Synchronization--Chinese

1、 Shanghai YFJC Guangzhou Branch1上海xxxxxx公司倡导者: xx过程所有人: xx黑带: xx黑带大师: xxSigma Trac ID # xxx项目时间进度项目时间进度定义阶段定义阶段:06/24/03衡量阶段衡量阶段:07/23/03分析阶段分析阶段:09/23/03改进阶段改进阶段:11/07/03控制阶段控制阶段:12/23/03确认阶段确认阶段:03/23/04 xx xx xx xx项目小组成员项目小组成员 Shanghai YFJC Guangzhou Branch2Complain conten抱怨内容抱怨内容Times缺陷次数缺陷次数Rat

2、e缺陷率缺陷率Non conform with synchronizationrequirement of FS 前座椅不符合同步性要求120070%Obstruct between outer board andrecliner handle.调角器手柄与侧护板干涉1579PPMPoor link between A/R J-retainerand board 后靠扶手罩板和扶手连接不紧1579PPM0Recognize project chance. Identify whats important to the customer. 2003年年6月份客户抱怨情况月份客户抱怨情况啊？不同步

3、问题的比率这么高呀，让我们一起请6sigma帮忙吧！ Shanghai YFJC Guangzhou Branch3Identify whats important to the customer. Define project scope. 1 Define Shanghai YFJC Guangzhou Branch4Background:某新车型于2003年6月批产客户要求座椅必须符合客户的相应标准此前的车型对于座椅没有相应要求Problem:客户于 2003年6月中旬, 抱怨很大比例的座椅不符合同步性要求These were the original dataSample SizeOK

4、RateSample SizeOKRtae6.24910.11940.446.25930.331040.406.26930.33930.336.27930.33910.116.28910.11910.116.30920.22920.227.01920.22910.117.03930.33930.337.04910.11900.007.07930.33940.447.09950.56950.567.10930.33930.337.11970.78930.337.12820.25840.50Total/Avg.125390.31126380.30Sample rate: 6%Oringinal D

5、ata of SynchronusDriverPassengerDate Define1Identify whats important to the customer. Define project scope. Shanghai YFJC Guangzhou Branch51Identify whats important to the customer. Define project scope. 0510150.00.10.20.30.40.50.60.70.80.9Sample NumberProportionP Chart for PassengeP=0.3016UCL=0.788

6、4LCL=00510150.00.10.20.30.40.50.60.70.80.9Sample NumberProportionP Chart for DriverP=0.312UCL=0.8034LCL=0从以上两个P图可以得出结论：初始过程是稳定的Measure Shanghai YFJC Guangzhou Branch6Measure Shanghai YFJC Guangzhou Branch7MeasureDetermine what to measure (Y) and validate the measurement system.2YC = Customer audit r

7、esult of Sunny (Average synchronization rate) YP = YFJC audit result of Sunny (Average synchronization rate) 客户处的衡量系统无法进行分析客户处的衡量系统无法进行分析Attribute Gage R & R EffectivenessSCORING REPORTAttribute LegendDATE:2003-6-261 YNAME:2 NPRODUCT:CHS seatingSBU:TEST CONDITIONS:Known PopulationOperator #1Oper

8、ator #2Operator #3Y/NY/NSample #AttributeTry #1Try #2Try #1Try #2Try #1Try #2AgreeAgree1NNNNNNNYY2YYYYYYYYY3NNNNNNNYY4NNNNNNNYY5NNNNNNNYY6NNNNNNNYY7NNNNNNNYY8YYYYYYYYY9NNNNNNNYY10NNNNNNNYY11NNNYNNYNN12NNNNNNNYY13NNNNNNNYY14NNNNNNNYY15YYYYYYYYY16NNNNNNNYY17YYYYYYYYY18NNYNNNNNN19YYYYYYYYY20YYYYYYYYY21

9、NNNNNNNYY22NNNNNNNYY23YYYYYYYYY24NNNNNNNYY25YYYYYYYYY26YYYYYYYYY27NNNNNNNYY28NNNNNNNYY29NNNNNNNYY30YYYYYYYYY% APPRAISER SCORE(1) -96.67%96.67%96.67% SCORE VS. ATTRIBUTE(2) -96.67%96.67%96.67%SCREEN % EFFECTIVE SCORE(3) -93.33%由此属性数据衡量系统分析结果可知：由此属性数据衡量系统分析结果可知：96.67%，我公司内的衡量系统是可接，我公司内的衡量系统是可接受的受的 Sha

10、nghai YFJC Guangzhou Branch8AnalyzeFor possible main effect selection 154236Will not discuss this cause of design Shanghai YFJC Guangzhou Branch9潜在原因如下潜在原因如下:X1: 在客户处座椅装车时装车方法不当在客户处座椅装车时装车方法不当X2: 夹具精度不同夹具精度不同X3: 装配座椅时装配方法不当装配座椅时装配方法不当X4: 前靠骨架开档尺寸偏小前靠骨架开档尺寸偏小X5: 高度调节器铆接间隙过大高度调节器铆接间隙过大3Identify causes

11、 (Xs) of variation and defects.AnalyzeWhich were the real root causes? Shanghai YFJC Guangzhou Branch104Cause validation and improve action for X1Analyze ImproveX1:在客户处座椅装车时装车方法不当在客户处座椅装车时装车方法不当客户处初始装车方法客户处初始装车方法:按图按图1所示车身孔顺序一次性拧紧螺栓所示车身孔顺序一次性拧紧螺栓我们向客户建议的装车方法我们向客户建议的装车方法:先用手预拧螺栓，先用手预拧螺栓，然后按图然后按图1所示车身

12、孔顺序拧紧螺栓，所示车身孔顺序拧紧螺栓，利用图利用图3所示工具确保滑道位置正确所示工具确保滑道位置正确2341InsideFrontRearPicture no.1Outside1342InsideFrontRearPicture no.2OutsidePicture no.3Which one is better? Shanghai YFJC Guangzhou Branch114Cause validation and improve action for X1Analyze ImproveTest and CI for Two ProportionsSample X N Sample p

13、1 10 30 0.3333332 19 30 0.633333Estimate for p(1) - p(2): -0.395% CI for p(1) - p(2): (-0.541228, -0.0587719)Test for p(1) - p(2) = 0 (vs not = 0): Z = -2.44 P-Value = 0.015这是影响同步的真这是影响同步的真正原因之一！正原因之一！在客户处实施了新的装在客户处实施了新的装车方法后，同步率由之车方法后，同步率由之前的前的30%提高到提高到63% ！为验证实施以上两种不同的装车方法后同步率是否有改进，我们实施了假设检验。H0: T

14、he synchronization rate was the same with the two different methodsH1: The synchronization rate was not the same with the two different methodsP0.05, accept H0: 不同精度的夹具，同不同精度的夹具，同步率相同。步率相同。这不是影响同步的这不是影响同步的真正原因！真正原因！ Shanghai YFJC Guangzhou Branch136Cause validation and improve action for X3Analyze I

15、mproveX3:装配座椅时装配方法不当装配座椅时装配方法不当初始状态初始状态方法方法A : 滑道上的滑道上的A杆在供应商处已被拧紧，因此在整个座椅装配过程杆在供应商处已被拧紧，因此在整个座椅装配过程中一直保持紧固状态中一直保持紧固状态A-杆建议状态建议状态方法方法B: 考虑到可能的应力消除，生产线上在装配滑道前预先把考虑到可能的应力消除，生产线上在装配滑道前预先把A杆拧杆拧松，并使它在整个座椅装配过程中保持松动状态，座椅装配完松，并使它在整个座椅装配过程中保持松动状态，座椅装配完成后才把成后才把A杆拧紧杆拧紧Which one is correct?为验证两种方法对同步率的影响是否相同，团队

16、实施了假设检验：为验证两种方法对同步率的影响是否相同，团队实施了假设检验：H0: The synchronization rate was the same with the two different methodsH1: The synchronization rate was not the same with the two different methodsTest and CI for Two ProportionsSample X N Sample p1 11 30 0.3666672 8 30 0.266667Estimate for p(1) - p(2): 0.195% C

17、I for p(1) - p(2): (-0.134043, 0.334043)Test for p(1) - p(2) = 0.05 (vs not = 0.05): Z = 0.42P-Value = 0.675P0.05, accept H0:这不是影响同步的这不是影响同步的真正原因！真正原因！ Shanghai YFJC Guangzhou Branch148Cause validation and improve action for X4Analyze ImproveX4:前靠骨架开档尺寸偏小前靠骨架开档尺寸偏小A: 457.4+/-1.5PlanformPrevious pack

18、agingImproved packaging456.2456.6456.4456.5456.0456.1456.3456.6457.0457.1457.2456.6456.8457.2457.1456.8457.2456.6456.8456.6456.6457.5457.5456.1457.0457.2456.7457.0456.1456.5如图所示，小组发现前靠骨架经过长途运输后，开档尺寸如图所示，小组发现前靠骨架经过长途运输后，开档尺寸A会偏小。分析认为会偏小。分析认为此前的包装会使该部位在长途运输中受压，从而导致偏小；而且小组认为此部此前的包装会使该部位在长途运输中受压，从而导致偏小；

19、而且小组认为此部位尺寸会对同步率有影响，因此建议更改包装方式以提高同步率。位尺寸会对同步率有影响，因此建议更改包装方式以提高同步率。Was the changing of packing effective on dimension A?Was the improvement of dimension A helpful for better synchronization?458.1458.1458.3458.1458.3458.4457.9458.5458.3458.0458.2458.2457.9458.3458.2458.2458.4458.4458.1458.3458.0458.24

20、58.3458.1458.3458.2457.9458.3458.4458.1 Shanghai YFJC Guangzhou Branch158Cause validation and improve action for X4Analyze ImproveX4:前靠骨架开档尺寸偏小前靠骨架开档尺寸偏小 假设检验假设检验1用于验证是否包装改进后，尺寸用于验证是否包装改进后，尺寸A随之得到改进随之得到改进H0: The dimension A was the same with the different packagingH1: The dimension A was NOT the sam

21、e with the different packaging Both P0.05, 改改进前后尺寸均为进前后尺寸均为正态分布正态分布P-Value: 0.342A-Squared: 0.400Anderson-Darling Normality TestN: 30StDev: 0.418660Average: 456.73457.5457.0456.5456.0.999.99.95.80.50.20.05.01.001ProbabilityPreviousNormal Probability PlotAverage: 458.199StDev: 0.156808N: 30Anderson-D

22、arling Normality TestA-Squared: 0.249P-Value: 0.726457.9458.0458.1458.2458.3458.4458.5.001.01.05.20.50.80.95.99.999ProbabilityImprovedNormal Probability Plot Shanghai YFJC Guangzhou Branch168Cause validation and improve action for X4Analyze ImproveX4:前靠骨架开档尺寸偏小前靠骨架开档尺寸偏小 假设检验假设检验1用于验证是否包装改进后，尺寸用于验证是

23、否包装改进后，尺寸A随之得到改进随之得到改进H0: The dimension A was the same with the different packagingH1: The dimension A was NOT the same with the different packagingP0.05, accept both H10.10.20.30.40.50.695% Confidence Intervals for SigmasImprovedPrevious456.0456.5457.0457.5458.0458.5Boxplots of Raw DataF-TestTest S

24、tatistic: 7.128P-Value : 0.000Levenes TestTest Statistic: 20.903P-Value : 0.000Factor LevelsPreviousImprovedTest for Equal VariancesTest for Equal VariancesTest for Equal VariancesLevel1 PreviousLevel2 ImprovedConfLvl 95.0000Bonferroni confidence intervals for standard deviations Lower Sigma Upper N

25、 Factor Levels0.323156 0.418660 0.588867 30 Previous0.121037 0.156808 0.220558 30 ImprovedF-Test (normal distribution)F-Test (normal distribution)Test Statistic: 7.128P-Value : 0.000 Levenes Test (any continuous distribution)Test Statistic: 20.903P-Value : 0.000 Shanghai YFJC Guangzhou Branch178Caus

26、e validation and improve action for X4Analyze ImproveX4:前靠骨架开档尺寸偏小前靠骨架开档尺寸偏小 假设检验假设检验2用于验证是否尺寸用于验证是否尺寸A改进后，改进后，同步率随之得到改进同步率随之得到改进H0: The synchronization rate was the same with the different dimension AH1: The synchronization rate was NOT the same with the different dimension A假设检验假设检验1用于验证是否包装改进后，尺用

27、于验证是否包装改进后，尺寸寸A随之得到改进随之得到改进H0: The dimension A was the same with the different packagingH1: The dimension A was NOT the same with the different packagingTwo-sample T for Previous vs Improved N Mean StDev SE MeanPrevious 30 456.730 0.419 0.076Improved 30 458.199 0.157 0.029Difference = mu Previous -

28、mu ImprovedEstimate for difference: -1.469095% CI for difference: (-1.6345, -1.3035)T-Test of difference = 0.05 (vs not =): T-Value = -18.61 P-Value = 0.000 DF = 36Test and CI for Two ProportionsSample X N Sample p1 10 30 0.3333332 16 30 0.533333Estimate for p(1) - p(2): -0.295% CI for p(1) - p(2):

29、(-0.445612, 0.0456117)Test for p(1) - p(2) = 0.05 (vs not = 0.05): Z = -1.99 P-Value = 0.046 Both P0.05, accept both H1这是影响同步的真这是影响同步的真正原因之一！正原因之一！ Shanghai YFJC Guangzhou Branch189Cause validation and improve action for X5Analyze ImproveX5:高度调节器铆接间隙过大高度调节器铆接间隙过大-仅针对驾驶座改进原因改进原因1和原因和原因5之后，同步率已得到一定提升（

30、详见下表），但驾驶座的同步率仍之后，同步率已得到一定提升（详见下表），但驾驶座的同步率仍远远低于乘客座，分析原因为高度调节器的铆接间隙过大，实施假设检验以验证远远低于乘客座，分析原因为高度调节器的铆接间隙过大，实施假设检验以验证:DriverPassenger31%30%72%93%92%Original Synchronization RateImproved Synchronization Rate-X1,X5Improved Synchronization Rate-X1,X5,X6铆接间隙过大仅驾驶座滑道有高度调节器Previous criterionRevised criterionAxial clearance0.1mm0.0mmRadial clearance0.3mm0.1mmTest and CI for Two ProportionsSample X N Sample p1 36 50 0.7200002 46 50 0.920000Estimate for p(1) - p(2): -0.295% CI for p(1) - p(2): (-0.3454