工厂生产及质量培训——CPK与GRR

1、華南檢測中心華南檢測中心華南檢測中心華南檢測中心F(x)x63-3NXXiNi12u標準差主要是用以衡量觀測資料與平均數之間的差異量數。u根據一組樣本估計其標準差。uCp(製程能力製程能力):Cp=TOL/6u設計公差與制程整個變異的比值設計公差與制程整個變異的比值, ,它反映的是它反映的是設計的極限指數設計的極限指數. .是對制程潛在能力的測定是對制程潛在能力的測定, ,一個一個高的高的CpCp指數表明制程具有好的潛在的再制能力指數表明制程具有好的潛在的再制能力u反映數據反映數據( (尺寸尺寸) )的波動范圍大小的波動范圍大小, ,CpCp數值越大數值越大, ,尺寸波動越小尺寸波動越小, ,

2、製程能力越充足製程能力越充足. .u Cpk(製程能力指數):反映製程滿足實際尺寸要求的能力,Cpk數值越大,製程越能保證實際尺寸的加工要求,u規格確定的中心值與制程變異相關聯的狀況,它是反映制程實際能力的指數.一個較高的Cpk指數表明制程實際的生產再制能力在要求的范圍內.Cpu=(USL-AVERAGE)/3Cpl=(AVERAGE-LSL)/3Cpk=MIN(Cpu,Cpl) (對形位公差,尺寸不可能小于設計下限值,因而Cpk=Cpu)Cp=Cpk(僅在實際加工尺寸平均值與設計中值相等時Cp=Cpu=Cpl=Cpk)用作量測分析的產品尺寸和樣本大小的選取由供應用作量測分析的產品尺寸和樣本大

3、小的選取由供應商與客戶協商確定商與客戶協商確定. . 樣本應有足夠大小樣本應有足夠大小, ,以減少抽以減少抽樣誤差樣誤差u對製程的判定對製程的判定:Cpk=Cpk=1.33製程能力滿足Cpk1.67 製程能力過足 Gauge Repeatability and Reproducibility華南檢測中心華南檢測中心量測系統量測系統環境環境標準件標準件操作者操作者量具量具True ValueMeasurement System v量測值= v真值+ v誤差TrueAverageAccuracyObservedAverageRebetabilityReproducibilityOperator B

4、Operator A3Number of Operators (2 or 3)Variable Data Gauge R&R Spreadsheet (ANOVA method)10Number of Parts (5-10)EXAMPLE2Number of Trials (Replicates) - Fixed at 2NOTE: COMPLETE ONLY THE WHITE CELLSOperator 1Operator 2Operator 3Part #Trial 1Trial 2Trial 12Trial 22Trial 1Trial 2Trial 12Trial 22Tr

5、ial 1Trial 2Trial 12Trail 22114.50214.508210.3080210.482114.50314.516210.3370210.714314.51914.514210.8014210.6562214.53014.541211.1209211.440714.52714.532211.0337211.179014.53914.533211.3825211.2081314.52514.523210.9756210.917514.53014.525211.1209210.975614.53014.525211.1209210.9756414.50414.523210.

6、3660210.917514.51514.511210.6852210.569114.50714.503210.4530210.3370514.53114.531211.1500211.150014.53514.532211.2662211.179014.53814.535211.3534211.2662614.51414.536210.6562211.295314.52714.524211.0337210.946614.52314.528210.9175211.0628714.54114.551211.4407211.731614.55414.540211.8189211.411614.55

7、414.555211.8189211.8480814.52314.528210.9175211.062814.52214.525210.8885210.975614.52314.526210.9175211.0047914.53114.525211.1500210.975614.53114.533211.1500211.208114.54214.541211.4698211.44071014.54814.544211.6443211.527914.54314.574211.4988212.401514.56614.560212.1684211.9936Column Totals145.2491

8、45.3102109.72922111.5010145.287145.3122110.83302111.5604145.341145.3202112.40342111.7929ANOVA Table With Operator*Part InteractionANOVA Table Without Operator*Part InteractionSupplierDateSource ofSum ofDegrees ofMeanPSource ofSum ofDegrees ofMeanFoItem NameVariabilitySquaresFreedomSquareVariabilityS

9、quaresFreedomSquareDrawing No.Parts0.01144790.001272Parts0.01144790.00127229.8089Part CodeOperators0.00026420.000132Operators0.00026420.0001323.0953Machine No.Operator by Part0.000654180.0000360.7047Repeatability0.002048480.000043Tool No.Repeatability0.001395300.000046Total0.01375959Cavity No.Total0

10、.01375959Raw materialGauge R&R With Operator*Part InteractionGauge R&R Without Operator*Part InteractionGauge IDFixture Ref. No.SourceVar CompSourceVar CompMeasurersTotal Gauge R&R0.000051Total Gauge R&R0.000047Nominal Dim. Repeatability0.000046 Repeatability0.000043Upper Spec. Limit

11、 Reproducibility0.000005 Reproducibility0.000004Lower Spec. Limit Operator0.000005 Operator0.000004Notes Operator by Part0.000000Part - To - Part0.000206Part - To - Part0.000205Total Variation0.000257Total Variation0.000252SourceSourceTotal Gauge R&R19.93%Total Gauge R&R18.70%Total Gauge R&a

12、mp;R Results - Measurement Capability Repeatability18.07% Repeatability16.93% Reproducibility1.86% Reproducibility1.77% Operator1.86% Operator1.77% Operator by Part0.00%Part - To - Part80.07%Part - To - Part81.30%Total Variation100.00%Total Variation100.00%Note: Use this branch if Operator by Part P

13、-value is = 0.25DMM00210-EN - V.3.0Part Sum of Part X Operator InteractionSquaresOpt 1Opt 2Opt37579.7918841.5801842.1024842.91517604.1888845.1230844.4255845.18127596.5170843.7863844.1930844.19307579.9660842.5667842.5087841.58017604.1888844.5998844.8905845.23937595.4711843.9025843.9606843.96067620.41

14、70846.3445846.4608847.33397594.5996843.9606843.7282843.84447604.3632844.2511844.7161845.82097627.4022846.3445847.7997848.323976006.905612667.8185Item NameDrawing No.Part CodeMachine No.Cavity No.Raw materialFixture Ref. No.MeasurersNominal Dim.Upper Spec. LimitLower Spec. LimitTotal Gauge R&R Re

15、sults - Measurement Capability0 - 10% EXCELLENT10-20% GOOD TO MARGINAL20-30% MARGINAL TO NOT CAPABLE30-100% NOT CAPABLE2-DIMENSION MEASURING MACHINEA, B, C14.314.514.712345Supplier Name16/06/1999HDXXXDMD12345FPC量測數據填入供應商生產信息量測信息及備注請在畫紅圈部份填入相關信息請在畫紅圈部份填入相關信息!Source ofSum ofDegrees ofMeanPVariabilityS

16、quaresFreedomSquarePartsSSpn-1MSpOperatorsSSok-1MSoOperator by PartSSop(n-1)(k-1)MSopFDISTRepeatabilitySSenk(r-1)MSeTotalTSSnkr-1ANOVA Table With Operator*Part InteractionSourceTotal Gauge R&R19.93% Repeatability18.07% Reproducibility1.86% Operator1.86% Operator by Part0.00%Part - To - Part80.07

17、%Total Variation100.00%Note: Use this branch if Operator by Part P-value is = 0.25PASSFAIL所有的檢查者對該樣品的判定是否一致所有的檢查者對該樣品的判定是否一致.DATA ENTRY WORKSHEETDATE:When study took placeAttribute Legend5 (used in computations)NAME:Study Co-Ordinator1 passITEM:Name and Number (Identification)All operators2 failLOCATION:Where Study took placeagree within andAll Operatorsbetween eachagree withOtherstandardKnown Po