SPC基本统计培训ppt课件

1、统计过程控制任务坊 SPC Work Shop精益管理顾问公司 -企业管理的好帮手 .根本统计概念 Basic SPC Concept.统计学 (Statistics) 搜集、 整理、展现 、分析 、解析统计资料Collect, collate, display, analysis, explain of data由样本推论母体/群体From sample to project the population能在不确定情况下作决策 Decision with uncertainty是一门科学方法、决策工具Scientific and decision tool根本统计概念 Basic SPC C

2、oncept抽样推论.统计量 Statistical ValueR 全距 (range) 算术平均数 (arithmetic mean)Md 中位数 (median)Mo众数 (mode)2 方差/变异 (variance)规范差 (standard deviation)根本统计概念Basic SPC Concept.R 全距 (range)R = Xmax - Xmin 算术平均数 (arithmetic mean)根本统计概念Basic SPC Concept.Md 中位数 (median)顺序数列中的中心项的数值The medial number in the seriesMo众数 (m

3、ode)资料中出现最多的数值The number with highest frequency根本统计概念Basic SPC Concept.2 方差/变异 (variance)根本统计概念Basic SPC Concept.规范差 (standard deviation)根本统计概念Basic SPC Concept.例：Case1, 1, 2, 3, 4, 6, 11R = 10 = 4Md = 3Mo= 1n 2 = 10.86 n-12 = 12.67n= 3.29 n-1= 3.56 根本统计概念Basic SPC Concept.数列 Series： 12, 11, 12, 13,

4、 18, 30, 24, 9请计算以下统计量 Calculate the following:R Md Mo n 2 = n-12 =n= n-1=练习Exercise.数据的搜集与整理Data Collection and Collation分析测试行动ActionTestAnalysis数据Data结Conclusion样本Sample群体PopulationSampling抽 样.数据搜集 Data Collection.数据整理 Data Collate - 次数分配 Frequency Distribution.直方图 (Histogram).分布曲线 Distribution Cu

5、rve.正态(常态)分布的曲线图Normal Distribution Curve.正态分布的性质Nature of Normal Distribution.数据 Data 直方图Histogram 分布曲线 Distribution.直方图 Histogram 分布 Distribution正常型Normal.直方图 Histogram 分布 Distribution偏向型 Bias.直方图Histogram 分布Distribution孤岛型 Island.过程变差Process Variation.输入 (资料)Input (Material)人 Man方法 Method过程 (消费/装

6、配)Process输出(产品)Output (Product)反响(丈量/检验)Feedback (Test/Insp.)丈量系统MSA)资料Material过程变差 Process Variation机器 Machine .过程变差 Process Variation输入资料 Material Input不同批次之间的差别 Lot to Lot Variation批次内的差别 Within Lot Variation随时间产生的差别 Variation in Time Series随环境而产生的差别 Variation due to Environment.过程变差 Process Vari

7、ation消费/装配 Production/ Assembly设备及工装夹具的差别 Equipment and Tooling Variation随时间而产生的磨损，漂移等 Aging and Shift by time操作工之间的差别(如手工操作的过程)Variation between Operators ( Manual Work)设置的差别 Different Setup环境的差别Different Environments.过程变差 Process Variation输出产品 Output Product输出的产品随时间而产生的变化Product Variation by time

8、series输出的产品随环境而产生的变化Product Variation due to environment.过程变差 Process Variation反响 - 丈量 Feedback- Measurement由于丈量用于过程中的一切组成部分，丈量的变差会对过程的各个阶段产生影响Measurements are part of the process, variation in the measurement can affect the process in various stages偏倚 Bias稳定性 Stability反复性 Repeatability再现性 Reproduci

9、bility分辨率 Resolution.持續改進過程循環的各個階段2. 維護過程 監控過程性能查找偏向的特殊缘由並採取措施 3. 改進過程.改變過程從而更好地了解普通缘由變差減少普通缘由變差分析過程本過程應做些什麼?會出現什麼錯誤?本過程正在做什麼?達到統計控制狀態?確定才干計劃實施措施研讨計劃措施實施研讨計劃實施措施研讨.过程变差 Process Variation范围范围范围范围每件产品的尺寸与别的不同Each product dimension has differences SPEC.过程变差 Process Variation范围范围范围但它们构成一个模型，假设稳定，可以描画为一个

10、分布The data are grouped to form the model. If stable, it can be descried as the distribution.过程变差 Process Variation分布可以通用过以下要素来加以区分Distribution can be descried with various elements或这些因数的组合 Or the combination of these elements范围范围范围位置 Position分布宽度置 Spread外形 Form/ Shape.过程变差 Process Variation预测Forecas

11、t范围 SPEC时间 Time假设只存在变差的普通缘由，随著时间的推移，过程的输出构成一个稳定的分布并可预测If there are only the common causes, and move in time series, the process outputs are predictable with stable distribution 目的直线Target Line.过程变差 Process Variation目的直线 Target Line预测 Forecast范围 Spec时间 Time假设存在变差的特殊缘由，随著时间的推移，过程的输出不稳定If the special c

12、ause is in the variation, in time series, the process become unstable？.过程控制和过程才干Process Control and Process Capability过程控制 Control Process 受控 In Control(消除了特殊缘由)Eliminate the Special Cause时间 Time范围 SPEC不受制 Out Of Control(存在特殊缘由) with Special Cause.过程变差 Process VariationDistribution can be described

13、by:Location (typical value)位置 (典型值) Spread 分布宽度 Shape(pattern of variation)外形 (变差的方式) LSLUSLTypical value典型值 Spread分布 .过程变差 Process Variation过程的变差分两个类型 Two Categories特殊缘由呵斥的变差 Special Causes普通缘由呵斥的变差 Common Causes.过程变差 Process Variation普通缘由变差 Common Causes in Variation影响过程中每个单位 affect each unit in t

14、he process是由一切不可分派的小变差源组成 Formed by various variation sources; and但遵照一个分布 follow a particular distribution通常需求采取系统措施来减小Use system corrective actions to reduce在控制图上表现为随机性random point in the control chartIf only common cause, the process output of a process is Predictable如只需普遍缘由，输出是可估计的过程。 .过程变差 Proce

15、ss Variation特殊缘由变差 Special Causes in Variation延续的，偶尔的，通常是不可预测的和不稳定的变差Discontinued, accidental, unpredictable and unstable非随机的图案 Non random pattern是由可分派的变差源呵斥该变差源可以被纠正Can be corrected, the cause is from the particular source.过程变差 Process Variation工业阅历建议为：Industrial Experience部分措施 Local action通常用来消除变差

16、的特殊缘由Usually required to eliminate special causes of variation通常由与过程直接相关的人员实施 Usually taken by people close to the process大约可纠正15%的过程问题 Only 15% of process problem can be corrected.过程变差 Process Variation工业阅历建议为：Industrial Experience对系统采取措施 Actions on the system通常用来消除变差的普通缘由 Usually required to elimi

17、nate / or reduce common causes of variation, and be taken by management大约可纠正85%的过程问题 About 85% of process problem can be corrected.过程控制和过程才干Process Control and Process Capability过程才干 Process Capability规范上限受控且有才干符合规范(普通缘由呵斥特变差)Control and capable to fit the spec (variation due to Normal Cause)受控但没有才干

18、符合规范 Control but without capability to fit the spec(普通缘由呵斥变差太大) Large variation due to Normal Cause Spec时间 Time.过程控制和过程才干Process Control and Process Capability每个过程可以分类如下：Each process can be categorized as: Control or out of control ? 受控或不受控? Fit the customer requirements ? 能否有满足客户要求 ? Meeting requir

19、ement满足要求In Control受控Not In Control 不受控Acceptance符合Case 1 第1类Case 3 第3类Not Acceptance不符合Case 2 第2类Case 4 第4类.过程控制和过程才干第1类 (符合要求，受控) Case 1 (Accept, In Control) 是理想情况。为继续改良能够需求进一步减小变差Ideal Status, to reduce variation for continuous improvement. 第2类 (不符合要求，受控) Case 2 (Not Accept, In Control)存在过大的普通缘由变

20、差 with large variation from normal cause 短期内，进展100%检测以维护客户不受影响In short term, go for 100% inspection to reduce the effect for customer 必需进展继续改善以减少普通缘由的变差 Must go for continuous improvement to eliminate the effect from common cause.过程控制和过程才干Process Control and Process Capability第3类 (符合要求，不受控) Case 3.

21、Accept but OUT of control有相对较小的普通缘由及特殊缘由变差With less normal and special causes 假设存在的特殊缘由曾经明确但消除具影响能够不大经济，客户能够接受这种过程情况If the special causes are known but the cost may be high to eliminate them, customer may accept this process status.过程控制和过程才干第4类 (不符合要求，不受控) Case 4 ( Not Accept, OUT of Control)存在过大的普通

22、缘由及特殊缘由的变差Larger Normal and special causes in the variation需求进展100%检测以维护客户利益 必需采取紧急措施使过程稳定，并减小变差Must go for contingency/ containment actions to stable the process and reduce variations, 100% inspection to protect customer.过程控制和过程才干判别一个过程能否满足规格要求： Judge the process can fit the spec requirementsCapabi

23、lity Index 才干指数 - Cpk (For stable Process only 只用於穩定过程)Performance Index 性能指数 Ppk判别一个 过程是受控还是不受控用：Judge the process is in control or out of control控制图 Control Charts.控制图 Control Charts 为判别制程变差的普通缘由或特殊缘由的主要统计分析工具To judge the process variation with COMMON or SPECIAL cause as the major statistical anal

24、ysis tool.根本概念 Basic Concept控制图中包括三条线 3 lines in Control Chart控制上限 (Upper Control Limit; UCL)中心线 (Center Line; CL)控制下限 (Lower Control Limit; LCL)UCLCLLCL.控制图的种类 Type of Control Charts 计量型数据的控制图 Variable Control ChartsXbar-RXbar-SX-MR计数型数据的控制图 Attribute Control Chartspnpcu.控制圖的選用程序注 : 本圖假設測量系統已經過評價並且

25、是適用的.控制图的运用谋划Planning for the Control Charts作控制图需求按以下步骤：Follow the necessary steps :方案 Planning资源 Resources评价和改良 Evaluation and Improvement.控制图的运用谋划Preparation for the use of Control Charts建立适于采取措施的环境 - 公司文化 Set the right environment to take actions Company Culture确定过程 Define the process确定待管理的特性 (如:

26、 特殊特性) ，思索Determine characteristics (e.g. Special Characteristics) that need to be managed Shall Consider :客户的要求 Customer Requirements当前及潜在的问题区 Existing and potential problem area特性间的相互关系 Interrelation between characteristics确定丈量系统 Define the Measurement System MSA使不用要的变差最小化 Reduce the variations in

27、 those avoidable area.控制图的运用谋划Preparation for the use of Control Charts过程 Process输出 Output输入 Input运用什么方式？(资料/设备)What?(Equipment/Raw Material)谁进展? (才干/技艺/培训)Who?(Competence, ability, training)如何做？(方法/程序/技术)How?(Method/Procedure/Technique)运用的关键准那么是什么？ (丈量/评价)Key measurement?(Measuring/Evaluation).Xbar

28、 - R Chart 图Average and Range Chart 平均数 - 全距控制图工业界最常运用的计量值控制图The most common chart for the industry.建立Xbar-R控制图的步骤Set up the steps for X-R Charts搜集数据 Collect Data 选择子组大小，频率和数据Select the subgroup size, frequency and numbers of subgroup 子组大小 Subgroup size : 一个子组内该单元之间出现变差时机小(如45件延续于单一过程的产品) variation

29、among units within the subgroup are small (e.g. 4 to 5 consecutively produced pieces by single production stream) 每个子组内的变差是普通缘由呵斥 Variation within each subgroup reflects COMMON cause代表短时间内零件间变产 Represent the piece-to-piece variation within short period of time不正常变差=过程发生变化 unusual variation between s

30、ubgroups = changes in process.建立Xbar-R控制图的步骤Set up the steps for X-R Charts选择子组大小，频率和数据Select the subgroup size, frequency and numbers of subgroup 子组频率 Subgroup frequency :检查过程经过一段时间的变化，如: 换班、温升趋势、资料变卦 To detect the change of process over time, e.g. changes due to work shift difference, warm-up tren

31、d, material lots.子组数大小 Number of Subgroups : 确保变差的主要缘由有时机出现(25子组包含100个单值) Major sources of variation have had an opportunity to appear (25 or more subgroups containing 100 or more readings) 可利用现有数据加速研讨进度Can use existing data to speed up the process建立Xbar-R控制图的步骤 Set up the steps for X-R Charts.建立控制图

32、及記錄原始數據Set up control chart and raw data gathering建立Xbar-R控制图的步骤 Set up the steps for X-R Charts.计算每个子组的X平均值和极差R Calculate the Average Range and Process average建立Xbar-R控制图的步骤 Set up the steps for X-R Charts.UCLCLLCL子组数足夠時(25子组包含100个单值), 計算及繪成控制線 試驗控制限When number of subgroup is adequate(25 or more su

33、bgroups containing 100 or more readings), calculate and draw the control limit trial control limits建立Xbar-R控制图的步骤 Set up the steps for X-R Charts.建立Xbar-R控制图的步骤 Set up the steps for X-R Charts过程控制解释 Explain the Process Control分析极差图(R图)上的数据点 Analyse the R chart first识别并标注特殊缘由(R图) Identify and mark th

34、e special causes糾正及預防再發生 Correct and prevent it form recurring消除受已識別的特殊缘由影響的子組Exclude all subgroups affected by the identified special cause 重新计算控制极限(R图) Recalculate the R control limits.當极差受控 過程分佈是穩定的,分析平均值图(Xbar图)When the ranges are in statistical control, process spread isstable, then看过程的位置能否改动 x

35、 图 Check if the process location is changing overtime x chart为继续控制延伸控制限 Extend the Control Limits for Process Control建立Xbar-R控制图的步骤 Set up the steps for X-R Charts.控制图 - 过程的声音Control Charts- the voice of the process控制图可以给我们提供出出现了哪种类型的变差的线索，供我们采取相应的措施The control chart can provide us the hints of what

36、 types of variations, for the right corrective actions.控制图上的信号解释 Explain The Signals on the Control Charts有很多信号规那么适用于一切的控制图(Xbar图和R图)，主要最常见的规那么 有以下3种：Many types of signals and rules in the XR charts, mainly 3 types:规那么1： 超出控制限的点 Rule #1: Points Exceed the control limitsUCLLCL.控制图上的信号解释Explain The Si

37、gnals on the Control Charts规那么2： 延续7点在中心线一侧Rules #2: continuous 7 points in one side of the centre linerunUCLLCL.控制图上的信号解释 Explain The Signals on the Control Charts规那么3： 延续7点升或下降 Rule #3: continuous 7 points in descending or raisingtrendUCLLCL.过制图上的信号解释 Explain The Signals on the Control Charts多于2/3

38、的点落在图中1/3以外。More than 2/3 of points outside the 1/3 zone .过制图上的信号解释 Explain The Signals on the Control Charts呈现有规律变化。 Regular Cyclical Trend.改动控制时限 Change In Control Limit将这些的控制限画到控制图上，并作为不断进展的过程制的根底。Plot these new control limits on the chart as the basis forongoing process control 只需过程的均值和极差坚持受控 可将

39、控制限延伸以于以后的时期 As long as the process remains in control for both and range ongoing limits can be extended for additional periods.圖形 Patterns極差圖 Range Chart均值圖 Average Chart超出控制限的點 Points beyond the control limits控制限繪錯 分佈寬度增加(零件間變化) 測量系統未有足夠分辨或已變化Mis-plotted of control limits Increase or decrease of s

40、pread of distribution (piece-to-piece variation) Change in Measurement system or lack of discrimination 控制限繪錯 過程已變化 測量系統己變化Mis-plotted of control limits Process has shifted Change in Measurement system .圖形 Patterns極差圖 Range Chart均值圖 Average ChartRun 輸出值的分佈寬度增加： 無規律的成因，如設備異常或夾具鬆動 測量系統改變 Greater sprea

41、d of output value due to: irregular cause such as equipment malfunction or loose fixturing shift in process elements such as new , less uniform raw material lots Change in Measurement system 過程均值已變化 測量系統逐漸改變Process average has changed Change in Measurement system such as drift . 圖形 極差圖 均值圖 明顯非隨機圖形 顯

42、著多於2/3以上的點落在中線外： 控制限繪錯 過程或抽樣方法會被分層：子組系統化包括兩個或以上的過程流過程均值變化 數據被編輯 顯著少於2/3以上的點落在中線外： 過程或抽樣方法形成連續的分組中包括多個具不同變化的過程流 顯著多於2/3以上的點落在中線外： 控制限繪錯 過程或抽樣方法會被分層：子組系統化包括兩個或以上的過程流過程均值變化 數據被編輯 顯著少於2/3以上的點落在中線外： 過程或抽樣方法形成連續的分組中包括多個具不同變化的過程流 如果存在幾個過程流，應分別識別和追蹤 .改动控制时限 Change In Control Limit估计过程的规范偏向用如今的子组容量计算：Estimat

43、e the process standard deviation. Using the existing subgroup size calculate :=R/d2式中 R为子组极差的均值(在极差受控时期)，d2 随样本容量变化的常数：Where R is the average of the subgroup ranges (for periods with the ranges in control) and d2 is a constant varying by sample size:n2345678910d21.131.692.062.332.532.702.852.973.08.

44、改动控制时限 Change In Control Limit按照新的子组容量查表得到系数d2、D3、D4和A2，计算新的极差和制限： Using the tabled factors for d2, D3, D4 and A2 based on the new subgroup size, calculate the new range and control limits:=Rnewd2UCLR=D4 RnewLCLR=D3 RnewUCLX=X + A2 RnewUCLX=X - A2 Rnew.改动控制时限 Change In Control Limit将这些的控制限画到控制图上，并作为

45、不断进展的过程控制的根底。Plot the new control limits on the chart as the basis for ongoing process control.只需过程的均值和极差坚持受控 可将控制图的目的是合理、经济的控制形状As long as the process remains in control for both averages and rangesOngoing limits can be extended for additional periods.有关控制的最后概念用于进一步的思索 在一个消费过程中永远无法到达一种完美的控制形状。A per

46、fect state of control is never attainable in a production process.过程控制图的目的是合理、经济的控制形状。 The goal of the process control charts is reasonable and economical state of control.假设一张控制图上从来不出现失控点，我们将严肃地查询该操作能否应画图。If a chart never went out of control we would seriously question whether that operation should

47、 be charted.对于车间目的来说，一个受控的过程即是仅有很少百分比的点失控并且对失控点采取过适当的措施。For shop purposes a controlled process is considered to be one where only a small percentage of the points go out of control and where out-of-control pointsare followed by proper action. .请完成 Xbar-R控制图的制造练习Please Complete Control Chart Drawing练

48、习 Exercise.控制图 - 过程的声音控制图可以区分出普通缘由变差和特殊缘由变差Control Chart can distinguish the normal causes and the special causes特殊缘由变差要求立刻采取措施Special Causes needs immediate actions减少普通缘由变差需求改动产品或过程的设计To Reduce the normal causes need product or process redesign.控制图 - 过程的声音错误的措施 Wrong Actions试图经过继续调整过程参数来固定住普通缘由变差，称

49、为过度调整，结果会导致更大的过程变差呵斥客户称心度下降Continue to adjust the process parameters to fix the normal process variations- over adjustments only cause larger variations and customer unsatisfied试图经过改动设计来减小特殊缘由变差能够处理不了问题，会呵斥时间和金钱的浪费Try to change design to reduce the special causes in the variations cannot solve probl

50、ems, only waste money and time.过度调整是把每一个偏离目的的值当作过程中特殊缘由处置的作法 Over adjustment is the practice of treating each deviation from the target as if it were the result of the action of a special cause of variation in the process. Results with no adjustment 沒有經過調整的結果Normal Variation 正常變差 .Note Increasein Va

51、riation留意變差添加Result with adjustment to compensate for last deviation from target對最終目標差補償調整後的結果Results with adjustment to compensate for last deviation from target if deviation was greater than 1 偏向大於目標1個單位時, 進行補償調整後的結果Note Increase in Variation留意變差添加.Xbar - S 图 Chart平均数 - 规范差控制图 Average and Std. Dev

52、 Control Chart与Xbar - R图一样 Same as X&R chartsS图检出才干较R图大，但计算大费事S can have better detection than R, trouble in calculation普通样本大小n小于是9运用R图，n大于9运用S图Sample size N9, use S charts配合电脑运用 Use with PC.Xbar - S 图 Chart.X - MR 图Chart个别值 - 挪动全距控制图 Moving Range Control Charts数据不能合理分组时运用 Data not suitable for the

53、sub grouping在以下情况可运用：In the following situation:一次只能搜集到一个数据，消费效率及损耗率。Can collect a single data per time, by considering the efficiency and scrap制程质量极为均匀，不需多取样本，如液体浓度。The product itself is very evenly distributed, no more sampling, like Conc.获得测定值既费时本钱又高，如复杂的化学分析及破坏性实验。Costly for the measurement, suc

54、h as complicated chemical analysis, and destructive test.X - MR 图.计数型数据控制图Attribute Control ChartsP图 (P Charts)nP图(nP Charts)C图 (C Charts)U图 (U charts).P 图 (P Charts)不合格品率(不良率)控制图Failure Rate Control Chart分析或控制制程不合格品率(不良率)Analyse or control the failure rate样本大小n可以不同Sample size n can varies.P 图 (P Ch

55、arts).P 图 (P Charts).nP 图 (nP Charts)不合格品数(不良数)控制图Non conforming no ( No of defective) Control Chart分析或控制制程不合格品数(不良数)Analyse and Control of Non conforming no ( No of defective) Control Chart样本大小n要一样Sample Size N must be the same.nP 图 (nP Charts).C 图 C Charts缺陷数控制图Defect Point Control Chart分析或控制制程缺陷数

56、Analyse or Control of Defect Point Control Chart样本大小 n 要一样Sample Size N must be the same.C 图 -在样本大小一致的子组内的不合格数.u 图 U Charts单位缺陷数控制图 Unit defective Control Charts分析或控制制程单位缺陷数Analyse or Control of Unit defective Control Charts样本大小 n 可以不同Sample Size n can varies.u 图 U charts.过程才干Process Capability.过程控制

57、和过程才干Process Control & Process Capability判别一个 过程是受控还是不受控用：To judge the process are in control or out of control:控制图 Control Chart判别一个过程能否满足规格要求：To judge the process can fulfill the specification :才干指数 Cpk ( Process Capability)性能指数 - Ppk ( Performance Capability).短期 Short Term长期 Long Term过程才干 Process

58、 Capability短期研讨 长期研讨一月星期一星期二二月Short TermLong Term.过程才干的研讨 Process Capability Study短期普通缘由特殊缘由短期才干研讨 - 过程性能 Short Term- Performance Capability 6.过程才干的研讨 Process Capability Study过程性能 (Process Performance)过程总变差 特殊缘由变差 + 普通缘由变差Total Process Variation due to both Special and Common Cause由 估计出 Estimate form Sigmas.过程才干的研讨 Process Capability Study输入 (资料)过程 (消费/装配)输出 (产品)反响 (丈量/检验)长期才干研讨 - 过程才干 Long Term Capability Study- Process CapabilityInput MaterialProcess (Production)Output ( Product)Fee