spc统计制程管制培训教案(共97页).ppt

1、2 3 4 Process 製程Variation 變異Data 資料Statistical Tools 統計方法5 6 “You cant improve a process that you dont understand” 你若對製程不懂你若對製程不懂,就無法改善製程就無法改善製程7 8 9 “Early on, we failed to focus adequately on core work processes and statistics.” 初期若核心工作製程與統計無法適當集中初期若核心工作製程與統計無法適當集中,其結果其結果 10 SECURE STOREKITLoad Pr

2、ogram Load Pick/Place Load Reflow Profile Load StencilScreen Solder PasteParts SMT PlacementI / R ReFlowCleanPEM Parts (ASIC, ADC, DAC) Placement & Hand SolderCleanSecond Level Assy. Touch-up solder joints Mechanical Installations Staking/BondingCleanElectrical Functional TestCleanBakeConformal

3、CoatPost Test InspectionAcceptance Test ElectricalControlled StorageInspection CheckpointInspection CheckpointInspection CheckpointInspection CheckpointInspection CheckpointInspection CheckpointInspection CheckpointThrough-hole and Plastic Parts Preparation Tin Components Form & Cut Axial Leads

4、Through-hole Component Placement & Hand SolderClean & Inspection CheckpointPWB Preparation: Clean Ink Stamp BakeProduction OperationInspection OperationTest OperationMaterial Control OperationKEY11 SECURE STOREKITLoad Program Load Pick/Place Load Reflow Profile Load StencilScreen Solder Past

5、eParts SMT PlacementI / R ReFlowCleanPEM Parts (ASIC, ADC, DAC) Placement & Hand SolderCleanSecond Level Assy. Touch-up solder joints Mechanical Installations Staking/BondingCleanElectrical Functional TestCleanBakeConformal CoatPost Test InspectionAcceptance Test ElectricalControlled StorageInsp

6、ection CheckpointInspection CheckpointInspection CheckpointInspection CheckpointInspection CheckpointInspection CheckpointInspection CheckpointThrough-hole and Plastic Parts Preparation Tin Components Form & Cut Axial Leads Through-hole Component Placement & Hand SolderClean & Inspection

7、 CheckpointPWB Preparation: Clean Ink Stamp BakeProduction OperationInspection OperationTest OperationMaterial Control OperationKEY12 13 14 .Managers use meeting management techniques 經理利用會議管理技巧經理利用會議管理技巧 Standardized project management systems are in place. 適當的標準化專案管理系統適當的標準化專案管理系統 Both project pro

8、cess and results are reviewed. 此專案的流程與結果已被審核此專案的流程與結果已被審核 Process variation is considered when setting goals. 當設定目標時當設定目標時,流程的變異已被考慮流程的變異已被考慮 Measurement is viewed as a process. 量測點被視為一個流程量測點被視為一個流程 The number of suppliers is reduced 供應者數目減少供應者數目減少 A variety of communication media are used. 廣泛的傳訊媒體被

9、採用廣泛的傳訊媒體被採用15 Work processes are flowcharted & documented 工作程序已被流程圖表化與書面化工作程序已被流程圖表化與書面化 Key measurements are identified.主要量測點已被確認主要量測點已被確認 Time plots displayed時間的圖示被展現時間的圖示被展現 Process management and improvement utilize: 製程管理與改善採用製程管理與改善採用 Knowledge of variation, and 變異觀念的知識及變異觀念的知識及 Data analy

10、sis 資料分析資料分析 Improvement activities focus on the process, not blaming employees. 改善工具著重於製程改善工具著重於製程,而非責備員工而非責備員工 16 17 18 19 21 24 Common Causes共同原因共同原因Assignable Causes特殊原因特殊原因What prevents perfection? Process variation. 何事阻礙完美何事阻礙完美?製程變異製程變異 26 Grams(a) LocationAverage(平均值平均值) 27 (a) LocationGrams

11、Average28 -3s s -2s s -1s s +1s s +2s s +3s sMean 平均值平均值 68.26% 95.44% 99.74%s= Standard deviation s=標準差標準差 29 XMean平均值平均值Central Limit Theorems ss sxxn X=Standard deviation 樣本標準差樣本標準差X =30 UCL 管制規格上限管制規格上限 Nominal 中心線中心線 LCL 管制規格下限管制規格下限 1 2 3 Samples31 1 2 3 SamplesUCL 管制規格上限管制規格上限 Nominal 中心線中心線

12、LCL 管制規格下限管制規格下限 32 Assignable causes likely 可能的特殊原因可能的特殊原因 1 2 3 SamplesUCL 管制規格上限管制規格上限 Nominal 中心線中心線 LCL 管制規格下限管制規格下限 33 FrequencyLower control limitSize Weight, length, speed, etc. Upper control limit(b) In statistical control, but not capable of producing within control limits. A process in co

13、ntrol (only natural causes of variation are present) but not capable of producing within the specified control limits; 共同原因變異共同原因變異and(c) Out of control. A process out of control having assignable causes of variation.特殊原因變異特殊原因變異In statistical control and capable of producing within control limits.

14、A process with only natural causes of variation and capable of producing within the specified control limits.正常型正常型34 UniformNormalBetaDistribution of sample means樣本平均值分配樣本平均值分配x means sample of MeannxxssStandard deviation of the sample means(mean)x2 withinfall x all of 95.5%sx3 withinfall x all of

15、99.7%s x3 x2 x x x1 x2 x3ssssssThree population distributions群體分配群體分配35 TargetTargetAt a fixed point in time At a fixed point in time 固定時間固定時間TimeTimeTargetTargetOver time Over time 連續時間連續時間Think of a manufacturing process producing distinct parts with measurable characteristics. These measurements

16、vary because of materials, machines, operators, etc. These sources make up chance causes of variation. 製造各零件之量測特性會因製造各零件之量測特性會因4M等機遇原因而發生變異等機遇原因而發生變異36 37 Control Charts Variables Charts Attributes Charts Continuous 連續的連續的 Numerical DataCategorical or Discrete 離散的離散的 Numerical Data計量計量計數計數38 39 Prod

17、uce Good Provide Service Stop Process Yes No Assign. Causes? Take Sample Inspect Sample Find Out Why Create Control Chart Start 40 41 43 0006. 0=40027. 0=3xxxxxorxxorx-Prob-Probnx/=Std. dev. of the sample means 樣本平均數標準差樣本平均數標準差: 44 nR Rin1i 45 46 47 Type 1 ( alpha Error No Error No Error Type 2 (Bet

18、a) Error AlarmNo AlarmIn-Control 管制內管制內 Out-of-Control 失控失控 48 49 Test Probability Type 1 Error2/37/710/1116/201/12(0.00135)0.00270.0052(0.5)7 0.007811) 5 . 0 (1111) 5 . 0 (10) 5 . 0 (10110.00586iii20)5.0()5.0(2016200.00593)0228.0()9772.0(2)0228.0(2350 1x3xProbssss/3/311nxxwhere F(z) denotes the the

19、 cumulative probability of a standard normal variate at z Power = 1- Type 2 Error. Power increases as n increases, as (m1-m) increases, and as s decreases. Extension to m1 184 Lower specification limitUpper specification limit(a) Acceptance sampling(b) Statistical process control(c) cpk 185 86 92 AQ