AC焊接不良下降(ppt 30).ppt

1、,Division : YOOWON 品质部 G/B Name : - 王剑,A/C 焊接不良下降,通过确保最佳条件达成目标, 焊接不良率高 修理数多，生产性低下 焊接不良高 资材浪费多，生产成本上升,公司竞争力下降 焊接不良高现场5S不良，品质不良易发生,PROJECT促进背景,现在的问题,VOB, 顾客不良多,影响公司形象,造成销售数下降,公司利润下降 焊接不良高生产性低下,作业者加班多,作业者疲劳度增加,缺勤率上,I,C,A,M,D, 蒸发器、冷凝器是通过焊条把铜管、U型管、铜配管焊接而成组成的回路，在 焊接过程中，因各种因素，会产生焊漏，从而造成组装空调时制冷剂外泄，空 调不能正常工作

2、,Define, 社外品质不良多，对公司的产品产生不信任 社外品质不良多 顾客CLAIM,Problem Statement:,Voice Of Customer,PROJECT对象选定,测定时间:2004.1月-11月,工程不良中焊接不良所占比例 最大,选定焊接不良进行改善,Mission Statement,Baseline,SAVING,GOAL,COPQ,焊 接 不良率,10894 ppm,4894ppm减少,6000 ppm,万元/年,5.90万元利润增加,万元/年,水准,3.8,向上0.2,4.0, COPQ改善金额 - 以树立好的改善计划为基础，节减计划定为减少万元， 改善前 C

3、OPQ = ( 5,500* 746,886台) * 元 / 1,000,000 = 元/年 改善目标 COPQ = (1000 * 746,886台) * 元 / 1,000,000 = 元/年 改善结束日 - 2005年 2月 05日止促进结束,I,C,A,M,D,Project Team,金来洙 副总,生产:金在中,技术:卢宝国,品质:王剑,张文龙 经理,Project Schedule,Plan,Doing,DEFINE,MEASURE,ANALYZE,IMPROVE,CONTROL,04.12.01,12.21,01.05,01.20,02.05,I,C,A,M,D,Measure,

4、Project .Y.的定义,选定改善LINE：,生产制品：,检测系统分析(计数型),对象测定工具：水压检漏,计数型Gage R&R,检测日期：,姓名：,产品：,2004.12.17,李洪波,热交换器,结论：检查者及测试仪器间有95%的信赖性，本系统适用,Process Capability,数据收集期间:,现在工程能力: 3.65 Sigma,详细Process Map(PFD),input,output,Base Cu-pipe.al-foil. plate Assy in.assy out U-bend. 焊条.Lpg.O2. 水压检漏. Packing case,原材料 1次半成品 2

5、次半成品 3次半成品 完成品,START,BASE投入,铜管.铝箔投入,热交换器投入组立,自动,手动 焊接,校正及包装,泄漏检查,外观检查,出厂,返修,VA,VA,VA,VA,NVA,NVA,VA,Analyze,I,C,M,D,A,Cause & Effect Diagram,焊接泄漏,人,设备,材料,方法,新员工,焊枪,焊嘴,技能不好,责任心不强,焊接气体,焊接部品,焊条,焊条太细,焊接顺序,火焰性质,焊接时间,PALLET,流水线,焊接姿势,堵,大,培训不足,气体不纯,焊棒不纯,流动性不好,速度快,速度慢,文化低,太重,手感不好,小,太长,未预热,火焰大小,太长,太短,有氧化物,间隙大,

6、I,C,M,D,A,未自检,未培训,未按标准,压力低,太短,还原焰,作业量,作业量多,反应慢,有油,预热时间长,疲劳,轻,左式,右式,氧化焰,熔点高,插入深度,太深,太浅,静止,运动,F.D.M(Function Deployment Matrix),I,C,M,D,A,I,C,M,D,A,Analyze Phase,I,C,M,D,A,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu

7、 T/T=17 Estimate for difference: -72.3 95% CI for difference: (-111.9, -32.6) T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,TEST #1 : 确认流水线速度对焊接泄漏的影响度, P - Value 0.05 归属假设(Ho) 放弃 , 对立假设(H1) 采取, 结果 : 焊接泄漏受流水线速度快慢的影响 .,Analysis Tool:2-Proportions HO: P T/T=20= P T/T=17 流

8、水线速度对焊接泄漏无影响 H1 : P T/T=20 P T/T=17 流水线速度对焊接泄漏有影响,Test and 流水线速度 for Two Proportions Sample X N Sample p T/T=20 5 3000 0.001667 T/T=17 18 3000 0.006000 Estimate for p(1) - p(2): -0.00433333 95% CI for p(1) - p(2): (-0.00745862, -0.00120805) Test for p(1) - p(2) = 0 (vs not = 0): Z = -2.72 P-Value =

9、0.007,I,C,M,D,A,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference: (-111.9, -32.6) T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16

10、,TEST #2 : 确认配管间隙对焊接泄漏的影响度, P - Value 0.05 归属假设(Ho) 放弃 , 对立假设(H1) 采取, 结果 : 焊接泄漏受配管间隙的影响 .,Analysis Tool:Chi-Square Test HO: P 间隙0.2 = 间隙0.3 = 间隙0.4 配管间隙对焊接泄漏无影响 H1 : P间隙0.2 间隙0.3 间隙0.4 配管间隙对焊接泄漏有影响,Chi-Square Test: 间隙0.5, 间隙0.6, 间隙0.7 Expected counts are printed below observed counts 间隙0.2 间隙0.3 间隙0

11、.4 Total 不良品 3 12 15 30 10.00 10.00 10.00 良品 1797 1788 1785 5370 1790.00 1790.00 1790.00 Total 1800 1800 1800 5400 Chi-Sq = 4.900 + 0.400 + 2.500 + 0.027 + 0.002 + 0.014 = 7.844 DF = 2, P-Value = 0.020,I,C,M,D,A,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10

12、 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference: (-111.9, -32.6) T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,TEST #3 : 确认焊嘴大小对焊接泄漏的影响度, P - Value 0.05 对立假设(H1) 放弃 , 归属假设(Ho) 采取, 结果 : 焊接泄漏不受焊嘴大小的影响 .,Analysis Tool

13、:Chi-Square Test HO: P 焊嘴0.6 = 焊嘴0.4 = 焊嘴0.7 焊嘴大小对焊接泄漏无影响 H1 : P 焊嘴0.6 焊嘴0.4 焊嘴0.7 焊嘴大小对焊接泄漏有影响,Chi-Square Test: 焊嘴0.6, 焊嘴0.4, 焊嘴0.7 Expected counts are printed below observed counts 焊嘴0.6 焊嘴0.4 焊嘴0.7 Total 不良品 6 7 5 18 6.00 6.00 6.00 良品 1794 1793 1795 5382 1794.00 1794.00 1794.00 Total 1800 1800 18

14、00 5400 Chi-Sq = 0.000 + 0.167 + 0.167 + 0.000 + 0.001 + 0.001 = 0.334 DF = 2, P-Value = 0.846,I,C,M,D,A,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference: (-1

15、11.9, -32.6) T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,TEST #4 : 确认部品表面污染对焊接泄漏的影响度, P - Value 0.05 归属假设(Ho) 放弃 , 对立假设(H1) 采取, 结果 : 部品表面污染对焊接泄漏有影响 .,Analysis Tool:2-Proportions HO: P 有污染 = P 无污染 PIPE有无污染对焊接泄漏无影响 H1 : P 有污染 P 无污染 PIPE有无污染对焊接泄漏有影响,Test and PIPE有无污染 fo

16、r Two Proportions Sample X N Sample p 无污染 3 1200 0.002500 有污染 12 1200 0.010000 Estimate for p(1) - p(2): -0.0075 95% CI for p(1) - p(2): (-0.0137988, -0.00120119) Test for p(1) - p(2) = 0 (vs not = 0): Z = -2.33 P-Value = 0.020,I,C,M,D,A,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20

17、10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference: (-111.9, -32.6) T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,TEST #5 : 确认焊条含银量对焊接泄漏的影响度, P - Value 0.05 对立假设(H1) 放弃 , 归属假设(Ho) 采取, 结果 : 焊条

18、含银量对焊接泄漏无影响 .,Analysis Tool:2-Proportions HO: P 3%银焊条 = P 2%银焊条 焊条含银量对焊接泄漏无影响 H1 : P 3%银焊条 P 2%银焊条 焊条含银量对焊接泄漏有影响,Test and 焊条含银量 for Two Proportions Sample X N Sample p 3%银焊条 12 3600 0.003333 2%银焊条 15 3600 0.004167 Estimate for p(1) - p(2): -0.000833333 95% CI for p(1) - p(2): (-0.00365692, 0.0019902

19、6) Test for p(1) - p(2) = 0 (vs not = 0): Z = -0.58 P-Value = 0.563,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference: (-111.9, -32.6) T-Test of difference = 0

20、 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,Analyze阶段开始的重要因子(Vital Few Xs),Improve,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference: (-111.9, -32.6)

21、T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,Non-DOE因子 改善PLAN,1）对策树立,2）改善内容,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference:

22、(-111.9, -32.6) T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,3）危险性评价,4）再现性试验结果,Test Method:流水线速设定后,焊接泄漏是否减少,适用2-Proporition test来验证,HO:改善前焊接泄漏不良 = 改善后焊接泄漏不良 H1:改善前焊接泄漏不良 改善后焊接泄漏不良,Test and CI for Two Proportions Sample X N Sample p 改善前 56 7440 0.007527 改善后 31 9000 0.0

23、03444 Estimate for p(1) - p(2): 0.00408244 95% CI for p(1) - p(2): (0.00177545, 0.00638942) Test for p(1) - p(2) = 0 (vs not = 0): Z = 3.59 P-Value = 0.000,P-Value0.05归属假设(Ho) 放弃 , 对策适用后焊接不良减少,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Diff

24、erence = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference: (-111.9, -32.6) T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,Non-DOE因子 改善PLAN,1）对策树立,2）改善内容,A=0.1mm,A0.1mm,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3

25、11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for difference: -72.3 95% CI for difference: (-111.9, -32.6) T-Test of difference = 0 (vs not =): T-Value = -3.87 P-Value = 0.001 DF = 16,3）危险性评价,4）再现性试验结果,Test Method:配管间隙控制后,焊接泄漏减少,适用2-Proportions来验证,HO:改善前焊接泄漏不良 = 改善后焊接泄漏不良 H1

26、:改善前焊接泄漏不良 改善后焊接泄漏不良,Test and CI for Two Proportions Sample X N Sample p 改善前 123 12000 0.010250 改善后 85 15000 0.005667 Estimate for p(1) - p(2): 0.00458333 95% CI for p(1) - p(2): (0.00241755, 0.00674911) Test for p(1) - p(2) = 0 (vs not = 0): Z = 4.28 P-Value = 0.000,P-Value0.05归属假设(Ho) 放弃 , 对策适用后焊接不良减少,Non-DOE因子 改善PLAN,1）对策树立,2）改善内容,Two-sample T for T/T=20 vs T/T=17 N Mean StDev SE Mean T/T=20 10 395.4 36.3 11 T/T=17 10 467.6 46.7 15 Difference = mu T/T=20 - mu T/T=17 Estimate for differen