在更好的车身制造中实施六西格玛质量ImplementingSixSigmaQualityatBetterBodyManufacturing课件

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