SPC进阶培训ppt课件

1、SPC进阶培训课程一Module 1课程二 : 内容Module 2 : Agenda统计技术重温 Statistics Review新统计技术概念New Statistical Concept直方图 Histograms正态分布 Normal Distributions控制限及规格限 Control Limits and Specification Limits流程才干 Process Capability流程稳定及才干 Process Stability and Capability统计技术重温Statistics Review中心趋向 - 平均 Central tendency - Av

2、erage典形数值的位置 The location of the typical value流程设定 Process setting平均值Average统计技术重温Statistics Review分布Spread极差，规范差Range, standard deviation (sigma)数据相距多远，数据的变量程度How spread apart are the data; the amount of variation in the data极差Range_统计技术重温Statistics Review新统计技术概念New Statistical Concept数据的分布Distribu

3、tion of the data某一数值出现多少次 how often certain data values occur数值在分布上的集中程度 the concentration of data values across the spread数据分布的外形 the shape of the datavery shortmediumtallvery tall short练习 - 孔径Exercise - Hole Diameters大量数据!A bunch of data!60个孔径数值,每行十个量度数值,按次序陈列60 hole diameters - 10 measurements pe

4、r column, listed in sequence直方图Histogram181614121086420孔径 Hole Diameters直方图 - 钟状曲线Histogram - Bell-Shaped Curve小样本数Small Sample Size较大样本数Slightly Larger Sample Size多加数据会将图形变成钟状Adding more data to the sample rounds out the shape like a bell!大样本数Large Size整体The Whole Population正态分布Normal Distribution钟

5、状曲线=正态分布 Bell curve = normal distribution用于 Use it to:预测 predict.计算事情发生的能够性(概率) calculate probabilities of things happening.如何制造? How?将钟状曲线分开为不同部分,如切饼. By dividing the bell curve into parts - like slicing a pie!正态分布Normal Distribution一切钟状图可分作六份. All bell-shaped pies have 6 slices.各份有多大? How big are

6、the slices?每一份都是一样准差宽! Each slice is one standard deviation wide!6规范差 = 整份的99.7%. Thats 6 standard deviations = 99.7% of the pie.两边各有小“尾巴 = 0.3% We left a few crumbs at each edge = .3%.其中: = 3.14159 e = 2.71828概率密度函数：那一部分最大?Which are the biggest slices?+1s+2s+3s-1s-2s-3s02.2%2.2%.2%.2%13.6%13.6%34.2

7、%34.2%68.3%95.4%99.7%正态分布Normal Distribution运用规范差决议控制上限及下限,如钟状曲线.To determine UCL & LCL, use standard deviation (s) - just like the bell curve!UCL = Average + 3sAverageLCL = Average - 3s+3s-3s-3s+3s如何将这些运用在控制图?How does this relate to control charts?设定控制限Setting Control Limits将钟状曲线转90度Flip the bell c

8、urve on its sideAverage-3s+3s-2s+2s-1s+1sLCLUCL-3s+3s-2s+2s-1s+1sLCLUCLAverage-3s+3s-2s+2s-1s+1sLCLUCLAverage设定控制限Setting Control Limits这是什么意思?What does it all mean?UCL=Average +3sLCL=Average - 3s-3s+3s-2s+2s-1s+1sAverageLCLUCL控制限 - 控制上,下限Control Limits - UCL, LCL假设流程遭到控制:If your process is in contr

9、ol:99.7%的数据将会在控制上限及下限之间. 99.7 % of the data points will be between the UCL and LCL.数据没有特定的图样,随机的. Data points will show no pattern = random.大部分数据会趋向平均值. Most data points will be close to the average.数据应有一半在平均值以上及一半在以下. Data points be 50/50 above and below average.规范差如何影响控制上限及下限How Standard Deviation

10、 Affects UCL & LCL将图1至图4与正确的规范差连线那一个规范差会在控制图上定出最宽的控制限规格限Specification Limits客户,供应商或内部工程要求Customer, supplier or internal engineering requirements包括 :Include :目的或中间值(最理想的) target or nominal value (the ideal!)在目的值两旁可接受的变异 allowable variation on either side of the target value规格上限 = 目的值 + 可接爱的变异USL = ta

11、rget + allowable variation规格下限 = 目的值 - 可接受的变异LSL = target - allowable variation例子- 酸浓度Example - Acid Concentration规格是130克/升+/-30克升Specification is 130 grams/liter +/- 30 grams/liter规格上限=目的值+可接受的变量USL = target + allowable variation130 + 30 = 160规格下限=目的值-可接受的变异LSL = target - allowable variation130 - 3

12、0 = 100可接受变异的总值=规格上限=规格下限Total allowable variation = USL - LSL160 - 100 = 60我们可以量度才干吗?Can We Measure Capability?USLLSL目的Target可接受的变异Allowable Variation以下图=规格Picture below = specifications正态分布(钟状曲线)=流程Normal distribution (bell curve) = process实践变异Actual Variation流程中心点Process CenterCp 必需大于1Cp Should B

13、e Greater Than 1显示实践变异少于可接受变异Indicates actual variation is less than allowable variation.LSLUSLLSLUSLLSLUSLCp大于1Cp greater than 1Cp = 1Cp少于1Cp less than 1Cp - 量度流程分布Cp - Measures Process Spread比较可接受变异(T)及实践变异(A)Compare allowable variation (T) to actual variation (A).T = USL LSL：给定的技术要求 T ( 公差)A = 6

14、：工序本身实践存在的才干( 质量程度) 6 Cp = T/ 6 LSLUSLATCp - 总结Cp - Conclusions数值越大越好! The bigger the number, the better!Cp的缺陷-只能显示流程分布,但不能显示能否符合规格 Deficiency of Cp - It shows only the spread of process, but not the compliance to specification.例子：两流程的Cp一样。 Example: Two processes with same Cp.USLLSLTargetUSLLSLTarge

15、tCa 准确度 Capability of accuracy想一想: 假设T 的中心( 公差中心 ), 与6 之中心不重合時, CP会是一种怎样的值, 不重合时CP如何思索呢?-Cp值是不会发生变化的？Why？偏移量 =X-如何去表征这种情况呢？Cpk - 量度流程才干Cpk - Measures Process Capability比较流程中间值设定及目的. Compares setting of process center (average) to target.Cpk = min(USL-X, X-LSL) 3USLLSL目的Target流程中间值Process Center偏离中间值

16、Off Center!CpkCpk良好Good CpkCpk差Poor CpkLSLUSLLSLUSL根本定律: Cpk要求最少1.33General rule - aim for Cpk of 1.33 minimum流程才干缺乏的两种情况Two Ways a Process Is NOT Capable1.实践流程变异(A : 6 )超出右接受变异的总值(B :规格)Actual process variation (A : six sigma) exceeds total allowable variation (B : spec)TargetBALSLUSL产品不符合规格Product

17、s out of spec产品不符合规格Products out of spec流程才干缺乏的两种情况Two Ways a Process Is NOT Capable2.如流程表现缺乏处于规格的中间位置,并其中一边的控制限超越规格限.If process is not centered properly and one of the control limits exceeds the spec limit.LSLUSLLCLUCLTargetAverage产品不能符合规格Products out of spec!产品不是最正确Products not the best.假设流程才干缺乏如何

18、办?What if a process isnt capable?流程需求改善The process needs improvement!首先,采取改善行动,减少变异,然后,按目的值将流程表现调至中间值.First, take action to reduce the variation. Then, center the process over the target.表现不良Bad news!表现改善Getting better进一步改善Much betterUSLLSLTargetUSLLSLTargetUSLLSLTarget他需求做什么?What should you do?USLL

19、SLCp 2 and Cpk 1.0采取预防行动去除不合格产品 Take precautions to remove non-conforming products 继续努力减少变异Continue efforts to minimize variation将流程表现控制到中间值Center the process维持流程于控制限内 Maintain process within control limits 继续努力减少变异Continue efforts to minimize variation将流程表现控制到中间值 Center the processUSLLSLCp 1.0他需求做什

20、么?What should you do?USLLSLCp 1.33维持流程于控制限内 Maintain process within control limits 继续努力减少变异Continue efforts to minimize variation采取预防行动消除不合格产品 Take precautions to remove non-conforming products将流程表现控制到中间值Center the processUSLLSLCp 2 and Cpk 2 and Cpk 1维持流程于控制限内 Maintain process within control limits

21、将流程表现控制到中间值Center the process维持流程于控制限内Maintain process within control limits USLLSLCp 2 and Cpk 1.5稳定的流程Stable Process一致的 Consistent可预测的 Predictable没有特别缘由 No special causes受控的 In control有才干的流程Capable Process继续的满足规格要求 Continually meet specifications.流程稳定及才干Process Stability & Capability流程可以是受控,但不符合规格

22、的.A process could be in control, but not meet specifications.重温- 稳定及才干Recap - Stability & Capability机師APilot A机師BPilot B跑道Landing runway跑道Landing runwayBeing inspec is notsufficient!只符合规格是缺乏够的！机師APilot A机師BPilot B跑道Landing runway跑道Landing runwayBeing in control is also not sufficient!只是受控也是缺乏够的！重温-

23、稳定及才干Recap - Stability & Capability重温 - 稳定及才干Recap - Stability & Capability流程稳定process stability+ 流程才干+ process capability+ 继续改善+ continual improvement_优越表现performance excellence受控形状In Control符合规格Meets specsCPK与精益6 程度关系衡量过程才干大小两种方式：1.CPK2.精益6 程度阴影部分即为不合格率:P = PL + PU = P( X TU )精益6 程度Z值，半个公差范围内含有的个数

24、无偏移。假设加工中心有偏移，Z值该如何计算？两种方式来衡量过程才干!两种表达方式共同点是什么？CPK与精益6 程度关系CPK与精益6 程度关系良率计算为99.98%CPK-minitab运用实例 进展CPK分析前，首先检测数据能否符合正态分布。假设是非正态数据，计算CPK时需将数据进展正态转换。采用正态分布计算的CPK为2.37，PPK为1.15CPK-minitab运用实例采用组间/组内才干分布计算的CPK为1.21，PPK为1.15CPK-minitab运用实例为何这两种计算方法存在差别？究竟那一种最合理？1484 14841484为何我们手动算的规范差与Minitab运算的不一样？课程三

25、Module3课程3: 内容Module 2 : Agenda制造控制图 Control Chart Preparation制造反响方案 Reaction Plans Preparation处理问题 Troubleshooting SPC稽核消费中运用SPCUsing SPC During Production1.搜集数据Collect data3. 了解数据 Interpret the data2. 在图上记录数据 Record data on chart4. 特别成因?SpecialCause?6. 采取纠正行动 Take corrective action5. 继续执行流程 Contin

26、ue torun the process是Yes否No7. 预备文件 DocumentSPC数据搜集记录Collection of SPC data由SPC联络员按照要求搜集并记录数据由SPC稽核员将数据录入SPC系统，对SPC图进展断定。假设断定失控，需实施纠正行动，那么发出失控反响方案。SPC联络员填写并在控制图上描点，假设有控制点或趋势图样满足判异条件时，应在2小时内反响工序主任及技术PE。反响方案 - 偏向报告Reaction Plan Discrepancy Report PE安排对失控点做初步分析和缘由排查,确定能否为特殊缘由导致SPC失控，PE需在12小时以内在上填写失效反响方案

27、，并对制定的改善措施及时落实。 SPC管理工程师对SPC实施情况进展跟进，跟进SPC纠正措施的效果验证。控制图格式Control Chart FormatPE安排对失控点做初步分析和缘由排查什么是处理问题?What is Troubleshooting?找出问题的根本缘由并采取纠正行动Looking for the root cause of a problem and taking corrective action.处理问题步骤:Troubleshooting process:特别成因? Special cause?作反响!按反响方案采取纠正行动. React! Follow reaction plan for corrective action.再次量度. Take another measurement.记录于反响方案及控制图. Document on reaction plan and control chart.处理问题指引Troubleshooting Guidelines每张控制图都要有反响方案 Each control chart has reaction