75)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent100.0000.00220.00200.0000.00110.00300.0000.00110.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.8653200.1825744.739550.0000OK0.8653200.1825744.739550.00002NG0.9326600.1825745.108390.0000OK0.9326600.1825745.108390.00003NG0.9326600.1825745.108390.0000OK0.9326600.1825745.108390.0000檢驗結(jié)果本身不一致次數(shù)Kappa值大于0.7,每個檢驗員檢驗結(jié)果與標準一致性可以接受所有檢查員檢查結(jié)果一致性(重復(fù)性)百分比P值小于0.05,說明檢驗員檢驗結(jié)果一致性結(jié)果可靠DMAICLQC成品外觀檢查第二次MSA結(jié)果2/18/202447精選課件pptBetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI10880.00(26.24,87.84)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.8218700.052704615.59390.0000OK0.8218700.052704615.59390.0000AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI10880.00(26.24,87.84)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.9102130.1054098.635040.0000OK0.9102130.1054098.635040.0000AttributeAgreementAnalysisKappa值大于0.7，說明所有檢驗員檢驗結(jié)果一致性可靠Kappa值大于0.9，說明所有檢驗員檢驗結(jié)果與標準一致性非常好DMAICLQC成品外觀檢查第二次MSA結(jié)果2/18/202448精選課件ppt現(xiàn)狀能力分析DMAIC2/18/202449精選課件ppt不良率控制圖，失控SIGMA水平百萬不良數(shù)DMAIC現(xiàn)狀能力分析2/18/202450精選課件ppt主要問題分析DMAIC需改善范圍現(xiàn)狀能力分析2/18/202451精選課件ppt1.進料膠件品質(zhì)C2.外購零件品質(zhì)C3.自制零件品質(zhì)C4.產(chǎn)品工程問題C5.工藝流程執(zhí)行度C6.生產(chǎn)工藝改善C7.人員判定能力U8.工裝夾具/設(shè)備C9.檢測方法/手段U10.產(chǎn)品規(guī)格標準U宏觀流程分析1.機身刮花2.連接頭漏水3.水龍頭漏水4.耐壓不良5.杯刮花6.手柄離縫7.絲印不良機身混色8.不通電.開關(guān)不良.9.機內(nèi)異物10.溫度高或低進料檢測主機總裝大杯總裝功能測試外觀檢查成品包裝耐壓測試煲水測試進料檢測DMAIC流程輸出輸入2/18/202452精選課件ppt-電鉻鐵溫度-作業(yè)員技能-桌面保護墊CU-大身刮花-絲印脫落-機身混色●電機品質(zhì)-INT流程輸出輸入流程輸出輸入拆底座裝腳墊與繞線蓋拆大身上座裝電源線到底座-機身混色裝固定板到電機裝馬達墊固定電機到大身插插座引線裝插座到大身-INT-無功能-不發(fā)熱-大身刮花-端子尺寸-端子材質(zhì)-桌面保護墊-作業(yè)員技能壓連接頭,裝開關(guān)-開關(guān)品質(zhì)-連接頭品質(zhì)焊接引線（一）焊接引線（二）焊接引線（三）固定壓線碼與PCB板接線綁扎帶流程分析(微觀）-開關(guān)不良-燈不亮-異音-不通電-大身刮花-機內(nèi)異物-大身刮花 ●底座品質(zhì)●作業(yè)員判斷能力-大身刮花-反轉(zhuǎn)-INT-大身刮花-作業(yè)者技能-閉端子品質(zhì)-桌面保護墊●大身上座品質(zhì)●絲印附著力●作業(yè)員判斷能力●桌面保護墊-電鉻鐵溫度-作業(yè)員技能-桌面保護墊-反轉(zhuǎn)-大身刮花-PCB品質(zhì)-桌面保護墊

DMAIC類型類型CCUCCCCCUCCCCC-電鉻鐵溫度-作業(yè)員技能-桌面保護墊CCCCCCCCUCC-檢查方法-桌面保護墊UC-反轉(zhuǎn)-INT-大身刮花-反轉(zhuǎn)-INT-大身刮花2/18/202453精選課件ppt機身內(nèi)檢不良品修理吹熱縮管裝裝飾圈插杯座引線（二）插杯座引線（一）壓插片到杯座裝腳墊固定FUSE與溫控器固定發(fā)熱盤到大杯壓滾動軸承,壓軸承到發(fā)熱盤-發(fā)熱盤邊口鋒利度-發(fā)熱盤外徑尺寸-銅杯仕內(nèi)徑尺寸-發(fā)熱盤品質(zhì)-耐壓不良，-發(fā)熱盤漏水，-連接頭漏水-不發(fā)熱，-功率不良-電批扭力-密封圈尺寸-作業(yè)員技能-耐壓不良-不通電-杯刮花固定大身上下座拆大杯,裝手柄蓋與水龍頭-水龍頭漏水-手柄蓋離縫-發(fā)熱盤漏水-耐壓不良-水溫高或低-耐壓不良-端子尺寸-端子材質(zhì)-桌面保護墊-大杯外觀-手柄蓋扣位尺寸-水龍頭尺寸-彈簧拉力-水龍頭密封圈硬度-溫控器品質(zhì)-FUSH壓板品質(zhì)-硅膠管品質(zhì)-硅油脂涂抹均勻度DMAIC流程輸出輸入流程輸出輸入類型類型CCCCC流程分析(微觀）-底座錯位-大身刮花UCC-作業(yè)者技能-底座結(jié)構(gòu)-桌面保護墊CCCCCCCCCCCCCC-耐壓不良-不通電-杯亂花-端子尺寸-端子材質(zhì)-桌面保護墊CCC-大身刮花-作業(yè)員技能-桌面保護墊-大身刮花-作業(yè)員技能-桌面保護墊-大身刮花-作業(yè)員技能-桌面保護墊-大身刮花-不通電-作業(yè)員技能-桌面保護墊UCUCUCUC-夾具可靠度C-不通電2/18/202454精選課件ppt包裝裝攪拌刀組件上連接頭固定杯座功率測試耐壓測試水溫測試清潔機身繞電源線-攪拌刀軸直徑尺寸-攪拌刀軸長度-裝配方法-密封圈品質(zhì)-連接頭漏水-杯刮花-清潔布粗糙度-清潔劑去污能力-大身刮花-絲印刮花清潔大杯與杯蓋外觀檢查DMAIC流程輸出輸入流程輸出輸入類型類型流程分析(微觀）CCUCCC-清潔布粗糙度-清潔劑去污能力-大杯刮花CC-作業(yè)者技能-裝配方法UU-耐壓不良2/18/202455精選課件ppt導(dǎo)出主要因子—關(guān)鍵流程DMAICC&E矩陣2/18/202456精選課件ppt導(dǎo)出主要因子—關(guān)鍵流程DMAICC&E矩陣2/18/202457精選課件ppt導(dǎo)出主要因子—關(guān)鍵流程DMAIC導(dǎo)出預(yù)想的16個流程和30個主要因子C&E矩陣2/18/202458精選課件pptFMEA分析DMAIC2/18/202459精選課件pptFMEA分析DMAIC通過RPN值，找出16個需改善的因子2/18/202460精選課件ppt問題點原因分析改善對策改善效果完成進度外觀刮花,刮傷、臟污,絲印不良轉(zhuǎn)儲、搬運不當膠件(外殼,底座,大杯，杯蓋)擺放高度控制,避免搬運時疊高運輸,擠壓產(chǎn)生不良通過此規(guī)定,目前小批量有較好改善,將在后續(xù)生產(chǎn)收集數(shù)據(jù)分析改善效果持續(xù)產(chǎn)品防護不當(產(chǎn)品只套PE袋保護)用干凈PE膠袋包裝,再套裝氣泡袋,每個膠框最上層用膠紙防護,避免灰塵工人操作刮花、刮傷對工人操作規(guī)程做培訓,并將操作規(guī)程列入產(chǎn)品檢驗作業(yè)指導(dǎo)書，必要時關(guān)鍵工位戴手套作業(yè)，臺面墊墊布工人操作防護意識逐漸形成,有一定改善,在平常工作中檢查及監(jiān)督,收集數(shù)據(jù)分析改善效果持續(xù)產(chǎn)品外觀即時改善DMAIC2/18/202461精選課件ppt作業(yè)現(xiàn)場改善作業(yè)現(xiàn)場改善前作業(yè)現(xiàn)場改善后DMAIC2/18/202462精選課件ppt結(jié)構(gòu)即時改善改善前改善后經(jīng)現(xiàn)場分析，耐壓不良80%由于發(fā)熱盤邊口裝配時刮傷內(nèi)配線所致。DMAIC2/18/202463精選課件ppt裂口模具即時改善水龍頭裂口模具改善DMAIC2/18/202464精選課件ppt現(xiàn)狀能力再分析不良率控制圖,已受控SIGMA水平，已初步提升百萬不良數(shù),降低了93477PPMDMAIC2/18/202465精選課件ppt主要問題分析DMAIC現(xiàn)狀能力再分析2/18/202466精選課件ppt二次FMEADMAIC通過RPN值，找出8個還需改善的因子2/18/202467精選課件pptY’S的確認LQC的MSA分析檢查人員培訓宏觀、微觀流程分析現(xiàn)狀能力分析CE矩陣和FMEA分析制定即時改善計劃二次能力分析，二次FMEADMAIC測量階級小結(jié)2/18/202468精選課件ppt分析階段2/18/202469精選課件ppt數(shù)據(jù)收集計劃DMAIC2/18/202470精選課件ppt分析階段MSADMAIC檢測員二人，樣品十個，重復(fù)三次。電子數(shù)顯卡尺測量系統(tǒng)分析2/18/202471精選課件pptGageR&RStudy-ANOVAMethodTwo-WayANOVATableWithInteractionSourceDFSSMSFP部件90.9423680.104708656.7030.000檢測員10.0002820.0002821.7670.217部件*檢測員90.0014350.0001591.4720.192Repeatability400.0043330.000108Total590.948418GageR&R%ContributionSourceVarComp(of