大连鸿源机械制造有限公司-801统计技术控制程序.doc

大连鸿源机械制造有限公司Dalian Hongyuan Machinery&Manufacturing Co,.Ltd.文件编号Doc.NO.:Q/HY. P. 8012004版本号/修订号Version/Revision: A/0发布日期Date of Issue: 2004-1-1页次/页数:Page 7 of 7统计技术控制程序Statistic Technique Control Procedure1 目的/Purpose为以下活动提供制度和指导，并明确责任：To provide system and guidance for the following activities and define responsibilities:统计技术的应用The application of statistic technique进行初始过程能力研究Conduct research of preliminary process capability 监视现有过程能力Monitoring existing process capability2 适用范围/Application Scope 本程序主要适用于关键工序。直接与产品小组、质量部有关。The procedure is applicable to key procedures, which directly link to product team and quality team.3 术语和定义/Terms and definition无/Nil4 程序流程图/Process Flow Chart无/Nil5 职责和权限/Responsibilities and Authorization产品小组负责确定SPC控制点，并写入控制计划。Product team is responsible for determining SPC control point, composing control plan.质量部和生产部负责SPC控制和其它统计技术的实施。Quality Dept. and Production Dept. are responsible for SPC control and implementation of other statistic technique.6 工作程序/Working Procedures6.1 初始过程能力的研究/Research on Preliminary Process Capability6.1.1 初始过程能力研究用于验证关键工序有能力生产满足顾客要求的产品。该研究通常由产品小组在产品试生产阶段进行。The research of preliminary process capability is designed for verifying key procedures and ensures capability to satisfy customers requirements. Basically, the research is conducted in trial-production stage by product team. 6.1.2 数据收集及绘制控制图/Collect Data and Protract Control Drawing6.1.2.1 “初始过程能力研究”中介绍了进行初始过程能力研究的步骤，该章节作为本程序文件的一部分。“Research of Preliminary Process Capability” introduces procedures of the research; the chapter is a part and parcel of the procedures documents.6.1.2.2只有计量型数据才进行初始过程能力研究。Only attribute data is applicable to research of preliminary process capability.6.1.2.3初始过程能力研究通常采用“均值和极差图”和“单值和移动极差值”进行分析，除非有理由采用其它控制图。产品小组最终决定采用何种控制图和样本的组数及个数。Research of preliminary process capability, basically, adopts methods of “X-R Chart” and “Individual and Moving Range” to conduct analysis, unless convincing enough to adopt other control drawing. Product team decides finally to adopt what control drawing, group number and individual number of samples.6.1.2.4 QS9000-“统计过程控制”手册中提供了有关控制图的空白表格及计算均值和极差、绘制控制图的详细指导。QS9000- the manual of “Statistic Process Control” provides blank form related to control drawing and detail instruction on X bar computation, range and control drawing.6.1.3控制图的评价及过程能力支书的计算Control drawings appraisal and computation of process capability analysis6.1.3.1当绘制均值和极差后，接着计算平均极差、平均均值机控制限，并绘制在控制图上。这时控制图即可用来评价过程的不稳定性。有关控制图的解释和评价详见QS9000-“统计过程控制”手册。After protract X bar and range, continue to compute means range and control limit, then protract in control drawing. By then, the control drawing is used for appraising process instability. The explanation of control drawing and appraisal details were provided in the manual of “Statistic Process Control”. 6.1.3.2当控制图显示过程不稳定时，必须调查引起不正常波动的特殊原因并加以消除。当过程趋向稳定时，即可计算过程能力指数Cpk，有关计算方法详见QS9000-“统计过程控制”手册。When the control drawing shows process instability, must investigate special reason caused abnormal fluctuation and eliminate. When the process trend stable, proceed computing Cpk, the details were provided in the manual of QS9000-“Statistice Process Control”.6.1.4 接受标准和顾客批准/Acceptance Standard And Customers Approval6.1.4.1 过程的接受标准由顾客决定。当顾客未指定接受标准是可由产品小组自行决定。Customer decided acceptance standard of process. When there in no designated acceptance standard from customers, products team decide themselves.6.1.4.2 若过程能力指数Ppk和/或Cpk低于顾客/自行规定的接受标准时，有关部门必须进行研究以发现引起不正常波动的特殊原因，必要时实施纠正措施以消除或减少过程波动。In the event of Ppk and/or Cpk lower than acceptance standard of customers/self-decided, the related departments must conduct analysis to find out the special reason, which cause abnormal fluctuation, implement corrective measures to eliminate or minimize the process fluctuation.6.1.4.3若过程的能力指数不能进一步改进以达到顾客的要求，但所生产的产品能满足顾客要求，则必须及时与客户联系，询问是否能降低过程能力指数要求。If fail to further improve Cpk to meet customers requirements, however, the products are able to meet customers requirements, please contact customers immediately, check weather can lower Cpk.6.2 监控现有生产过程/Monitoring the existing production process6.2.1 现有生产过程中的关键工序必须运用统计过程控制技术进行连续监控。质量部及生产部门负责数据的收集、控制图的绘制。质量部负责能力指数的计算。由应用部门决定过程是否受控及是否需要实施纠正措施。We must adopt statistic process control technique to conduct consecutive monitoring on key procedures of existing production process. Quality Dept. and Production Dept. are responsible for collecting data and protracting control drawing. Quality dept. is responsible for computing Cpk. The application Dept. decided whether control the process and implement corrective measures.6.2.2 数据收集和绘制控制图/Collect Data and Protract Control Drawing6.2.2.1 “控制计划”中明确了所有的关键控制点、控制方法、样本数量及取样频率。“Control Plan” defines all key control point, control method, samples quantity and sampling frequencies.6.2.2.2 控制图中必须记录所有会导致过程参数改变的事项。该信息将用于研究这些事项对过程能力的影响。The control drawing must contain all items, which cause process parameter change. The information will be used for researching impact to process capability.6.2.3 过程能力评价/Process Capability Appraisal6.2.3.1 当有一个点或多个点超出控制限外，或呈现某种失控模式时，操作者必须立即通知主管，主管负责采取适当的措施。When there is one or more than one items exceed control limit, or show certain lose-control mode, operator must inform superintend immediately, the supervisor adopt appropriate measures. 6.2.3.2 有关部门至少每三个月计算一次过程能力指数Ppk和/或Cpk，当Cpk值低于规定值时，即证明过程能力不足。The relevant dept. computes Ppk and /or Cpk once for every three months at least, When Cpk lover than agreed figure, indicate process capability is inadequate.6.2.4 反应措施/Response Measures6.2.4.1 针对能力不足的过程，有关部门必须进行研究以发现引起非正常波动的特殊原因，必要时，还应调查引起波动的普通原因，实施纠正措施以消除或减小波动。The relevant departments must conduct research to find out the special reason cause abnormal fluctuation against inadequate process, when necessary, investigate the general reasons which cause fluctuation, implement corrective measures to eliminate or minimize fluctuation.6.2.4.2 若过程的能力指数不能进一步改进以达到顾客的要求，但所生产的产品能满足顾客要求，则必须及时与客户联系，询问是否能降低过程能力指数要求。If Cpk fail to improve further to meet customers requirements, however, the products are able to meet customers requirements, contact customer immediately, check whether can lower Cpk value. 6.2.4.3 若过程能力明显不足，必须及时与顾客联系已采取临时性的反应措施，如限制产量和进行100%的检验。同时应尽快找出原因，实施纠正措施以确保过程稳定及过程能力。If Cpk is obviously inadequate, must contact customers immediately to adopt temporary measures, such as restrict output and conduct 100% inspection.6.2.4.4 当过程能力过高时，有关部门应适当减少取样频次和/或改变过程监控方法。必要时，以上改变须征得顾客同意。When Cpk is obviously high, the relevant departments should reduce the frequencies appropriately/or change monitoring method. When necessary, must obtain customers approval.6.2.5 持续改进/Continuous Improvement当过程能力已达到要求时，也可以进一步改进，尤其当顾客希望减少公差范围内的波动时。已达到要求的过程是否需要进一步改进取决于成本-收益分析的结果，即比较进一步改进过程所需划分的成本和该改进将会带来的收益。When Cpk reach requirements, has possibility for further improvement, especially when customers hope to reduce fluctuation within tolerance range. Whether it is necess