sigma入門案例實用教案

1、會計學1sigma入門入門(r mn)案例案例第一頁，共38頁。第1頁/共37頁第二頁，共38頁。 噪音(zoyn)不良為止到2004年3月CAR的故障類中占 WORST-1， 非故障類的 WORST-2。但噪音(zoyn)測試中頻繁發(fā)生不良， CPK只有0.46 ；Sigma Level 2.5Sigma 。（1M3M噪音(zoyn)測試DB數(shù) ； SPEC:55DB)Problem statementsProblem statementsTARGET TARGET 記記述述(jsh)(jsh)Sigma Level達成 4Sigma(含異音(y yn)不良)。454749515355575

2、961LSLUSLProcess Capability Analysis for Noise dBUSLTargetLSLMeanSample NStDev (Within)StDev (Overall)CpCPUCPLCpkCpmPpPPUPPLPpkPPM USLPPM TotalPPM USLPPM TotalPPM USLPPM Total55.0000 *45.000052.66341111.676872.366160.990.461.520.46 *0.700.331.080.33 0.00108108.11108108.11 2.44 81746.81 81749.25 600.

3、26161699.55162299.80Process DataPotential (Within) CapabilityOverall CapabilityObserved PerformanceExp. Within PerformanceExp. Overall PerformanceWithinOverall Project Project 選選定背景定背景 noise&蟶?晚姻?礪PCB荇轍鍶?荇轍?壅荇轍?詎涮?荇轍顎?夼檳Others0.0610.0310.0260.0230.0140.0110.0110.0100.00531.816.113.512.0 7.3 5.7

4、5.7 5.2 2.6 31.8 47.9 61.5 73.4 80.7 86.5 92.2 97.4100.00.00.10.2020406080100DefectCountPercentCum %PercentCountPareto Chart for AS DATA噪音振動占故障類和非故障類的數(shù)據(jù)的31.8%第2頁/共37頁第三頁，共38頁。 S S I I P P O O C C 業(yè)體業(yè)體 NSNWNSNW 部品 SPEC FLOW 操作員 設(shè)備(shbi)&工具 合格合格(hg)(hg)產(chǎn)產(chǎn)品品 不良產(chǎn)品不良產(chǎn)品 物流 營業(yè)(yngy) 代理商 消費者 ProjectProj

5、ectScopeScope部品入庫部品入庫部品檢查部品檢查部分資材預裝部分資材預裝部品投入部品投入TUBTUB底部組立底部組立返品返品& &邀請對策邀請對策完成包裝完成包裝工程檢查工程檢查部品進廠部品進廠入庫入庫FRAMEFRAME等組立等組立YNN修理修理Y SIPOC SIPOC 第3頁/共37頁第四頁，共38頁。Black BeltBlack BeltCHAMPIONCHAMPIONMBBMBB 總經(jīng)總經(jīng)理理 A W/M OQCB W/M TECHC W/M IQC Process Mapping Noise Test SPC System 整機噪音 研討及驗證 Proc

6、ess Mapping 單品噪音 研討及驗證 SPC System 業(yè)體訪問 及指導EW/M OQC 改善方案 研討及驗證 SPC SystemDW/M R&D單品噪音 研討及驗證 業(yè)體訪問 及指導支援者支援者 KDefine M A PhaseImprove Control 04.04 04.16 04 05 06 07 TEAMTEAM SCHEDULESCHEDULE第4頁/共37頁第五頁，共38頁。PJT PJT 番番號號PJT PJT 名名ChampionChampionPJT TeamPJT TeamBB/MBBBB/MBB指指標項標項目目 水準水準計計財務(wù)財務(wù)成果成果P

7、PJ JT T計計劃劃開開始日始日DefineDefineMeasureMeasureAnalyzeAnalyzeImproveImproveControlControlFinishFinish選題選題背景背景問題記問題記述述AUTO W/M 噪音不良改善GM。PULSATOR W/M NOISE現(xiàn)現(xiàn)水準水準指指標標目目標標水準水準 水準水準指指標標 水準水準2.54.004.0004.04.1004.04.1604.04.3004.05.1504.06.1504.07.1504.07.30-噪音不良2004年3月CAR的故障類的Worst-1，非故障類的Worst-2。 是需要長期改善的頑固

8、不良。- 與TEAM員每周2次推進現(xiàn)況會議，每次會議時間不超過30分鐘。- 業(yè)體 + 廠內(nèi)預裝 + 廠內(nèi)組立。-噪音測試CPK 0.46，Sigma Level 2.5 Sigma （1M3M噪音測試分貝數(shù))。 Sigma Level 達成 4Sigma (含異音不良)。1 12 23 3運營計劃運營計劃目目標記標記述述PJT PJT 范范圍圍 Project Project 實實行行(shxng)(shxng)計劃計劃 第5頁/共37頁第六頁，共38頁。第6頁/共37頁第七頁，共38頁。 BASE LINE & COPQ BASE LINE & COPQ COPQ財務(wù)效果返工

9、費用96K CNY計算方法返工費用= 12個月*每月平均次數(shù) *每回返工平均費用非財務(wù)效果降低市場故障類和非故障類,提高Company BRAND IMAGE.4547495153555759LS LU S LProcess C apability Analysis for auto noiseU S LT argetLS LM eanS am ple NS tD ev (W ithin)S tD ev (O v erall)C pC P UC P LC pkC pmP pP P UP P LP pkP P M U S LP P M T otalP P M U S LP P M T otalP

10、 P M U S LP P M T otal55.0000 *45.000051.6362341.965632.334640.850.571.130.57 *0.710.480.950.48 0.0058823.5358823.53 367.6043511.0443878.64 2238.1574815.8677054.01P rocess D ataP otential (W ithin) C apabilityO v erall C apabilityO bserv ed P erform anceE x p. W ithin P erform anceE x p. O v erall P

11、 erform anceW ith inO verall第7頁/共37頁第八頁，共38頁。 DETAIL PROCESS MAP DETAIL PROCESS MAP INPUTSOUTPUTS CHECK SHEET,作業(yè)(zuy)指導書 箱體 ASSY DAMPER DAMPER涂膠機 LABEL,SCREW, BOLT, SADDLE等附件 外桶及相關(guān)附件 內(nèi)桶及相關(guān)附件 C/P,TOP COVER, LID T.C等 I/W測試儀,功率儀, 接地測試儀,偏心GAGE等 BOX,LABEL,BAG, PP BEND等包裝物 良品洗衣機 體感異常噪音 振動(zhndng)數(shù)據(jù) 噪音測試數(shù)據(jù)

12、START部品運輸?shù)綇SDAMPER GREASE涂布TUB ASSY作業(yè)ASSY FRAME投入輸入檢查NGOK工程檢查OKNGVAVAVAVANVAC/P&T/C&LID T.C組立RETURN包裝入庫NVAVA修理VANVAFRAME PRESS&BENDING&RIVETINGDAMPER ASSY出廠抽檢測dBOKOKNG返機NVANVANVA第8頁/共37頁第九頁，共38頁。 洗衣機洗衣機構(gòu)構(gòu)造造(guzo) (guzo) 第9頁/共37頁第十頁，共38頁。 CE-DIAGRAM CE-DIAGRAM 內(nèi)內(nèi)桶桶BUSH高度BEARING噪音箱體箱體外桶

13、外桶頂頂部部COVER T.CCONTROL PANELLID T.CTOP COVER線束整理異物橡膠變形內(nèi)桶PULSATORFLANGE導水板桶圈尺寸平整度圓度GAP尺寸平整度ASSY后同心度內(nèi)徑尺寸整體高度厚度平面度安裝孔尺寸緊固力線束整理SHAFTMOTORBELT底板OUT TUB張力異物固定孔平面度外桶孔尺寸BEARINGBEND噪音PULLY變形線束夾位置線捆扎處理異物尺寸SHAFT組裝孔PULLY變形SCREW禁固END PLAY氣隙電磁音矽鋼片層疊ROTOR尺寸單品壓入底座平整度尺寸CORNER材料SCREW緊固力FRAME上部折彎高度材料LEG相對BASE松緊度橡膠硬度GR

14、EASE材料均勻度DAMPERSPRING K異物DAMPER 力長度作業(yè)作業(yè)SPECSPECGREASE涂布作業(yè)BELT GAGE使用CASE內(nèi)壁磨擦內(nèi)壁直徑S/A硬度直徑方法GAGE點檢第10頁/共37頁第十一頁，共38頁。 FDMFDM 第11頁/共37頁第十二頁，共38頁。 FMEAFMEA 第12頁/共37頁第十三頁，共38頁。NEXT GB PJT推進DAMPER力關(guān)聯(lián)的分析和改善 M PHASE M PHASE重要重要(zhngyo)XS (zhngyo)XS 第13頁/共37頁第十四頁，共38頁。 A PHASE A PHASE 要分析要分析(fnx) XS LIST(fnx)

15、 XS LIST無GREASE流掛，遺漏，誤適用。1050 2000 g520+0/-1.2 mm無分析后設(shè)定SPEC45 dB70+5/-5 60 62 mmMODEL別BELT張力不一樣第14頁/共37頁第十五頁，共38頁。 DATA DATA 收集收集(shuj) PLAN(shuj) PLAN沒有影響有影響2 Sample T計量型10EA許樺紀錄表沒有影響有影響2 Sample T計量型10EA宣云祥紀錄表沒有影響有影響2 Sample T計量型10EA宣云祥紀錄表沒有影響有影響2 Sample T計量型10EA許樺紀錄表沒有影響有影響2 Sample T計量型10EA宣云祥紀錄表沒

16、有影響有影響2 Sample T計量型10EA許樺紀錄表第15頁/共37頁第十六頁，共38頁。 ANALYSE 1ANALYSE 1 Average: 56.06StDev: 1.20388N: 10Anderson-Darling Normality TestA-Squared: 0.233P-Value: 0.7245455565758.001.01.05.20.50.80.95.99.999Probabilitya1Normal Probability PlotP-Value: 0.411A-Squared: 0.343Anderson-Darling Normality TestN:

17、10StDev: 1.30792Average: 51.4253525150.999.99.95.80.50.20.05.01.001Probabilitya2Normal Probability PlotTwo-Sample T-Test and CI: a1, a2Two-sample T for a1 vs a2 N Mean StDev SE Meana1 10 56.06 1.20 0.38a2 10 51.42 1.31 0.41Difference = mu a1 - mu a2Estimate for difference: 4.64095% CI for difference

18、: (3.454, 5.826)T-Test of difference = 0 (vs not =): T-Value = 8.25 P-Value = 0.000 DF = 17第16頁/共37頁第十七頁，共38頁。 ANALYSE 2ANALYSE 2 P-Value: 0.875A-Squared: 0.186Anderson-Darling Normality TestN: 10StDev: 0.980703Average: 51.7853.252.251.250.2.999.99.95.80.50.20.05.01.001Probabilityb1Normal Probabilit

19、y PlotP-Value: 0.790A-Squared: 0.215Anderson-Darling Normality TestN: 10StDev: 0.583476Average: 56.3457.056.556.055.5.999.99.95.80.50.20.05.01.001Probabilityb2Normal Probability PlotTwo-sample T for b1 vs b2 N Mean StDev SE Meanb1 10 51.780 0.981 0.31b2 10 56.340 0.583 0.18Difference = mu b1 - mu b2

20、Estimate for difference: -4.56095% CI for difference: (-5.334, -3.786)T-Test of difference = 0 (vs not =): T-Value = -12.64 P-Value = 0.000 DF = 14第17頁/共37頁第十八頁，共38頁。 ANALYSE 3ANALYSE 3 P-Value: 0.933A-Squared: 0.155Anderson-Darling Normality TestN: 10StDev: 1.46458Average: 50.9553.452.451.450.449.4

21、48.4.999.99.95.80.50.20.05.01.001Probabilityc1Normal Probability PlotP-Value: 0.591A-Squared: 0.271Anderson-Darling Normality TestN: 10StDev: 0.670323Average: 54.06555453.999.99.95.80.50.20.05.01.001Probabilityc2Normal Probability PlotTwo-Sample T-Test and CI: c1, c2Two-sample T for c1 vs c2 N Mean

22、StDev SE Meanc1 10 50.95 1.46 0.46c2 10 54.060 0.670 0.21Difference = mu c1 - mu c2Estimate for difference: -3.11095% CI for difference: (-4.220, -2.000)T-Test of difference = 0 (vs not =): T-Value = -6.11 P-Value = 0.000 DF = 12第18頁/共37頁第十九頁，共38頁。 ANALYSE 4ANALYSE 4 P-Value: 0.411A-Squared: 0.343An

23、derson-Darling Normality TestN: 10StDev: 1.30792Average: 51.4253525150.999.99.95.80.50.20.05.01.001Probabilityd1Normal Probability PlotP-Value: 0.552A-Squared: 0.284Anderson-Darling Normality TestN: 10StDev: 1.24477Average: 52.855453525150.999.99.95.80.50.20.05.01.001Probabilityd2Normal Probability

24、PlotTwo-sample T for d1 vs d2 N Mean StDev SE Meand1 10 51.42 1.31 0.41d2 10 52.85 1.24 0.39Difference = mu d1 - mu d2Estimate for difference: -1.43095% CI for difference: (-2.635, -0.225)T-Test of difference = 0 (vs not =): T-Value = -2.50 P-Value = 0.023 DF = 17第19頁/共37頁第二十頁，共38頁。 ANALYSE 5ANALYSE

25、 5 P-Value: 0.411A-Squared: 0.343Anderson-Darling Normality TestN: 10StDev: 1.30792Average: 51.4253525150.999.99.95.80.50.20.05.01.001Probabilitye1Normal Probability PlotP-Value: 0.385A-Squared: 0.354Anderson-Darling Normality TestN: 10StDev: 1.53348Average: 52.665453525150.999.99.95.80.50.20.05.01.

26、001Probabilitye2Normal Probability PlotTwo-sample T for e1 vs e2 N Mean StDev SE Meane1 10 51.42 1.31 0.41e2 10 52.66 1.53 0.48Difference = mu e1 - mu e2Estimate for difference: -1.24095% CI for difference: (-2.585, 0.105)T-Test of difference = 0 (vs not =): T-Value = -1.95 P-Value = 0.068 DF = 17第2

27、0頁/共37頁第二十一頁，共38頁。 ANALYSE 6ANALYSE 6 P-Value: 0.411A-Squared: 0.343Anderson-Darling Normality TestN: 10StDev: 1.30792Average: 51.4253525150.999.99.95.80.50.20.05.01.001Probabilityf1Normal Probability PlotP-Value: 0.623A-Squared: 0.261Anderson-Darling Normality TestN: 10StDev: 1.27906Average: 53.345

28、5.554.553.552.551.5.999.99.95.80.50.20.05.01.001Probabilityf2Normal Probability PlotTwo-sample T for f1 vs f2 N Mean StDev SE Meanf1 10 51.42 1.31 0.41f2 10 53.34 1.28 0.40Difference = mu f1 - mu f2Estimate for difference: -1.92095% CI for difference: (-3.141, -0.699)T-Test of difference = 0 (vs not

29、 =): T-Value = -3.32 P-Value = 0.004 DF = 17第21頁/共37頁第二十二頁，共38頁。 ANALYSE ANALYSE SUMMARY SUMMARY 2 Sample T2 Sample T2 Sample T2 Sample T2 Sample T2 Sample T第22頁/共37頁第二十三頁，共38頁。 DOE FACTOR IMPROVE PLANDOE FACTOR IMPROVE PLAN Vital Few XVital Few Xs from Analyze Phases from Analyze Phase Y = f ( X1,

30、X2, X3, X4 ) Y = f ( X1, X2, X3, X4 ) XSFACTOR單位LOWHIGHX1DAMPER力g13501650X2DAMPER長度mm518519X3FRAME左右高度-不一致一致X4BELT張力mm6165X3X1&X2X4第23頁/共37頁第二十四頁，共38頁。 根據(jù)根據(jù)(gnj)DOE PLAN(gnj)DOE PLAN的的測試結(jié)測試結(jié)果果 2 要因配要因配置置(pizh)法法1 次試驗次試驗(shyn)第24頁/共37頁第二十五頁，共38頁。 FACTORIAL PLOTSFACTORIAL PLOTS 65611-1519518545250

31、545250545250damper蒸damper?峪frame瘰橛馱belt?蒸1-151951816501050Interaction Plot (data means) for ?妄50.0548.8549.8649.0949.1647.8949.3648.1054.0152.6953.8853.0553.2252.2153.6252.13belt?蒸frame瘰橛馱damper?峪damper蒸656116501050519518 1-1Cube Plot (data means) for ?妄belt?蒸frame瘰橛馱damper?峪damper蒸6561 1-1519518165

32、010505352515049?妄Main Effects Plot (data means) for ?妄第25頁/共37頁第二十六頁，共38頁。 效果效果(xiogu(xiogu)NORMAL&PARETO PLOTS )NORMAL&PARETO PLOTS 10-1-2-3-410-1E ffe ctNormal ScoreAB C DBDN o rm a l P ro b a b ility P lo t o f th e E ffe cts(re sp on se is ? 妄 , A lp h a = .1 0 )A : d a m p e r蒸B : d a m

33、 p e r? C: fra m e 瘰 D: b e lt? 蒸43210ADBB C DCB DA BA B C DC DB CA C DA B CA B DA DA CP a re to C h a rt o f th e E ffe cts(re sp on se is ? 妄 , A lp h a = .1 0 )A : d a m p e r蒸B : d a m p e r? C: fra m e 瘰 D: b e lt? 蒸第26頁/共37頁第二十七頁，共38頁。 效果效果(xiogu(xiogu)NORMAL&PARETO PLOTS )NORMAL&PARET

34、O PLOTS 403020100d am p er蒸b elt?蒸d am p er?峪P a re to C ha rt o f the S ta nda rdize d E ffe cts(respon se is ?妄 , A lph a = .10)100-10-20-30-40-500.50.0-0.5S ta nda rdize d E ffe ctNormal Scoredam per蒸dam per?belt?蒸N o rm a l P ro ba bility P lo t o f the S ta nda rdize d E ffe cts(respon se is ?妄

35、 , A lph a = .10)第27頁/共37頁第二十八頁，共38頁。 確確認認模型模型(mxng)(mxng)的適合性的適合性 0.30.20.1-0.0-0.1-0.2543210ResidualFrequencyHistogram of Residuals1510500.50.0-0.5Observation NumberResidualI Chart of ResidualsMean=4.49E-14UCL=0.4198LCL=-0.4198545352515049480.30.20.10.0-0.1-0.2FitResidualResiduals vs. Fits210-1-20

36、.30.20.10.0-0.1-0.2Normal Plot of ResidualsNormal ScoreResidualResidual Model Diagnostics第28頁/共37頁第二十九頁，共38頁。 SURFASE SURFASE PLOTS & PLOTS & 最最優(yōu)優(yōu)化化 5 1 9 .05 1 8 .51 0 0 04 81 1 0 04 9d a m p e r辨 撈5 01 2 0 05 15 21 3 0 05 31 4 0 01 5 0 0搬 苞1 6 0 05 1 8 .01 7 0 0d a m p e r仿S u rfa c e P lo

37、 t o f 搬 苞H o ld v a lu e s : b e lt厘 仿 : 6 1 .0 6 56 46 31 0 0 04 8b e lt厘 仿1 1 0 04 95 01 2 0 05 15 21 3 0 05 36 21 4 0 01 5 0 0搬 苞1 6 0 06 11 7 0 0d a m p e r仿S u rfa c e P lo t o f 搬 苞H o ld v a lu e s : d a m p e r辨 : 5 1 8 .0 6 56 46 35 1 8 .05 2b e lt厘 仿5 35 46 25 1 8 .5搬 苞6 15 1 9 .0d a m p

38、e r辨 撈S u rfa c e P lo t o f 搬 苞H o ld v a lu e s : d a m p e r仿 : 1 0 5 0 .0 第29頁/共37頁第三十頁，共38頁。 CONTROL PLANCONTROL PLANPROJECT NAME：AUTO W/M 噪音不良改善日期：2004.06.20NO管理對象管 理 項 目紀錄方法措施基準措施事項擔當備注1DAMPER力部品每批采集數(shù)據(jù)5EA.SPEC由10502000g變更為13501650。X BAR R CHART脫離管理狀態(tài)檢討原因并采取對策IQC周星輝2DAMPER長度部品每批采集數(shù)據(jù)5EA.SPEC :

39、518+0/-1.2mm。X BAR R CHART脫離管理狀態(tài)檢討原因并采取對策IQC周星輝3BELT張力BELT張力為6163mm.BELT JIG氣壓調(diào)整在2.54公斤。X BAR R CHART脫離管理狀態(tài)檢討原因并采取對策L/P周磊4DAMPER GREASEL/P TIME別確認DAMPER有無GREASE流掛。CHECK SHEETGREASE流掛F/B問題點L/P周磊第30頁/共37頁第三十一頁，共38頁。 MONITORING MONITORING 0Su b g r o u p51 05 1 7 . 15 1 7 . 25 1 7 . 35 1 7 . 45 1 7 . 5

40、5 1 7 . 65 1 7 . 75 1 7 . 8Sample MeanMe a n = 5 1 7 . 4UCL = 5 1 7 . 5L CL = 5 1 7 . 35 1 7 . 5 25 1 7 . 4 50 . 00 . 51 . 0Sample RangeR= 0 . 1 9 8 3UCL = 0 . 4 1 9 4L CL = 05 1 7 . 5 25 1 7 . 4 5Xb a r / R Ch a r t f o r DAMPER? 峪 b y c 10Su b g r o u p51 01 3 0 01 4 0 01 5 0 01 6 0 01 7 0 0Sample

41、 MeanMe a n = 1 5 4 6UCL = 1 7 1 8L CL = 1 3 7 41 3 5 01 6 3 001 0 02 0 03 0 04 0 05 0 06 0 07 0 08 0 0Sample RangeR= 2 9 8 . 3UCL = 6 3 0 . 8L CL = 01 3 5 01 6 3 0Xb a r / R Ch a r t f o r DAMPER蒸 b y x 10Su b g r o u p51 06 06 16 26 36 46 5Sample MeanMe a n = 6 2 . 2 2UCL = 6 3 . 5 1L CL = 6 0 . 9

42、 26 1 . 06 1 . 50123456789Sample RangeR= 2 . 2 5UCL = 4 . 7 5 8L CL = 06 1 . 06 1 . 5Xb a r / R Ch a r t f o r BEL T ? 蒸 b y B第31頁/共37頁第三十二頁，共38頁。 PROJECT OUTPUT PROJECT OUTPUT 項目改善前改善后改善率Sigma Level2.93.417%PPM77054.0131365.6359%5957555351494745U S LLS LP ro ce ss C a pa bility A na lysis fo r a ut

43、o no iseP P M T o ta lP P M U S LP P M U S LP P M U S LP P M L S LP p kP P LP P UP pC p mC p kC P LC P UC pS tD e v (O v e ra ll)S tD e v (W ith in )S a m p le NM e a nL S LT a rg e tU S L7 7 0 5 4 .0 17 4 8 1 5 .8 6 2 2 3 8 .1 54 3 8 7 8 .6 44 3 5 1 1 .0 4 3 6 7 .6 05 8 8 2 3 .5 35 8 8 2 3 .5 3 0 .0 00 .4 80 .9 50 .4 80 .7 1 *0 .5 71 .1 30 .5 70 .8 52 .3 3 4 6 41 .9 6 5 6 33 45 1 .6 3 6 24 5 .0 0 0 0 *5 5 .0 0 0 0E x p . O v e ra ll P e rfo rm a n ceE x p . W ith in