六西格玛应用实例.ppt

Content Awareness 1 SixSigmaMethodologya D M A I CDefineMeasureAnalyzeImproveControlb ProjectReviewonD M A I C 6 ProjectfromMachine shopProjectfromCleanroom OptimizedProcess 30 50 10 15 4 8 KeyProcessInput Variables KPIVs 8 10 KPIVs CriticalKPIVs InputsVariables ProcessMap Multi VariCharts Correlations Hypothesistest DesignOfExperiments ResponseSurfaceMethods Cause EffectMatrices GageRepeatability Reproducibility ProcessCapability T Test ANOVA MultipleRegression QualitySystems SPC Measure Analyze Improve Control Average RangeControlCharts FailureModeEffectAnalysis SixSigmaMethodology Define ProblemStatement Baselinestudy 6 ProjectExplorationProcessFlowDiagramC EMatrix ProcessFMEA FishboneDiagramsDataCollectionSystemMeasurementSystemAnalysisAttribute VariableGageStudiesCapabilityAssessment oneachY Response Cp Cpk Pp Ppk DPU Graphical StatisticalToolsProjectSummaryConclusionsIssues MeasurePhase 6 ProcessDataAnalysisGraphicalAnalysis histograms boxplots trend controlcharts etc Multi VariStudiesTestsofsignificance Means Standarddeviations proportions DOEPlanningSheetUpdateProcessFMEAProjectSummaryConclusionsIssues AnalyzePhase 6 ImprovePhase DesignofExperimentsDOEPlanningSheet Doe doc FactorialExperimentsRSM ResponseSurfaceMethodology UpdatedFMEAProjectSummaryConclusionsIssues 6 ControlPhase PlanforMonitoringY s Response PlanforControllingX s Process Sustainingthegain UpdatedFMEAProcessControlPlanActionPlanProjectsummary ConclusionsIssues 6 ProjectTitle OptimizationofCheetahX15 TopSwagingStopPin ProjectTitle SixSigmaProject TampoiCleanroom Champion KevinLimProjectTeamMembers a Engineering Aozzudin TeamLeader b Quality Nizam MKLaic Production Afidahd Finance Rohayatie BB GSLim LLLim ProjectTeam DefinePhase ProjectDefined ProjectDescription ProblemStatement ThepresenthighrejectionofCX15TopSwagingStopPinisaffectingtheproductionyieldperformance resultinginunnecessaryscraps Past7weeks data WW44 WW50 showrejectionraterangesfrom0 2 to15 4 inWW50 Goal ObjectiveStatement Tostudy optimizeswagingstoppinprocesssoastoreduceaveragerejectionratefrom3 20to0 Defects Therejectionrateofstoppinis 0 ProjectedBusinessBenefits Yieldimprovement Savingsinscraps Savingsinre inspection resources Abletomeetproductionoutputtarget DefinePhase Baseline Entitlement Goal DefinePhase Note TherewasnoproductioninWW47 Baseline3 2 Goal0 Entitlement0 InitialCostSavingsEstimation DefinePhase Averageweeklyyieldlossof3 20 whentranslatedtoquantityofstoppinsbeingscrapped 320pcs estimated Estimatedqty scrappedpermonth 320 x4 1 280pcsEstimatedqty scrappedperyear 1280 x12 15 360pcsScrapcostperpc RM0 722Estimatedscrappedcostperyear RM0 722x15 360 RM11 090Inspectioncycletime inspection rework 50sec pc Then inspncycletimeincurredperyearbasedonscrappedqty 213hrsInspectioncostbasedonscrappedqty peryear RM1 225 1hr RM5 75 Hardsavingsperyear RM11 090Softsavingsperyear RM1 225 ValidatedbyFinanceRepon1 10 2001 SourceVarCompStdDev5 15 SigmaTotalGageR R3 22E 095 68E 052 92E 04Repeatability2 94E 095 42E 052 79E 04Reproducibility2 86E 101 69E 058 72E 05Operator2 86E 101 69E 058 72E 05Part To Part9 08E 099 53E 054 91E 04TotalVariation1 23E 081 11E 045 71E 04Source Contribution StudyVar ToleranceTotalGageR R26 2151 2036 55Repeatability23 8848 8734 89Reproducibility2 3315 2610 90Operator2 3315 2610 90Part To Part73 7985 9061 33TotalVariation100 00100 0071 39NumberofDistinctCategories 2 GR RStudy MeasurePhase Gagename MicrometerDateofstudy 9 7 2001Reportedby Anita GR RStudy MeasurePhase GaugeRunChart MeasurePhase MacroProcessMap MeasurePhase Cause EffectDiagram MeasurePhase Baseplateflatnesscalibration C Measurement Materials Men Methods Machines PotentialFMEA MeasurePhase PriorityRankingofKPIVs MeasurePhase Holdingtimeofpuncher Chamferofinsertionhole StoppinID OD CheetahX 15SwagingFixtureParameter 1 Thefollowingswereestablished MacroProcessMap Causeand3 varyingpunch uptimerfrom0to1 6secondsat0 2secintervals4 varyingpunch downtimerfrom0to1 0secondat0 1secintervals MeasurePhase CheetahX 15SwagingFixtureParameter AnalysePhase 1stEvaluationResult AnalysePhase 2ndEvaluationResult AnalysePhase VaryingPunch UpTimer AnalysePhase VaryingPunch DownTimer AnalysePhase AnalyzePhaseConclusion AnalysePhase 1 CylinderPressure Norejectsdetectedforcylinderpressuresettingsat7 0theresultshows100 rejects2 Punch UpPressure Norejectwasdetectedat6 5 7 0 7 5bar3 Punch UpTimer At1 0 1 1seconds theresultsweregood4 Punch DownTimer At0 5 0 6second theresultsweregood DOE ImprovePhase DOE ImprovePhase GeneralLinearModelFactorTypeLevelsValuesCylinderPressurefixed27 58 0Punch upPressurefixed35 56 06 5Punch upTimerfixed21 41 5AnalysisofVarianceforDPPM usingAdjustedSSforTestsSourceDFSeqSSAdjSSAdjMSFPCylinder12083333332083333332083333330 840 391Punch up2104166667104166667520833330 210 816Punch up18333333833333383333330 030 860Error717458333331745833333249404762Total112066666667 InteractionPlot ImprovePhase MainEffectPlot ImprovePhase RSM 1 ImprovePhase RSM 2 ImprovePhase RSM 3 ImprovePhase OptimumSettingsatLowestDPPM Samplesize 500pcsPlatesupplier SelektaSettings CylinderPressure 8 0bar Punch upPressure 5 5or6 5bar Punch upTimer 1 45bar Result Allsamplespassedthetest ConfirmationRun ImprovePhase ControlPhase ControlPhase 1 IQAinspectionatAQL 1 0 C 0SamplingPlan StopPinID 0 058 0 002 StopPinOD 0 08 0 0004 HoleonTopPlate 0 0817 0 0 0012 Chamfer 0 010Max forinsertionholeofTopPlate PerpendicularityofStopPin Len