RedX天教材PPT课件

Page1,StatisticalEngineeringRedXStrategyOverview,Page2,LearningObjectives学习目标,Attheendofthiscoursethelearnerwillunderstand:本课程结束的时候，学习者应了解以下几个方面：RedXTerms“RedX”专业术语TheImportanceofStrategicThinking“RedX”策略想法的重要性HowtoUsethefollowingRedXTechniques:StrategyDiagramComponentSearchGroupComparisonToleranceParallelogramNote:RedXStrategiesnowincludesover30techniques.,Page3,HistoryOverview发展历史概括,DorianShainin(1940s),ShaininConsulting(1970s),GMyouonlyneedtofindoutwhatdrivesthecontrast不要试图了解所有的事情，只需要找到谁引起的变化Understandthatthereisalwaysgoingtobe“noise”,2-24,Using“RedXStrategy”toFindtheCureforSmallpox,Page41,XtoYThinkingX到Y的思索,ScientificMethod科学的方法Strategy:Makeachange(X)andwaittoseeiftheproblem(Y)getsbetter.策略：通过改变一个或者使更多的原因(X)来确定它们是否会使结果(Y)变好。ThisisaGuessingStrategy.IfwedonotguesswhattheRootCauseis,wewillneverfixtheproblem.这是一个假设的策略。如果我们不假定根本原因的话，我们可能永远也解决不掉问题。Assumption:Iknowtherelationshipbetweencauseandeffect假定：已经知道了原因与结果之间的关系,Page42,YtoXThinkingY与X的思索,RedXStrategiesSelectBOBsandWOWsatoppositeextremesoftheGreenYDistribution.WithinthesesampleswewillhavecapturedextremesoftheRedX.在GreenY两个极端处选择BOB和WOW，通过这些样本，我们可以抓出极端的RedXEliminatewhatisthesameandfocusonwhatisdifferent.排除掉相同的因素而关注于差异ThemoreContrastwehave,theeasieritwillbetoidentifytheRedX.差异越大越容易找出RedX来Assumption:Icanunderstandthephysicsbyobservingtheextremes假设：通过对极端的观察，可以了解其原理,Page43,YtoXRelationship,Page44,StrategyDiagram策略图,WherecanIobservethemostcontrast?我在哪里可以观测到最大的差异？,Page45,StrategyDiagrams策略图,WhatisaStrategyDiagram?什么是策略图？StrategydiagramisanorganizedlistofContrastopportunities.策略图是列出所有可能产生差异因素的清单。Generally,theWOWconditionisknownandclearlyidentified.HowevertherearemanyopportunitiesforselectingtheBOB.通常，WOW很容易识别，然而，BOB时常会有很多的选项，比较难以选择。ContrastchoicesarearrangedfromSmallest(Feature/Defect/Event)toBiggest(Time).差异项选择按照从小到大排列ThesmalleststrategychoicethatshowsthelargestContrastisusuallythebeststrategytouse.差异越大而体现差异的因素项越小，策略图越有效。Thefirstcontrastchoiceisalwaysaquestionofthemeasurement/evaluationsystem.Youcannotproceedwithanotherstrategychoiceifyoudonothavearepeatablefailuremodeormeasurementsystem.第一个差异项总是询问测量评估系统。如不能重现失效或没有可重复测量系统，就不能再进行其他的策略。ThelastcontrastchoiceisTime.Thiscouldinclude:ShifttoShift,DaytoDay,MonthtoMonth,etc.最大的差异项是时间。有可能是班组和班组、天与天、月与月等的对比。,Page46,StrategyDiagrams策略图,StrategyDiagramscannotbecompletedatyourdesk.策略图不是在办公桌上完成的StrategyDiagramsshouldbedevelopedwhileyouareexperiencingthefailuremode.策略图应该是在体验到失效之后而发展进行的EvaluateStrategyChoiceswithresultsfromConcentrationDiagram,Multi-Vari,andotherrelevantobservations.评估策略选项应根据集中图、多边差和其它相关的观测。VehicletoVehicleisthemostpopularstrategychoice;however,itisoftennotthebestchoice.车与车之间的对比是最通用的策略选项，却不一定是最好的选项。RememberthePhysicsofFailureandlookforcreativeContrastopportunities(RegiontoRegion,SidetoSide,ModeltoModel,etc)记住失效的原理和创造性地选择差异项(区域对区域、边对边、类型对类型等),Page47,MeasurementSystemContrast,ThefirstStrategyChoicethatwemustevaluateis“dowehavearepeatablemeasurementsystem?”Thisistrueforalltypesofproblems.WecannotproceedwithanyotherStrategyifourmeasurementsystemisnotrepeatable.,FeatureIfwemeasurethesamepartmultipletimes,dowegetsimilarreadings?DefectIfweevaluateaBOBvehiclea2ndtimeisitstillBOB?IfweevaluateaWOWvehiclea2ndtimeisitstillWOW?EventIstheFailuremodeintermittent?IsaBOBvehiclealwaysBOB?IsaWOWvehiclealwaysWOW?,Page48,FeatureStrategyDiagrams特征策略图,HowcanIobservecontrastwithaFeaturetypefailure?通过失效类型的特征，如何观测差异？,Page49,HoodFitInconsistentGaptoFender,ObservedClueList:Featureisrepeatable.MeasurementSystempassesIsoplot.Hoodtofendergapsarealwaysparallel.No“A”or“V”Gaps.Somecars=BigLeftTagscanfalloffandpenmarkswearoff用蚀刻的方式作标记，因为标签可能脱落，用笔作的标记也可能会被磨损消蚀掉Usetheactualassemblyprocessascloseaspossible拆解过程要和实际装配过程尽量接近Remembertoswapassemblies,noteverynut,bolt,spring记住交换的是个集合，不是每个螺母、螺钉、弹簧Beawarethatthreadintegrityonaluminumblocksandcasesisanimportantissue注意在铝块上的线的完整性以及案例是比较重要的问题。,Page75,ComponentSearchNCC736ComponentSearchStageI&IIData阶段一和阶段二的数据汇总,Original,Disassembly/Reassembly#1,Disassembly/Reassembly#2,Disassembly/Reassembly#3,Pump,ValveBody,&ChannelPlateOnly,DrivenSprocketSupportOnly(Pump,VB,CPputback),ReverseClutchHousingOnly(DSSputback),Original,Original,Disassembly/Reassembly#1,Disassembly/Reassembly#2,Disassembly/Reassembly#3,Pump,ValveBody,&ChannelPlateOnly,DrivenSprocketSupportOnly(Pump,VB,CPputback),ReverseClutchHousingOnly(DSSputback),Original,308,310,200,299,319,309,310,307,308,203,WOWTransmission,GreenY,NeutraltoReverse,ShiftDelay(ms),199,202,208,205,BOBTransmission,GreenY,NeutraltoReverse,ShiftDelay(ms),196,199,Page76,Thelargerthegroupsize,thelowertherisk.组越大，风险越低Therecommendedgroupsizeis4,4.推荐的组的大小是4,4。Stage1rules-Completeseparation-Stage2DecisionLimits,SearchAlgorithmFactors搜索算法系数,ComponentSearch,RiskFactorI,RiskFactorII,(ProductVariationRiskFactorIxProcessVariation),(DecisionLimits=Median+RiskFactorIIxAverageRange),Page77,ComponentSearch,PassingRules,Rule1:CompleteseparationmustexistbetweenBOBandWOWvalues(notouching/overlap)规则1：BOB和WOW取值必须完全分离（没有接触及重叠）Rule2:Thedifferencebetweenthemediansmustbegreaterthantheaveragerangetimesariskfactor两者的中数之差必须大于极值平均值与风险系数的乘积,RBOBandRWOWmustbesmall,DYmustbebig,Page78,ComponentSearch,DecisionLimits决策界限PurposeoftheDecisionLimits设定决策界限的目的Tostatisticallycalculateyourlimitsofprocessvariation用统计的方法计算过程差异的界限,Page79,Page80,Page81,ComponentSearchExercise元件查找练习,Page82,GroupComparison分组和配对对比,WhichcomponentfeatureisdrivingtheGreenYfailure?哪一个元件失效导致了GreenY的失效？,Page83,GroupComparison分组和配对对比,WhatisaGroupComparison?什么是分组与配对对比？Itisapowerfulcluegenerationtoolsusedwhenthe“dictionary”cannolongerbesplitintosmallercomponents.当“字典”不能被拆分为更小的元件时，“分组和配对对比”可以被用作有力的线索产生工具。ItisatoolthatcanquicklyidentifypotentialRedXcandidates!“分组和配对对比”是能够很快识别出潜在的RedX候选者的工具。,Page84,GroupComparison分组与配对对比,InaGroupComparison,thecharacteristicsorfeaturesmeasuredbetweenBOBsandWOWsarerankordered.Then,TukeysEndCountisusedtoidentifyRedXcandidates.在分组对比中，在BOB和WOW之间测量到的特征或特性是按从最好到最差的顺序排列的，然后用图基计算终值方法识别RedX的候选者。GroupComparisonrequiresonlythecollectionofagroupofBOBandWOWassembliestoidentifythedifferencebetweenthegroups.ItdoesnothavetheabilitytoseethesmallRedXfeaturedifferenceslikethePairedComparison.分组对比只需要收集一个组中BOB和WOW的集合来辨别组之间存在的差异。但不能象配对对比那样可以识别细微的RedX特征的差异。,Page85,GroupComparisonRules:分组对比原则：,Selectaminimumof5BOBsand5WOWs(recommended8).最少选择5对BOB和WOW配对样本（推荐8组）。Measureanypertinentcharacteristic.Dontbetoorestrictive,butrememberthephysics!测量每一个相关的特征。不要太过苛刻，但要记住所要测量的物理性质。Beawareofmeasurementvariationwhencheckingdifferentdimensions.在核对不同的尺寸时，应该考虑到测量的偏差。Stage0AnalysisisrecommendedforestimatingDeltaM。推荐进行0阶段分析来估计M的值。DeterminetheendcountforeachfeaturefollowingtheguidelinesofRankOrderANOVA.UseTable5.5fromRedXStrategiesPocketGuidetodeterminetheminimumendcountrequirementsforidentifyingRedXcandidates.根据ANOVA的排序指导确定每一个特征的计算终值。使用源自REDX策略指导手册的表5.5确定用以识别RedX候选者所需的最小计算终值。,Page86,GroupComparisonRules:分组对比原则：,UpdatesolutiontreewiththeappropriatesplitsandidentifytheRedXcandidate.ProceedwiththeConfirmationphase.通过适当的拆解和识别RedX候选者的方法来修正问题解决树。并且继续进入到确认阶段。,Page87,GroupComparisonTableRequiredEndCount分组对比表所必需的计算终值,*Thisisnotastatisticalconfirmationtest这不是一个统计学验证试验,Page88,Itisagoodideatoincludeanillustrationofthefeaturesanddimensionsyouaremeasuring!为你正在测量的特征和尺寸加上说明是好的想法。,ItisagoodideatoincludetheoriginalGreenYmeasurementsfortheBOBandWOWgroups.对BOB和WOW分组中包括原始的GreenY的测量是个好主意,DeterminethefeaturesordimensionstobemeasuredbetweentheBOBsandWOWs.在BOB和WOW之间确定将要测量的特征或尺寸。,WorksheetforGroupComparison分组对比作业单,Steps.步骤,Page89,Determinethe“endcount”foreachmeasureddimension.为每一测量尺寸确定终值。,RankordereachdimensionandindicateifthemeasurementisfromaBOBorWOW.将每一尺寸从好到坏进行排列，同时指出该测量是出自BOB还是WOW。,Thedimension(s)thatmeettheminimumendcountrequirementistheRedXcandidate(s)!大于或等于所需最小终值的尺寸就是REDX的候选者。,WorksheetforGroupComparison(continued)分组对比作业单（续）,Page90,Page91,Notes,Page92,ToleranceParallelogram允许度平行四边形法则,Page93,X-YScatterPlotPatterns,Page94,ToleranceParallelogram允许度平行四边形法则,WhatisToleranceParallelogram?什么是允许度平行四边形法则？ToolusedtoshowtherelationshipbetweenaRedXandtheGreenY.能够体现RedX和GreenY关系的工具。Whydoweneedit?为什么需要用这种工具？ShowtherelationshipbetweentheRedXandGreenY.能够显示RedX和GreenY的关系。Determinationofrealistictolerances.决定现存的允许度。,Page95,PlotpointsfrompreviouslycollecteddatatoshowtherelationshipbetweentheRedXandtheGreenY.将先前所收集的GreenY和对应的RedX数据用点的形式表示出来。RedXcontrollimitsmustbeselectedsuchthatcustomerenthusiasmisalwaysachieved.RedX控制线的选择必须与客户接受度有关。,ToleranceParallelogramRealWorldRelationship,Page96,ToleranceParallelogram允许范围的平行四边形法则,Page97,1.PlottheRedXrelativetotheGreenY(obtain30pointsfrompreviousand/orcurrentdatacollection)画出GreenY及相对应的RedX为坐标的点(从先前或是现在所获得的数据取30个点),Drawinaregressionlinethatreflectsamidpositionofthedistribution.画一条能够反映这些点分布的中间位置的恰当线。,BuildingAToleranceParallelogram确定允许范围的平行四边形,Page98,Eliminatethefurthestpointfromtheregressionline.Drawinthelimitlineparalleltotheregressionlineandpassingthroughthesecondfurthestpointfromtheline.Drawintheoppositelimitlineparallelto,yetoppositetheregressionline.去掉距离这条恰当线最远的一个点。通过距离第二远的点做一条与恰当线平行的直线。同时以恰当线为中心，向另一面做镜射，这样就得到了与恰当线距离相等的两条平行线。,BuildingAToleranceParallelogram(Cont)确定允许范围的平行四边形(续),Page99,4.DrawintheupperandlowercontrollimitsontheGreenYwithhorizontallines.Connecttheupperlimittotheupperlimitlineandthelowerlimittothelowerlimitline.用水平线标出GreenY上下控制线(客户接受度)。如右图所示通过上控制线与上平行线的交点向下引一条垂线；同样，通过下控制线与下平行线的交点也做一条垂线。Reminder:ToptoTopBottomtoBottom提示：顶对顶，底对底