SPC統(tǒng)計過程控制培訓

統(tǒng)計過程控制StatisticalProcessControlforOperatorsWelcome歡迎培訓目的

TrainingGoal目的--助你獲得SPC的知識及技巧OurGoal--TohelpyougainrelevantSPCknowledge&skills.什么是SPC及SPC的益處

WhatisSPCandbenefits.數(shù)據(jù)的收集及測量

Datacollectionandmeasurement.使用反應計劃解決問題

Troubleshootingusingreactionplans工序的穩(wěn)定&能力(CP和CPK)

ProcessStabilityandCapability.(CPandCPK)培訓內容

TrainingAgenda什么是SPC?

WhatisSPC?利用統(tǒng)計技術如控制圖去分析工序或其產物,以采取適當?shù)男袆尤ミ_致及維持一個受統(tǒng)計技術控制的狀態(tài)以及改善工序能力.Theuseof

statistical

techniquessuchascontrolchartstoanalyzea

process

or

itsoutputssoastotakeappropriateactionstoachieveandmaintainastateof

statisticalcontrol

andtoimprovetheprocesscapability.Outofcontrol失控Trends趨勢Shifts偏移ControlChart控制圖統(tǒng)計技術Statistical工序Process控制ControlLCLUCL什么是SPC?

WhatisSPC?Measurement測量

Cause—EffectDiagram

因果圖（魚骨圖）Effect

果Machine機Environment環(huán)境Man人Material物料Methods方法

Cause因什么是SPC?

WhatisSPC?

ParetoDiagram柏拉圖DefectivesScratchPlugholeOpenShort什么是SPC?

WhatisSPC?DetermineKeyProductCharacteristics介定關鍵的產品特性DetermineKeyVariables介定關鍵的變量PlantheMatrixofValidationTests計劃確認測試的矩陣

DOE實驗設計什么是SPC?

WhatisSPC?Functionaffected被影響的功能PotentialFailuremode潛在缺陷模式-PotentialEffect潛在影響-PotentialCause潛在原因-DesignControl設計控制

ActionPlan行動計劃Result結果FMEA缺陷模式與后果分析什么是SPC?

WhatisSPC?什么是SPC?

WhatisSPC?SPC數(shù)據(jù)=工序的聲音SPCdata=thevoiceoftheprocess!統(tǒng)計技術Statistical收集及整理數(shù)字化的事實數(shù)據(jù)Collection&arrangementofnumericalfacts.Data!控制Control

預防,預測,監(jiān)管Prevention.Prediction.Regulation.工序Process執(zhí)行一件工作的一連串步驟Seriesofstepstoperformatask是否一組圖表?Isitasetofcharts?是否一個警告系統(tǒng)?Isitawarningsystem?是否一個預防性方法?Isitapreventivemethod?使用SPC目的

UsingSPCObjectives我們的SPC目的是為你提供一個有利于持續(xù)改善的工具:OurSPCobjectivesistoprovideyouwithatoolforcontinualimprovementthathelpsto:將工序變異減致最少 minimizeprocessvariation.消除流程的錯敗 eliminatefailuresinourprocesses.將產品能力盡量提升 maximizeproductcapability.加強客戶滿意程度 increasecustomersatisfaction.SPC價值

SPCValue

少報廢Lessscarp

少返工Lessrework

少停機Lessdowntime

更佳利潤Betterprofit

更佳市場信譽Goodreputationinmarketplace!SPC價值

SPCValue

更佳產品質量Betterqualityproduct

更多可靠產品Morereliabledelivery

可以信賴的供應商Asuppliertheycancounton客戶CustomersSPC價值

SPCValue

少挫敗感及無聊時間

Lessfrustration&downtime

更能控制工作Morecontrol

更能對工序及產品問題作正確決定Abilitytomaketherightdecisionaboutprocessofproductproblems

能生產更優(yōu)值的產品Betterproductcomingfromtheareinfrontofme你YouSPC如何幫忙?

HowSPCCanHelp生產中DuringProduction發(fā)生問題時(特殊原因)SPC數(shù)據(jù)會發(fā)出訊號SPCdatasendasignalthatthere’saproblem(specialcause).我們采取糾正行動防止問題Wetakecorrectiveaction

topreventdefects.將來FortheFutureSPC數(shù)據(jù)提供一個工序變異的歷史記錄SPCdataprovideahistoryofthevariationintheprocess.我們改善工序以減少一般原因導致的變異Weimprovetheprocesstoreducecommoncausevariation.統(tǒng)計技術及控制圖

StatisticsandControlCharts如何運用統(tǒng)計技術于控制圖?Howdoweusethesestatisticsoncontrolcharts?收集數(shù)據(jù)--數(shù)目或量度某物Collectdata--countormeasuresomething.于控制圖上畫上數(shù)值Plotthedataonthecontrolchart.或...OR...計算統(tǒng)計數(shù)值于控制圖上畫上數(shù)值Calculateastatisticandplotthestatisticonthechart.SPC步驟:WWHWWW

SPCStep-WWHWWW什么數(shù)據(jù)需要收集?

Whatdatadoweneed?為什么需要收集數(shù)據(jù)?

Whydoweneedtocollectdata?如何得到數(shù)據(jù)?

How

willwegetthedata?何時收集數(shù)據(jù);多久收集一次?

When

dowecollectit;howoften?流程中哪處收集數(shù)據(jù)?

Where

intheprocessdowegetthedata?誰收集數(shù)據(jù)?

Who

collectsthedata?收集數(shù)據(jù)Collectdata什么數(shù)據(jù)需要收集?

Whatdatadowecollect?收集數(shù)據(jù)Collectdata客戶要求:功能;外觀CustomerRequirementsFunctionalAesthetic產品特性（計數(shù)型）ProductFeatures工序參數(shù)（計量型）ProcessVariables為什么需要收集數(shù)據(jù)?

Whyshouldwecollectthedata?收集數(shù)據(jù)Collectdata監(jiān)控變異Tomonitorvariation.盡早指出工序問題Toidentifyprocessproblemsasearlyaspossible.為什么?Why?如何收集數(shù)據(jù)?

Howdowecollectthedata?如何?How?收集數(shù)據(jù)Collectdata我們需要一個測量系統(tǒng)Weneedameasurementsystem.方法--技巧,工具,經(jīng)培訓的員工Method

--technique,tool,trainedpeople記錄--數(shù)據(jù)收集表格,表達數(shù)據(jù)的格式(即控制圖)Record--datacollectionsheet,formattopresentdata(i.e.,controlchart)計劃--負責人,收集數(shù)據(jù)地點,頻率,時間Plan--who,where,howoften,when何時及何處收集數(shù)據(jù)?

When&wheredowegetthedata?那一個比較好?Whichisbetter?工序中作測量Measureon-line最后檢查Inspectatend何時收集數(shù)據(jù)?

Whendowecollectthedata?流程中作測量MeasureOn-line,DuringtheProcessSPCSPC預防性Preventionfocus避免浪費Avoidswaste提供質量一致的產品Deliversconsistentproducts減少變量Reducesvariation主動性Proactive于流程終點作檢查InspectProductattheEndoftheProcess檢查Inspection偵察性Detectionfocus容忍浪費Tolerateswaste返工Reworksproducts容忍變異Toleratesvariation被動性Reactive數(shù)據(jù)的種類

TypesofData計量的Variables可用連續(xù)性的單位Measureonacontinuousscale可以是流程或量度的特性Foraprocessorproduct例子:Examples:線寬linewidth板料厚度laminationthickness計數(shù)的Attributes數(shù)量,等級,類別Count,grade,categorize不能量度的Can’tmeasureit

一般是產品特性Usuallyforaproduct例子:Examples:壞品百分比%defectiveparts甩貨百分比%orderslate控制圖種類

TypesofControlCharts計量控制圖VariablesCharts用于連續(xù)單位的量度Fordatawegetbymeasuringonacontinuousscale.例子Examples溫度temperature線寬circuitwidth厚度pinheight分別監(jiān)察兩組統(tǒng)計數(shù)值的三對控制圖Threepairsofchartsthatmonitortwostatistics.平均及范圍(X-R)Average&R(averageandrange)平均及標準差(X-S)Average&S(averageandstandarddeviation)個別值移動范圍(X-MR)X&MR(individualsandmovingrange)計數(shù)控制圖AttributeCharts用于數(shù)量等級或分類的數(shù)據(jù)Fordatawegetbycounting,gradingorcategorizingthings.例子Examples甩貨百分比#oflatedeliveries壞板百分比#ofdefectivecircuitboards計數(shù)控制圖AttributeChartsNPPUC控制圖種類

TypesofControlCharts規(guī)格

Specifications客戶,供應商或內部工程要求Customer,supplierorinternalengineeringrequirements包括:Include:目標或中間值(最理想的)targetornominalvalue(theideal!)在目標值兩旁可接受的變異allowablevariationoneithersideofthetargetvalue規(guī)格上限=目標值+可接愛的變異USL=target+allowablevariation規(guī)格下限=目標值-可接受的變異LSL=target-allowablevariation例子--酸濃度

Example--AcidConcentration規(guī)格是130克/升+/-30克升Specificationis130grams/liter+/-30grams/liter規(guī)格上限=目標值+可接受的變量USL=target+allowablevariation130+30=160規(guī)格下限=目標值-可接受的變異LSL=target-allowablevariation130-30=100可接受變異的總值=規(guī)格上限=規(guī)格下限Totalallowablevariation=USL-LSL160-100=60控制限--控制上,下限

ControlLimits--UCL,LCL若流程受到控制:Ifyourprocessisincontrol:99.7%的數(shù)據(jù)將會在控制上限及下限之間.99.7%ofthedatapointswillbebetweentheUCLandLCL.數(shù)據(jù)沒有特定的圖樣=隨機的.Datapointswillshownopattern=random.大部分數(shù)據(jù)會趨向平均值.Mostdatapointswillbeclosetotheaverage.數(shù)據(jù)應有一半在平均值以上及一半在以下.Datapointsbe50/50aboveandbelowaverage.控制限--好處

ControlLimits--Benefits減少兩個可能的錯誤Minimizestwopossiblemistakes:忽略問題Ignoringaproblem.采取不必要的糾正行動Takingunnecessarycorrectiveaction.

曲線下的出現(xiàn)可能性已知Probabilitiesunderthecurveareknown.有利于預測和計劃Goodforpredictionandplanning.有利于偵察不正常的數(shù)據(jù)Goodforspottingweirdpatternsofpoints.控制圖及標準差

ControlCharts&StandardDeviation使用標準差決定控制上限及下限,如鐘狀曲線.TodetermineUCL&LCL,usestandarddeviation(s)--justlikethebellcurve!+3s-3sUCL=Average+3sAverageLCL=Average-3s-3s+3s利用變異的數(shù)值(標準差)去建立變異的一般范圍(控制上限及下限之間的范圍)是否合理?Doesn’titmakesensetouseameasureofvariation(standarddeviation)toestablishanormalrangeofvariation(areabetweenUCLandLCL)foraprocess?設定控制限

SettingControlLimitsAverage-3s+3s-2s+2s-1s+1sLCLUCL-3s+3s-2s+2s-1s+1sLCLUCLAverage-3s+3s-2s+2s-1s+1sLCLUCLAverage將鐘狀曲線轉90度Flipthebellcurveonit’sside.設定控制限

SettingControlLimitsUCL=Average+3sLCL=Average-3s-3s+3s-2s+2s-1s+1sAverageLCLUCL這是什么意思?Whatdoesitallmean?生產中使用SPC

UsingSPCDuringProduction1.收集數(shù)據(jù)Collectdata3.理解數(shù)據(jù)Interpretthedata2.在圖上記錄數(shù)據(jù)Recorddataonchart4.特別原因SpecialCause?6.采取糾正行動

Takecorrectiveaction5.繼續(xù)執(zhí)行流程

Continuetoruntheprocess是Yes否No7.準備文件

Document使用SPC--例子

UsingSPC--AnExample88.18.28.38.48.58.68.78.88.99123456789101112131415mils是否有特別問題發(fā)生?Didanythingspecialhappen?1.收集數(shù)據(jù)

Collectdata3.理解數(shù)據(jù)Interpretthedata2.在圖上記錄數(shù)據(jù)

Recorddataonchart4.特別原因SpecialCause?基本控制圖格式

BasicControlChartFormat一般原因導致的變異

Commoncausevariation特別原因導致的變異Specialcausevariation88.18.28.38.48.58.68.78.88.99123456789101112131415milsUCLLCLY軸-量度

y-axis-scaleformeasurementsX軸-時間

X-axis-timesequence

平均值(典形數(shù)值)Average(thetypicalvalue)平均年齡=(27+27+33+46+57)÷5=38歲Averageage=(27+27+33+46+57)÷5=38years2727334657Averageage=38統(tǒng)計技術--中間值傾向

Statistics--CentralTendency統(tǒng)計技術--分布

Statistics--Spread范圍(R)--最大數(shù)字減最小數(shù)字Range(R)--highestnumberminuslowestnumberR=(57-27)=30歲R=(57-27)=30years幅度=30歲Range=30years2727334657統(tǒng)計技術--分布

Statistics--Spread標準差(S)=個別數(shù)值與平均值相差的平方Standarddeviation(S)--Howfaraway,onaverage,aretheindividualdatavaluesfromtheaverageage?S=13.2歲S=13.2yearsAverage=3811

years11

years19years8years5years2727334657例子--計數(shù)控制圖

Example--AttributeChartPChart--VAASFastechFinalInspectionAverageLCLUCL0150003000045000600007500090000105000120000135000150000123456PPM流程穩(wěn)定性

ProcessStability穩(wěn)定的流程StableProcess一致的Consistent可預測的Predictable特別原因Nospecialcauses受控的Incontrol穩(wěn)定性可用控制圖量度Stabilityismeasuredusingcontrolcharts.流程可以是受控,但不符合規(guī)格的.Aprocesscouldbeincontrol,butnotmeetspecifications.??????什么是流程?

Whatisaprocess?完成一件工作的一連串步驟Aseriesofstepswefollowtoaccomplishatask.步驟Steps成品Outputs輸入Inputs??????流程的內容

ThepartsofaProcess物料Materials人People機器/設備Machines方法Methods環(huán)境

Environment穩(wěn)定,能力及質量

Stability,Capability&Quality為能做到優(yōu)越的表現(xiàn),工作流程必須:Toachieveperformanceexcellence,workprocessesmustbe:

穩(wěn)定

Stable一致的,可預計的consistent,predictable

有能力

Capable持續(xù)符合規(guī)格continuallymeetsspecifications

持續(xù)改善

Continuallyimproved流程穩(wěn)定及能力

ProcessStability&Capability有能力的流程CapableProcess流程有能力持續(xù)的滿足規(guī)格要求Processhastheabilitytocontinuallymeetspecifications.工序必須處于受控狀態(tài)(統(tǒng)計技術角度),才可被認為有能力Processmustbeinstatisticalcontrolbeforeitcanbeconsideredcapable.穩(wěn)定

Stability穩(wěn)定的工序Stableprocess受統(tǒng)計技術控制instatisticalcontrol無特別原因導致的變異nospecialcausesofvariation穩(wěn)定工序的控制圖Controlchartfromastableprocess無超越控制上限或下限的點nopointsoutsideUCLorLCL無偏移或走勢noshiftsortrends工序可以說是于一定時間內受到控制,而只有一般原因導致的變異Suchaprocessissaidtobeincontroloveraseriesoftime,withonlycommoncausespresent.LCLUCLCL變異

Variation個別成品之間不可避免的分別Theinevitabledifferencesamongindividualoutputsofaprocess.一般原因導致的變異CommonCauseVariation正常,常見,可預計的-自然的normal,usual,expectedthings--natural特別原因導致的變異SpecialCauseVariation偶發(fā)性,不可預計的-特定的sporadic,unexpectedthings--assignable變異何時何地都會出現(xiàn)

VariationisEverywhere!物料變異:化學品濃度,混合比例及補料份量,不同供應商MaterialVariation:chemicalconcentration,mixratios&dosing;differentsuppliers設備變異:保養(yǎng)時間,損耗,調校過程MachineVariation:maintenanceschedules,wear&tear,calibrationprocess人為變異:技巧及經(jīng)驗,身材及體能,態(tài)度及紀律PeopleVariation:skill&experience,size&strength,attitude&disciplinea方法變異:程序文件,文件維持MethodVariation:documentationofprocedures,maintenanceofdocumentation環(huán)境變異:時間,天氣,廠房位置,空氣污染EnvironmentalVariation:time,weather,locationofplant,aircontamination變異結果

ConsequencesofVariation流程中太多一般原因導致的變異Toomuchcommoncausevariationinaprocess流程中出現(xiàn)特別原因導致的變異Anoccurrenceofspecialcausevariationinaprocess影響工作disruptioninwork生產力下降lostproductivity報廢及返工scrapandrework甩交貨期misseddeliverydates不穩(wěn)定的產品表現(xiàn)variableproductperformance不穩(wěn)定的產量erraticproductyields不穩(wěn)定的產品特性variationsinproductfeaturesAAAAAAAAAAAAAACp及Cpk值

ValueofCpandCpk根據(jù)規(guī)格評估流程表現(xiàn).Evaluateprocessperformanceagainstspecs.決定流程是否能滿足新規(guī)格要求.Determineifprocesscanmeetnewspecs.根據(jù)Cpk及Cp值的距離制訂改善目標.SetimprovementgoalbasedondistancebetweenCpkandCp.評估供應商.Evaluatesuppliers.用于銷售過程的一部分.Useaspartofsalesprocess.Cpk--量度工序設定

Cpk-MeasuresProcessSetting比較工序參數(shù)中間值設定及目標.Comparessettingofprocesscenter(average)totarget.基本定律:Cpk要求最少1.33Generalrule--aimforCpkof1.33minimumUSLLSL目標Target工序參數(shù)中間值ProcessCenter偏離中間值OffCenter!!Cpk--例子

CpkExamplesCpk良好GoodCpkCpk差PoorCpkLSLUSLLSLUSLCp--量度流程分布

Cp-MeasuresProcessSpread比較可接受變異(A)及實際變異(B)Compareallowablevariation(B)toactualvariation(A).B=USL-LSLA=6標準差A=6standarddeviationsCp=B/ALSLUSLABCp必須大于1

CpShouldBeGreaterThan1顯示于實際變異少于可接受變異Indicatesactualvariationislessthanallowablevariation.LSLUSLLSLUSLLSLUSLCp大于1Cpgreaterthan1Cp=1Cp小于1Cplessthan1Cp--總結

Cp-Conclusions數(shù)值越大越好!Thebiggerthenumber,thebetter!Cp的缺點--只能顯示流程分布,但不能顯示是否符合規(guī)格DeficiencyofCp--Itshowsonlythespreadofprocess,butnotthecompliancetospecification.例子：兩流程的Cp一樣。

Example:TwoprocesseswithsameCp.USLLSLTargetUSLLSLTarget工序能力不足的兩種情況

TwoWaysaProcessIsNOTCapable1.實際工序變異超出可接受變異的總值

Actualprocessvariation(A-sixsigma)exceedstotalallowablevariation(B-spec)TargetBALSLUSL產品不符合規(guī)格Productsoutofspec產品不符合規(guī)格Productsoutofspec工序能力不足的兩種情況

TwoWaysaProcessIsNOTCapable2.如工序表現(xiàn)不足處于規(guī)格的中間位置,并其中一邊的控制限超越規(guī)格限.

Ifprocessisnotcenteredproperlyandoneofthecontrollimitsexceedsthespeclimit.LSLUSLLCLUCLTargetAverage產品不能符合規(guī)格Productsoutofspec!產品不是最佳Productsnotthebest.若工序能力不足如何辦?

Whatifaprocessisn’tcapable?流程需要改善Theprocessneedsimprovement!首先,采取改善行動,減少變異,然后,按目標值將流程表現(xiàn)調至中間值.First,takeactiontoreducethevariation.Then,centertheprocessoverthetarget.表現(xiàn)不良Badnews!表現(xiàn)改善Gettingbetter進一步改善MuchbetterUSLLSLTargetUSLLSLTargetUSLLSLTarget你需要做什么?

Whatshouldyoudo?USLLSLCp<2andCpk<1采取預防行動清除不合格產品

Takeprecautionstoremove

non-conformingproducts持續(xù)努力減少變異

Continueeffortstominimizevariation將工序表現(xiàn)控制到中間值

Centertheprocess維持工序于控制限內Maintainprocesswithincontrollimits持續(xù)努力減少變異Continueeffortstominimizevariation將工序表現(xiàn)控制到中間值

CentertheprocessUSLLSLCp<2andCpk>1你需要做什么?

Whatshouldyoudo?USLLSLCp<2andCpk>1.5維持工序于控制限內

Maintainprocesswithincontrollimits持續(xù)努力減少變異

ContinueeffortstominimizevariationUSLLSLCp>2andCpk<1采取預防行動清除不合格產品

Takeprecautionstoremove

non-conformingproducts持續(xù)努力減少變異

Continueeffortstominimizevariation將工序表現(xiàn)控制到中間值

Centertheprocess你需要做什么?

Whatshouldyoudo?維持工序于控制限內

Maintainprocesswithincontrollimits將工序表現(xiàn)控制到中間值

CentertheprocessUSLLSLCp>2andCpk>1維持工序于控制限內

MaintainprocesswithincontrollimitsUSLLSLCp>2andCpk>1.5失控圖樣--第一定律

Out-ofControlPatterns--Rule1任何點超越控制限Anypointbeyondthecontrollimits控制上限以外OutsidetheUpperControlLimit8.08.18.28.38.48.58.68.7123456789101112131415LCLAverageUCL控制下限以外OutsidetheLowerControlLimit8.08.18.28.38.48.58.68.7123456789101112131415LCLAverageUCL失控圖樣--第二定律

Out-ofControlPatterns--Rule2連續(xù)七點向上或向下--走勢Upwardordownwardrunof7consecutivepoints--trend連續(xù)七點向下Downwardrunofsevenconsecutivepoints連續(xù)七點向上Upwardrunofsevenconsecutivepoints8.08.18.28.38.48.58.68.7123456789101112131415LCLAverageUCL8.08.18.28.38.48.58.68.7123456789101112131415LCLAverageUCL失控圖樣--第三定