6西格玛绿带培训教材(PPT 217页).ppt

1、1,版本: 1.00 日期: May 2003,6西格玛绿带培训教材 ONE,2,DAY1 第一天(定义阶段): - 6西格玛及精简优化与COQ(質量成本）的关系 COQ的脑力风暴 - First Pass Yield Exercise II初始直通率的練習 IPO（輸入輸出流程）and flow diagram（IPO和流程圖） Flow analysis of dropping cards onto target Repeating the exercise重復練習 Results and discussions結論和檢討 - 西格玛培训中的某些质量改进工具 脑力风暴技术 第一天結束 wr

2、ap up 通過以上的教學引導學員對品質成本的認識運用六西格瑪就是有效的降低品質成本,課程安排,3,DAY2 第二天(Variance Reduction降低变差的理解): - The power of Plato chart and the 80/20 rules柏拉圖表的功能和80/20的規則 Construction of a Plato Chart using computer flow diagram and its associated symbols流程圖和其制作符號含義 Two 实例of flow diagram (using a common scenario)兩個流程圖的實

3、例（使用通用的情節） Barriers that hinder 6西格玛implementation阻礙開展執行六西格瑪的因素 -Break- What is FMEA 什么是FMEA Example of FMEA關于FMEA的實例 Group exercise on FMEA of barriers to 6西格玛implementation FMEA presentations關于FMEA的介紹 -Lunch- - Concept of precision and accuracy對准確和准確的理解（Cp和Ca） How does it link to the mean and 标准偏差

4、（如何將平均值和標准偏差聯系起來） Precision and accuracy example (i.e. Selection of fund manager准確和精確的實際例子 Catapult exercise I彈弓拋物發射器的思維練習一 -Break- - Introducing concept of variance reduction (i.e. PF/CE/CNX/FMEA/SOP)介紹降低變差的觀念 Variance reduction 脑力风暴exercise for Catapult用彈弓發射器進行降低變差的腦力風暴練習 Catapult exercise II彈弓拋物發

5、射器思維練習二 Computation of Catapult exercise result after variance reduction評估計算彈弓發射器游戲中的數據來了解降低變差的含義 Discussion of variance contributors討論降低變差的意義 第二天wrap up 在以上學習中通過彈弓發射器游戲的了解在游戲中掌握了解在六西格瑪中(Variance Reduction）降低变差重要性,4,DAY 3 (Measure Phase測量階段): Recap of statistical terminology全新的統計學朮語 Histogram and a

6、normal data對直方圖和常態數據的理解 Construction of histogram對直方圖的解釋 Transformation of data數據的轉換 Calculate Cp, Cpk from non-normal data計算非正態數據的Cp, Cpk -Break- The importance of good measurement正確的測量方法的重要性 Direct 和indirect measurement (i.e. Introduction to scatter diagram) Risk of wrong interpretation錯誤解釋的風險 - U

7、nder and variance concept in measurement system在變異范圍內的測量系統的觀念 - Introduction to Gauge repeatability and reproducibility (GR Project / Candidate Selection,Candidate Selection,To fill in ; Characteristics of 6西格玛candidate Score-sheet 和Summary Leadership Values Score-sheet 6西格玛Candidates Leadership Val

8、ues Summary 6西格玛Candidates,Project Selection,To fill in ; 6西格玛Project Selection Summary Ease of Implementation Assessment ROI Impact Assessment,Candidates must score greater than 2.5 pts for each to qualify,Candidates must score at least 0.9 pts in the in the 6西格玛Project Selection Summary to qualify

9、,6西格玛Project Summary,Matching right project to the right people,31,Phase 2; 6西格玛培训和application of 6西格玛工具s,Collect Baseline Data on Project,yield COQ Cost Cycle Time Inventory level,To fill in ; 6西格玛R0 Project Review Sheet 6西格玛COQ Template 6西格玛Project Progress Report To get all relevant parties appro

10、val signatories,Attend 6西格玛GB/BB Academic 培训,Application of 6西格玛工具to Project(s),PF/CE/CNX/SOPs FMEA MSA PARETO PROBABILITY DISTRIBUTION ANOVA DOE STATISTICAL INTERVAL SPC,Create Certification Template,Follow DMAIC Presentation Summary Rev A , to complete each phase of the project,流程to 6西格玛GB/BB cert

11、ification,32,Phase 3; Certification of Candidate,Complete Closure Technical Report,Presentation of 6西格玛Certification Project(s),Site Assessment of Project(s),Issue Plaque /Certificate Achievement to candidate,Update Candidate LOR Career Profile on 培训和Recognition,Finance to verify project savings Cha

12、mpions 和MBB to assess candidate understanding 和application of 6西格玛工具s Candidate Certification Evaluation Form,流程to 6西格玛GB/BB certification,Finance to verify project savings Champions 和MBB to assess candidate understanding 和application of 6西格玛工具s Candidate Certification Evaluation Form,33,Requirement

13、s for Certification,Completion of 6西格玛培训course Successful project completion (goal achievement 和documentation) Demonstration on the understanding of 6西格玛工具s Effective 和successful completion of steps to “hold the gain” Completion of each project within 1 yr 绿带Certification; completion of 2 projects w

14、ith minimum saving of US$25,000 per project 黑带 Certification; completion of 2 projects with minimum saving of US$100,000 per project,交付ables for Certification,Demonstration of six-sigma though 流程 Completion of 6西格玛R0 Project Review Sheet Completion of 6西格玛 Project Progress Report Completion of 6西格玛C

15、OQ Template Completion of DMAIC Presentation Summary Completion of Closure Technical Report,34,Certification 结构,Candidate Certification Board Site Leader Champions Master 黑带 Certification Board Review 流程 Candidate to distribute the Closure Report Summary to the board at least one week before the rev

16、iew date (may be waived at the discretion of the site leader) MBB to act as the chair of the board Candidate to present project details using using thought 流程map with emphasis on how each 工具was applied Questions, clarifications 和review by the board,35,Certification 结构(cont),Board members to rate can

17、didate using Certification Evaluation Form Pass if ; Candidate Technical Assessment is greater than 20 pts for Greenbelt 和greater than 40 pts for Blackbelt 流程Variation 和Measurable Results Evaluation is at least 4 pts for each category Inform candidate of the outcome,36,Sample Forms,Characteristics o

18、f 6西格玛Candidates,Leadership Values Score-sheet,37,Sample Forms; Leadership Values Summary,38,Sample Form; Closure Technical Report,39,Sample Form; Candidate Certification Evaluation Form,40,Definition of a 流程 A 流程is an activity which utilize inputs from external source 和transform them into desired o

19、utput(s).,Example: Manufacturing 流程es (i.e. wire bonding, injection molding, glass sawing) Financial 流程es (i.e. double book keeping, 产品costing) HR 流程es (i.e. recruiting, ranking 和appraisal, 培训) Daily activity (i.e. parking a car, buying lunch, brushing your teeth),41,IPO (Input-流程-Output) Diagram,Pe

20、ople Material Equipment Policies Procedures Methods Environment,Performa service Producea 产品 Completea task,utilizing external INPUTS to achieve the desired OUTPUT(S),A visual representation of a 流程which lists input variables 和output characteristics,42,What is the purpose of IPO,A high level interpr

21、etation of a 流程, which enable ease of understanding, through outlining the 关系hips between input variables 和output response(s).,43,What is a distribution ?,It is a pattern form by the collection of data, grouping the outcome horizontally (x-axis), 和indicates the observed frequency of the outcome vert

22、ically (y-axis). In statistic, this generate a theoretical pattern whereby information of entire population can be obtained from observing limited samples.,44,Characteristic of a normal distribution It has a single peak 和a bell shape curve It is a distribution for continuous data - The mean (average

23、) is is at the center of the curve The variance describe the spreading of data,45,为什么is distribution important to a 流程 The output of a 流程can most of the time associates with a statistical distribution, giving opportunity for engineer to analyze the data statistically, hence arriving conclusion with

24、a statistical confidence 和at a lower cost.,46,流程Capability Study,流程capability potential, Cp Based on the assumptions that :,Cp= 流程capability potential Cpk= 流程capability index It is a measurement of the capability of a 流程, by indexing the 流程natural tolerance with respect to the device specification (

25、i.e. customer tolerance),流程is normal,It is a 2-sided specification,流程mean is centered to the device specification,Spread in specification,Natural tolerance,47,流程Capability Index, Cpk,1. Based on the assumption that the 流程is normal 2. An index that compare the 流程center with specification center,There

26、fore when , Cpk Cp ; then 流程is not centered,Cpk = Cp ; then 流程is centered,48,Arbitrary sample data of starch content (gram) in 1gram anti-biotic pill,What is the mean starch content ? What is the variance ? What is the 标准偏差 ? What is the 流程capability potential, Cp ? What is the 流程capability index, C

27、pk ? What can you do to improve the 流程? The above activity is a sigma 流程.,What can you conclude from the below 流程?,49,关系hip between 流程Capability 和DPPM,50,First Pass Yield Exercise I,Break into team of 9 persons. Each team consist of 1 供应商, 1 supervisor, 3 operators, 3 inspectors 和1 customer. The obj

28、ective is to 交付20 complete 产品 to the customer The task of 供应商is to supply card (i.e. raw material) to the first operator. The task of the operator is to drop the card with edge facing down onto the target area, 和count the number of drop throughout the exercise. The task of the inspector is to verify

29、 that the card has drop within the target area If card fall within the target: Pass the card to the next operator (or to the customer for the last inspector) Record down the number of good units that are passed to the next 流程 If card does not fall within the target: Pick up the card 和h和it back to th

30、e operator The task of the customer is to receive the 20 cards, 和record the time required (i.e. lead time) At the end of the exercise, the 供应商will count the number of raw material issue to the 流程,51,Computation of 产品cost,52,What is Cost of 质量 (COQ),It is the total cost incur from the result of poor

31、质量 of materials, 产品, 流程es, 和the cost of not doing things right at the first time.,What are 某些of the COQ that you can see at your site ?,Scrap, Rework, Cycle Time Warranty, Liability, Service Audits, Inspections, Evaluations 培训without ROI, Consultation Lost of sales, Lost of market share,53,How does

32、6 Sigma 和Lean related to COQ ? 2 ways the entire business 流程can be improved 和reduce COQ :,To lean up the 流程chain 和reduce chances for error,To improve the sigma capability of the 流程,54,What are the overall yield for your 流程?,Going back to the dropping cards exercise,How can we reduce the 产品cost ? Wha

33、t is the main problem that associate to the cost factor ? Knowing the problem, what is the root cause to the problem ? Can changing the way we do thing help to improve the situation ?,55,First Pass Yield Exercise II,Break into team of 9 persons. Each team consist of 1 供应商, 1 supervisor, 3 operators,

34、 3 inspectors 和1 customer. The objective is to 交付20 complete 产品 to the customer The task of 供应商is to supply card (i.e. raw material) to the first operator. The task of the operator is to drop the card with the surface facing down onto the target area, 和count the number of drop throughout the exercis

35、e. The task of the inspector is to verify that the card has drop within the target area If card fall within the target: Pass the card to the next operator (or to the customer for the last inspector) Record down the number of good units that are passed to the next 流程 If card does not fall within the

36、target: Pick up the card 和h和it back to the operator The task of the customer is to receive the 20 cards, 和record the time required (i.e. lead time) At the end of the exercise, the 供应商will count the number of raw material issue to the 流程,56,What is the 产品cost after the change of 流程method,57,某些质量改进工具i

37、n 6西格玛培训,Pareto Chart Graphical representation that describe categories in descending occurrence order 80% of a problem is contributed by 20% of the categories Separate the important few factors from the many trivial factors Extensively use to define areas to focus on for detail analysis,58,59,60,脑力

38、风暴,It is the generation of ideas in a group situation, based on the principle of suspending judgement. A principle which is highly 产品ive in both individual or group effort,Effective 脑力风暴,Well defined 和clearly stated problem Assign a recorder to write down all the ideas as they occur Maintain managea

39、ble group size (i.e 5 to 8 persons) Enforce following guide lines: Suspend judgement Every idea is accepted 和recorded Encourage people to build on the ideas of others Encourage wild or odd ideas,61,某些脑力风暴Practices,62,63,为什么do I use it? To focus our efforts on the problems that offer the greatest pot

40、ential for 改进,What is it? A bar chart for non-numerical categories that displays attribute data from highest to lowest frequency (based on “Pareto Principle” which states that 80% of the effects are due to 20% of the causes),What does it do? Identifies the causes that will have the greatest impact o

41、n solving the problem,Introduction to Pareto Chart,64,Example of Pareto Chart,65,66,Pareto Analysis,67,68,69,70,71,72,73,流程Flow Diagram - Making my cup of coffee,74,流程Flow Example I,75,流程Flow Example II,76,Exercise -: Putting them togetherDevelop 流程flow for your project,Construct a 流程flow chart for

42、your projects Mark ( *) next to the 流程or step which is value added 和产品ive Identify the number of decision box Indicate the time require in every step including transport Construct a table to summary the number of 产品ive 和non 产品ive 流程 , decision 和flow Present you Flow chart 和propose changes,77,FMEA (

43、Failure Mode Effect Analysis ),FMEA , is a attempt to identify possible failure modes 和effects or consequences that failure modes may have on performance ,提供a mean of prevention FMEA 提供s an excellent basis for classification of characteristics It is a fundamental 工具in creating a reliability system D

44、o you have an FMEA in Your 流程? When you have a Failure do you know what causes it ?,How does FMEA help in Daily work,Improves the 质量, reliability, 和safety of 产品 Increases customer satisfaction Reduces 产品development timing 和cost Documents 和tracks actions taken to reduce risk,78,Types of FMEA,System F

45、MEA: Used to analyze systems 和subsystems in the early concept 和设计stages. Focuses on potential failure modes associated with the functions of a system caused by design. 设计FMEA: Used to analyze 产品 before they are released to 产品ion. 流程FMEA: Used to analyze manufacturing 和assembly 流程es. Defect FMEA : Us

46、ed to analyze 和prioritize 缺陷to prevent reoccurrence (in 产品 和流程es),$305,000 Increased Annual Revenue 3220 Minutes Less Maintenance Downtime/ Machine/Month 452,000 More Piece Increased Annual 产品ion 28 Less Maintenance Calls/Machine/Month 15 Less Sensor Failures Per Year $7,200 Annual Reduction in Main

47、tenance 和Replacement Costs (Source from GE , Motorola ,Bombardier , ABB ,IBM Allied Signal),FMEA Benefits 实例From 6西格玛Company,79,FMEA : 流程/ 产品FMEA,80,Severity Severity is an assessment of the seriousness of effect Severity is applies to the effect only The following is the evaluation Criteria,81,Occu

48、rrence This means how Frequently the failure mode is projected to occur as a result of a specific cause It can be thought of as the probability of occurrence of the failure mode Use a scale of 1(very low) to 5( very high) Frequency,82,Detection ( DET ) Assume the failure has occurred; then asses the

49、 probability that the current control will detect the failure mode before the 产品 is shipped out Use a scale of 1(very low) to 5( Nil) Detection,83,Possible Controls item :,Fixture fool- proofing SPC inspection Testing gauge R for statistical dependence event,= 0.3 / 0.4 = 0.75,165,Solving the proble

50、m with a table What is the probability that a drawn box is striped, given that the box is red ?,Symbolically = P(Striped | Red),What is the probability that the drawn box is red ?,What is the probability of drawing a red striped box ?,What is the conditional probability of the drawn box to be stripe

51、d when drawn red ?,= P(Striped 和Red) / P(Red) = 0.4 / 0.6 = 0.667,166,“Joint probabilities under statistical dependence”,We know that the formula for conditional probability under statistical dependence is : P(A|B) = P(A 和B) / P(B),If we shift P(A 和B) to the left 和P(A|B) to the right, we will have:

52、P(A 和B) = P(A|B) x P(B),167,With reference to the scenario of 10 boxes in a bag, what is the probability to draw a green dotted box ? P(Dotted 和Green) = P(Dotted|Green) x P(Green) = 0.75 x 0.4 = 0.3,168,Posterior Probability (Bayes Theorem),Posterior probability defines that certain probabilities we

53、re altered after the people involved obtained additional information. This new probabilities are known as revised, or posterior probabilities.,A Chef has formulated a new chicken recipe 和based on his experience with formulating a steak recipe, the probability of selling a recipe well is to increase

54、the amount of garlic powder in the ingredients. However, after introducing the new recipe for one week, he found that the new chicken recipe does not sell as well as the old one, he must therefore revise his prior probabilities 和use other ingredients in the recipe.,Calculating posterior probabilitie

55、s Assuming that we have equal numbers of 2 types of “biased” dice in a bowl. One type of the biased die will roll out a value of Five 40% of the time, 和the other type will roll out the value Five, 70% of the time. If one dice is drawn 和roll to the value Five, what is the probability that it is a typ

56、e 1 dice ?,169,Type 1 Type 2,0.4 0.7,Calculating posterior probabilities (Cont),To find the probability that the dice we have drawn is type 1, we should adopt the formula for conditional probability under statistical dependence: P(B | A) = P(BA) / P(A),P(Type 1 | Five) = P(Type 1, Five) / P(Five) =

57、0.20 / 0.55 = 0.364,Therefore the probability of drawing a type 1 dice is 0.364,170,Calculating posterior probabilities (Cont),As such, what is the probability of drawing a type 1 dice before the dice was rolled ? 0.5,What is the revised probability of drawing a type 1 dice after the dice was rolled

58、 和having a value of Five ? 0.364,If we are to roll the same dice again 和achieve a value of Five, what is the probability that it is a type 1 dice ?,P(Type 1 | 2 Fives) = P(Type 1, 2 Fives) / P(2 Fives),Type 1 Type 2,0.4 x 0.4 = 0.16 0.7 x 0.7 = 0.49,= (0.08 / 0.325),= 0.246,171,Further example of posterior probabilities更多的實際例子,Kenneth is a manager of a automation 设计company 和has previously 8 engineering staffs reporting to him. Based on his assessments on the 8 engineers, he is only satisfied with the performance of 6 of his engineers. He further concluded from past