SIGMA黑带项目教材

2022/12/8SixSigma1通过6Sigma项目改善提高搅拌式水壶直通率实施单位：实施时间：项目BB：6SigmaBB项目2022/12/8SixSigma2定义阶段DMAIC2022/12/8SixSigma3

客户对此款搅拌水壶产品需求量大,品质要求严.同行业产品价格竞争激烈外部环境搅拌式水壶现时直通率为78.5%客户要求1.产品需求量大(30万/年)2.品质要求严提升直通率提升品质DMAIC<现象><要求><结果>项目选定背景2022/12/8SixSigma4项目选定背景内部环境1.2013年1-4月成品直通率低,为78.5%2.成品合格率低，2012年QA验货合格率为86.2%3.劣质成本高，占销售额的比例大。检查工序水温检测功能检测耐压测试外观检测总装直通率单站直通率88.9%98.6%96.4%92.9%78.5%DMAIC2013年1-4月产品直通率2022/12/8SixSigma5顾客及CTQ直通率低DMAIC外部顾客销售/客服要求提升产品品质/低廉的价位/较少的维修机会利益获取更大利润/节省维修投入内部顾客财务管理中心/成本核算部要求降低劣质成本/一次就做好利益增加利润VOCCTQ2022/12/8SixSigma6项目范围PMC进料成品入仓OQC检验IQC检验总装主要生产过程过程范围DMAIC2022/12/8SixSigma7项目范围主要装配流程（SIPOC)DMAIC拆底座装脚垫与绕线盖拆大身上座,装电源线到底座装马达垫装固定板到电机固定电机到大身插插座引线装插座到大身压连接头,装开关焊接引线(一）焊接引线(二）焊接引线(三）固定压线码与PCB板接线扎扎带机身内检吹热缩管找出影响直通率的关键流程装装饰圈2022/12/8SixSigma8项目范围主要装配流程（SIPOC)DMAIC固定大身上下座拆大杯装手柄盖与水龙头压滚动轴承压轴承到发热盘固定发热盘到大杯固定FUSE与温控器装脚垫压插片到杯座，插杯座引线（一）插杯座引线（二）固定杯座装搅拌刀组件上连接头水温测试耐压测试功率测试清洁机身，绕电源线清洁大杯与杯盖外观检查找出影响直通率的关键流程2022/12/8SixSigma9战略分析1.高品质生活供应商2.质量上台阶，管理上层次，

满足客户要求3.经市场为中心，以客户为中心，

以技术为中心集团战略提高直通率，既降低了劣质成本，又降低了制造成本，而且提高了产品品质，保证了交期，提高了产品市场竞争力和客户满意度。DMAIC2022/12/8SixSigma10问题综述DMAIC2022/12/7SixSigma11总装一车车间近期期直通率率走势图图DMAIC问题综述述2022/12/7SixSigma12Y和缺陷定定义Y=直通率=Y1*Y2*Y3*Y4DMAICY1定义:煲水测试试合格率率Y2定义:耐压测试试合格率率Y3定义:功能测试试合格率率Y4定义:外观检查查合格率率Y的定义缺陷定义义2022/12/7SixSigma13项目目标DMAIC现状1-5月目标11月78.5%90%2022/12/7SixSigma14财务收益预预计改善目标计算工式合计(RMB)年度收益(人工费用x50%+装配费用0.53x30%+公共费用0.23x100%）x预计订单量300,000x直接提高直通率10%=(1.49x50%+0.53x30%+0.23x100%)x300,000x11.5%￥:44365元

投入费用改模费用3000+制作夹具费2000=5000元￥:5000元相关费用1.人工成本：1.49元2.装配成本：0.53元3.公共费用：0.23元财务总收益:￥年度预计收益总值=预期收益-投入费用

=44365-5000=39365元DMAIC无形收益：：直通率的的提高，同同时产能也也显著提高高，产品品品质明显改改善，提高高了产品的的市场竞争争力和客户户满意度。。2022/12/7SixSigma15项目目团团队队组组织织ChampionX君BB:B君MBB：M君XXXXXXXXX品质质监监控控及及检检验验标标准准的的制制定定现场场作作业业改改善善及及作作业业方方式式标标准准化化，，控控制制文文件件。。FMEA分析析，，流流程程改改进进，，工工程程优优化化测量量系系统统分分析析，，人人员员培培训训计计划划，，实实验验实实施施。。项目目协协调调跟跟进进及及MSA、DOE、各各阶阶段段分分析析品管管部部ZZZ工程程部部VVV总装装部部YYY数据据的的收收集集和和改改善善的的实实施施，，生生产产现现场场的的控控制制DMAIC2022/12/7SixSigma16阶段段6月定义义测量量分析析改进进控制制5月7月11月内容容项目目进进程程计计划划项目目建建立立，，完完成成定义义阶阶段段的的9个部部分分Y的确确认认，，数数据据收收集集，，MSA现水水平平分分析析C&EMatrix,FMEA数据据收收集集，，多多变变量量分分析析主变变量量确确定定，，方方差差分分析析FMEA改善善计计划划作作成成确立立质质量量改改进进的持持续续有有效效方方案案，，通过过实实验验确确认认工艺艺，，管理理标准准化化，，制造造系系统统内内推推广广提交交项项目目报报告告DMAIC10月9月8月5.6-6.46.6-7.67.7-9.109.11-10.1510.16-11.202022/12/7SixSigma17沟通方式

时间

地点参加人员

主题周总结会隔周周五下午16：00

中试部小组全体成员工作进度汇报阶段总结会各阶段完成时

中试部小组全体成员

各阶段工作总结沟通协调DMAIC2022/12/7SixSigma18定义阶段总结结以VOB、VOC导出CTQ，定义Y.分析内外部环环境找到项目范围围确定项目目标标和收益估算算组建项目团队队、成员角色色分工制定项目进程程计划DMAIC2022/12/7SixSigma19测量阶段2022/12/7SixSigma20Y´S的确认顾客CTQ品质投诉，成成本增加项目Y：提高直通率率（计量型数数据）可操作Y’S(计量型数据））煲水测试合格格率、功能测测试合格率耐压测试合格格率、外观检检查合格率DMAIC2022/12/7SixSigma21Y´S的确认Y的问题描述煲水测试试☆不通电☆反转☆灯不亮☆不加热☆水龙头漏漏水☆连接头漏漏水☆温度高或或低☆发热盘漏漏水☆开关不良良耐压测试试☆耐压不良良功能测试试☆INT☆杂音☆功率高或或低外观检查查☆大身刮花花☆杯刮花☆机身混色色☆丝印不良良☆手柄盖离离缝☆大身错位位☆底座错位位☆机内异物物DMAIC2022/12/7SixSigma22测量日期期：2013.6.12分析人员：A君B君Y的MSA-LQC成品外观判断断测试员3名;样品10个;反复3次样品标准测试员A测试员B测试员CⅠⅡⅢⅠⅡⅢⅠⅡⅢ1OKNGNGNGNGNGNGNGNGNG2OKNGNGNGOKOKOKNGNGNG3NGOKOKNGOKOKNGNGNGOK4NGOKOKOKOKNGOKOKOKNG5OKOKOKOKNGNGNGNGNGNG6OKNGNGNGNGOKNGNGNGNG7NGOKOKOKOKOKOKNGNGNG8NGOKNGNGOKNGNGOKOKOK9OKNGNGNGNGNGNGNGNGNG10NGOKOKOKOKOKOKOKOKOKDMAIC2022/12/7SixSigma23LQC成品外观检查查MSA结果DMAIC2022/12/7SixSigma24WithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110880.00(44.39,97.48)210660.00(26.24,87.84)310880.00(44.39,97.48)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.7333330.1825744.016630.0000OK0.7333330.1825744.016630.00002NG0.4666670.1825742.556040.0053OK0.4666670.1825742.556040.00533NG0.6825400.1825743.738420.0001OK0.6825400.1825743.738420.0001Kappa值小于0.7,需要改善每个检查员检检查结果一致性(重复性)百分比DMAICLQC成品外观检查查MSA结果2022/12/7SixSigma25EachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110110.00(0.25,44.50)210110.00(0.25,44.50)310110.00(0.25,44.50)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent1360.00480.00220.002240.00360.00440.003240.005100.00220.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG-0.6107740.182574-3.345350.9996OK-0.6107740.182574-3.345350.99962NG-0.4774410.182574-2.615050.9955OK-0.4774410.182574-2.615050.99553NG-0.6666670.182574-3.651480.9999OK-0.6666670.182574-3.651480.9999Kappa值小于0.7,需要改善P值大于0.05,说明一致性性检验结果果不可靠检验错误次次数每个检查员员检查结果果与标准一致致性(重复性)百分比DMAICLQC成品外观检检查MSA结果2022/12/7SixSigma26BetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI10330.00(6.67,65.25)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.3438910.05270466.524880.0000OK0.3438910.05270466.524880.0000AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI1000.00(0.00,25.89)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG-0.5849610.105409-5.549421.0000OK-0.5849610.105409-5.549421.0000所有检验验员检查查结果））一致性(重复性））百分比所有检验验员检查查结果一一致性Kappa小于0.7，需改善善所有检验验员检查查结果与与标准一一致性百百分比所有检验验员检查查结果与与标准一一致性Kappa小于0.7，需改善善DMAICLQC成品外观观检查MSA结果2022/12/7SixSigma27样品标准测试员A测试员B测试员CⅠⅡⅢⅠⅡⅢⅠⅡⅢ1OKOKOKOKOKOKOKOKOKNG2NGNGNGNGNGNGNGNGNGOK3OKOKOKOKOKOKOKOKOKOK4OKOKOKOKOKOKOKOKOKOK5NGNGNGNGNGNGNGNGNGNG6OKOKOKOKOKOKOKOKOKOK7OKOKOKOKOKOKOKOKOKOK8NGNGNGNGNGNGNGNGNGNG9NGOKOKOKNGNGNGOKOKOK10OKOKOKOKOKOKOKOKOKOKY的MSA-LQC成品功能能测试测试员3名;样品10个;反复3次DMAIC2022/12/7SixSigma28LQC成品功能测试试MSA结果DMAIC2022/12/7SixSigma29WithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI11010100.00(74.11,100.00)21010100.00(74.11,100.00)310990.00(55.50,99.75)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG1.000.1825745.477230.0000OK1.000.1825745.477230.00002NG1.000.1825745.477230.0000OK1.000.1825745.477230.00003NG0.850.1825744.655640.0000OK0.850.1825744.655640.0000Kappa值大于0.7,每个检验员检检验结果一致致性可以接受受P值小于0.05,说明一致性检检验结果可靠靠LQC成品功能测试试MSA结果每个检查员检检查结果一致性(重复性)百分比DMAIC2022/12/7SixSigma30EachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110990.00(55.50,99.75)21010100.00(74.11,100.00)310880.00(44.39,97.48)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent1125.0000.0000.00200.0000.0000.003125.0000.00110.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.780220.1825744.273440.0000OK0.780220.1825744.273440.00002NG1.000000.1825745.477230.0000OK1.000000.1825745.477230.00003NG0.714590.1825743.913980.0000OK0.714590.1825743.913980.0000检验错错误次次数Kappa值大于于0.7,每个检检验员员检验验结果果与标标准一一致性性可以以接受受P值小于于0.05,说明检检验员员检验验结果果与标标准一一致性性结果果可靠靠所有检检查员员检查查结果果一致性性(重复性性)百分比比DMAICLQC成品功功能测测试MSA结果2022/12/7SixSigma31BetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI10880.00(44.39,97.48)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.8400770.052704615.93930.0000OK0.8400770.052704615.93930.0000AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI10880.00(44.39,97.48)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.8316040.1054097.889280.0000OK0.8316040.1054097.889280.0000AttributeAgreementAnalysisKappa值大于0.7，说明所有有检验员检验验结果一致致性可靠所有检验员员检查结果果一致性(重复性）百百分比所有检验员员检查结果果与标准一一致性百分分比Kappa值大于0.7，说明所有有检验员检验验结果与标标准一致性性可靠DMAICLQC成品功能测测试MSA结果2022/12/7SixSigma32Y的MSA-LQC成品耐压测测试测试员3名;样品10个;反复3次DMAIC2022/12/7SixSigma33Y的MSA-LQC成品耐压测测试结果DMAIC2022/12/7SixSigma34WithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI11010100.00(74.11,100.00)21010100.00(74.11,100.00)31010100.00(74.11,100.00)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG10.1825745.477230.0000OK10.1825745.477230.00002NG10.1825745.477230.0000OK10.1825745.477230.00003NG10.1825745.477230.0000OK10.1825745.477230.0000Kappa值大于0.9,每个检验验员检验验结果一一致性非非常好P值小于0.05,说明一致致性检验验结果可可靠每个检查查员检查查结果一致性(重复性)百分比DMAICY的MSA-LQC成品耐压压测试结结果2022/12/7SixSigma35EachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI11010100.00(74.11,100.00)21010100.00(74.11,100.00)31010100.00(74.11,100.00)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent100.0000.0000.00200.0000.0000.00300.0000.0000.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG10.1825745.477230.0000OK10.1825745.477230.00002NG10.1825745.477230.0000OK10.1825745.477230.00003NG10.1825745.477230.0000OK10.1825745.477230.0000所有有检检查查员员检检查查结结果果一致致性性(重复复性性)百分分比比没有有检检验验错错误误Kappa值大大于于0.9,每个个检检验验员员检检验验结结果果一一致致性性非非常常好好P值小小于于0.05,说明明每每个个检检验验员员检检验验结结果果可可靠靠DMAICY的MSA-LQC成品品耐耐压压测测试试结结果果2022/12/7SixSigma36BetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI1010100.00(74.11,100.00)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG10.052704618.97370.0000OK10.052704618.97370.0000AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI1010100.00(74.11,100.00)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG10.1054099.486830.0000OK10.1054099.486830.0000Kappa值大于0.9，说明所所有检验员检检验结果果一致性性非常好好所有检验验员检查查结果一致性(重复性））百分比比所有检验验员检查查结果与与标准一一致性百百分比Kappa值大于0.9，说明所所有检验员检检验结果果与标准准一致性性非常好好DMAICY的MSA-LQC成品耐压压测试结结果2022/12/7SixSigma37Y的MSA-LQC成品煲水水测试测试员3名;样品10个;反复3次DMAIC2022/12/7SixSigma38Y的MSA-LQC成品煲水水测试结结果DMAIC2022/12/7SixSigma39WithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110990.00(55.50,99.75)210990.00(55.50,99.75)310990.00(55.50,99.75)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.8564590.1825744.691020.0000OK0.8564590.1825744.691020.00002NG0.8642530.1825744.733710.0000OK0.8642530.1825744.733710.00003NG0.8642530.1825744.733710.0000OK0.8642530.1825744.733710.0000Kappa值大于于0.7,每个检检验员员检验验结果果一致致性可可以接接受P值小于于0.05,说明检检验员员检验验结果果一致致性结结果可可靠每个检检查员员检查查结果果一致性性(重复性性)百分比比DMAICY的MSA-LQC成品煲煲水测测试结结果2022/12/7SixSigma40EachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110990.00(55.50,99.75)210990.00(55.50,99.75)310990.00(55.50,99.75)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent100.0000.00110.00200.0000.00110.00300.0000.00110.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.9267400.1825745.075960.0000OK0.9267400.1825745.075960.00002NG0.9326600.1825745.108390.0000OK0.9326600.1825745.108390.00003NG0.9326600.1825745.108390.0000OK0.9326600.1825745.108390.0000检验结结果本本身不不一致致次数数Kappa值大于于0.,每个检验员检检验结果与标标准一致性可可以非常好所有检查员检检查结果一致性(重复性)百分比P值小于0.05,说明检验员检检验结果一致致性结果可靠靠DMAICY的MSA-LQC成品煲水测试试结果2022/12/7SixSigma41BetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI10770.00(34.75,93.33)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.8623150.052704616.36130.0000OK0.8623150.052704616.36130.0000AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI10770.00(34.75,93.33)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.9306870.1054098.829270.0000OK0.9306870.1054098.829270.0000Kappa值大于0.7，说明所有检验员检验结结果一致性可可靠Kappa值大于0.9，说明所有检验员检验结结果与标准一一致性非常好好DMAICY的MSA-LQC成品煲水测试试结果2022/12/7SixSigma421.成品外观检查查结果不可以以接受，需对对检验员进行行培训。责任人：XXX、YYY。培训结束后需需进行第二次次MSA分析。2.成品功能、耐耐压、煲水测测试结果可以以信赖。MSA结果分析人员培训DMAIC2022/12/7SixSigma43成品品外外观观检检查查培培训训DMAIC培训训记记录录2022/12/7SixSigma44LQC成品品外外观观检检查查第第二二次次MSA样品标准测试员A测试员B测试员CⅠⅡⅢⅠⅡⅢⅠⅡⅢ1OKOKOKOKOKOKOKOKOKOK2NGNGOKNGNGNGNGNGNGNG3OKOKOKOKOKOKOKOKOKOK4NGNGNGNGNGNGNGNGNGNG5OKOKOKOKOKOKOKOKOKOK6OKOKOKOKOKOKNGOKOKOK7NGNGNGNGNGNGNGNGNGNG8NGNGNGNGNGNGNGNGOKNG9OKOKOKOKOKOKOKOKOKOK10NGNGNGOKNGNGNGNGNGNG测试试员员3名（（同同第第一一次次））;样品品10个;反复复3次DMAIC2022/12/7SixSigma45LQC成品品外外观观检检查查第第二二次次MSA结果果DMAIC2022/12/7SixSigma46WithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110880.00(44.39,97.48)210990.00(55.50,99.75)310990.00(55.50,99.75)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.7285070.1825743.990200.0000OK0.7285070.1825743.990200.00002NG0.8660710.1825744.743670.0000OK0.8660710.1825744.743670.00003NG0.8660710.1825744.743670.0000OK0.8660710.1825744.743670.0000Kappa值大于0.7,每个检验员员检验结果果一致性可可以接受P值小于0.05,说明检验员员检验结果果一致性结结果可靠每个检查员员检查结果果一致性(重复性)百分比DMAICLQC成品外观检检查第二次次MSA结果2022/12/7SixSigma47EachAppraiservsStandardAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI110880.00(44.39,97.48)210990.00(55.50,99.75)310990.00(55.50,99.75)#Matched:Appraiser'sassessmentacrosstrialsagreeswiththeknownstandard.AssessmentDisagreementAppraiser#OK/NGPercent#NG/OKPercent#MixedPercent100.0000.00220.00200.0000.00110.00300.0000.00110.00#OK/NG:Assessmentsacrosstrials=OK/standard=NG.#NG/OK:Assessmentsacrosstrials=NG/standard=OK.#Mixed:Assessmentsacrosstrialsarenotidentical.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs>0)1NG0.8653200.1825744.739550.0000OK0.8653200.1825744.739550.00002NG0.9326600.1825745.108390.0000OK0.9326600.1825745.108390.00003NG0.9326600.1825745.108390.0000OK0.9326600.1825745.108390.0000检验结果本本身不一致致次数Kappa值大于0.7,每个检验员员检验结果果与标准一一致性可以以接受所有检查员员检查结果果一致性(重复性)百分比P值小于0.05,说明检验员员检验结果果一致性结结果可靠DMAICLQC成品外观检检查第二次次MSA结果2022/12/7SixSigma48BetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI10880.00(26.24,87.84)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.8218700.052704615.59390.0000OK0.8218700.052704615.59390.0000AllAppraisersvsStandardAssessmentAgreement#Inspected#MatchedPercent95%CI10880.00(26.24,87.84)#Matched:Allappraisers'assessmentsagreewiththeknownstandard.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs>0)NG0.9102130.1054098.635040.0000OK0.9102130.1054098.635040.0000AttributeAgreementAnalysisKappa值大于0.7，说明所有有检验员检验验结果一致致性可靠Kappa值大于0.9，说明所有有检验员检验验结果与标标准一致性性非常好DMAICLQC成品外观检检查第二次次MSA结果2022/12/7SixSigma49现状能力分分析DMAIC2022/12/7SixSigma50不良率控制制图，失控控SIGMA水平百万不良数数DMAIC现状能力分分析2022/12/7SixSigma51主要问题分分析DMAIC需改善范围围现状能力分分析2022/12/7SixSigma521.进料胶件品品质C2.外购零件品品质C3.自制零件品品质C4.产品工程问问题C5.工艺流程执执行度C6.生产工艺改改善C7.人员判定能能力U8.工装夹具/设备C9.检测方法/手段U10.产品规格标标准U宏观流程分分析1.机身刮花2.连接头漏水水3.水龙头漏水水4.耐压不良5.杯刮花6.手柄离缝7.丝印不良机机身混色8.不通电.开关不良.9.机内异物10.温度高或低低进料检测主机总装大杯总装功能测试外观检查成品包装耐压测试煲水测试进料检测DMAIC流程输出输入2022/12/7SixSigma53-电铬铬铁铁温温度度-作业业员员技技能能-桌面面保保护护垫垫CU-大身身刮刮花花-丝印印脱脱落落-机身身混混色色●电机机品品质质-INT流程程输出出输入入流程程输出出输入入拆底底座座装装脚脚垫与与绕绕线线盖盖拆大大身身上上座座装电电源源线线到到底底座座-机身身混混色色装固固定定板板到到电电机机装马马达达垫垫固定定电电机机到到大大身身插插插座座引引线线装插插座座到到大大身身-INT-无功功能能-不发发热热-大身身刮刮花花-端子子尺尺寸寸-端子子材材质质-桌面面保保护护垫垫-作业业员员技技能能压连连接接头头,装开开关关-开关关品品质质-连接接头头品品质质焊接接引引线线（（一一））焊接接引引线线（（二二））焊接接引引线线（（三三））固定定压压线线码码与PCB板接线线绑扎扎带带流程程分分析析(微观观））-开关关不不良良-灯不不亮亮-异音音-不通通电电-大身身刮刮花花-机内内异异物物-大身身刮刮花花●底座座品品质质●作业业员员判判断断能能力力-大身身刮刮花花-反转转-INT-大身身刮刮花花-作业业者者技技能能-闭端端子子品品质质-桌面面保保护护垫垫●大身身上上座座品品质质●丝印印附附着着力力●作业业员员判判断断能能力力●桌面面保保护护垫垫-电铬铬铁铁温温度度-作业业员员技技能能-桌面面保保护护垫垫-反转转-大身身刮刮花花-PCB品质质-桌面面保保护护垫垫DMAIC类型型类型型CCUCCCCCUCCCCC-电铬铬铁铁温温度度-作业业员员技技能能-桌面面保保护护垫垫CCCCCCCCUCC-检查查方方法法-桌面面保保护护垫垫UC-反转转-INT-大身身刮刮花花-反转转-INT-大身身刮刮花花2022/12/7SixSigma54机身内内检不良品品修理理吹热缩缩管装装饰饰圈插杯座座引线线（二二）插杯座座引线线（一一）压插片片到杯杯座装脚垫垫固定FUSE与温控控器固定发发热盘盘到大大杯压滚动动轴承承,压轴承承到发发热盘盘-发热盘盘边口口锋利利度-发热盘盘外径径尺寸寸-铜杯仕仕内径径尺寸寸-发热盘盘品质质-耐压不不良，，-发热盘盘漏水水，-连接头头漏水水-不发热热，-功率不不良-电批扭扭力-密封圈圈尺寸寸-作业员员技能能-耐压不不良-不通电电-杯刮花花固定大大身上上下座座拆大杯杯,装手柄盖与与水龙龙头-水龙头头漏水水-手柄盖盖离缝缝-发热盘盘漏水水-耐压不不良-水温高高或低低-耐压不不良-端子尺尺寸-端子材材质-桌面保保护垫垫-大杯外外观-手柄盖盖扣位位尺寸寸-水龙头头尺寸寸-弹簧拉拉力-水龙头头密封封圈硬硬度-温控器器品质质-FUSH压板品品质-硅胶管管品质质-硅油脂脂涂抹抹均匀匀度DMAIC流程输出输入流程输出输入类型类型CCCCC流程分分析(微观））-底座错错位-大身刮刮花UCC-作业者者技能能-底座结结构-桌面保保护垫垫CCCCCCCCCCCCCC-耐压不不良-不通电电-杯乱花花-端子尺尺寸-端子材材质-桌面保保护垫垫CCC-大身刮刮花-作业员员技能能-桌面保保护垫垫-大身刮刮花-作业员员技能能-桌面保保护垫垫-大身刮刮花-作业员员技能能-桌面保保护垫垫-大身刮刮花-不通电电-作业员员技能能-桌面保保护垫垫UCUCUCUC-夹具可可靠度度C-不通电电2022/12/7SixSigma55包装装搅拌拌刀组组件上连接接头固定杯杯座功率测测试耐压测测试水温测测试清洁机机身绕电源源线-搅拌刀刀轴直直径尺尺寸-搅拌刀刀轴长长度-装配方方法-密封圈圈品质质-连接头头漏水水-杯刮花花-清洁布布粗糙糙度-清洁剂剂去污污能力力-大身刮刮花-丝印刮刮花清洁大大杯与与杯盖盖外观检检查DMAIC流程输出输入流程输出输入类型类型流程分分析(微观））CCUCCC-清洁布布粗糙糙度-清洁剂剂去污污能力力-大杯刮刮花CC-作业者者技能能-装配方方法UU-耐压不不良2022/12/7SixSigma56导出出主主要要因因子子—关键键流流程程DMAICC&E矩阵阵2022/12/7SixSigma57导出出主主要要因因子子—关键键流流程程DMAICC&E矩阵阵2022/12/7SixSigma58导出出主主要要因因子子—关键键流流程程DMAIC导出出预预想想的的16个流流程程和和30个主主要要因因子子C&E矩阵阵2022/12/7SixSigma59FMEA分析析DMAIC2022/12/7SixSigma60FMEA分析DMAIC通过RPN值，找出16个需改善的因因子2022/12/7SixSigma61问题点原因分析改善对策改善效果完成进度外观刮花,刮伤、脏污,丝印不良转储、搬运不当胶件(外壳,底座,大杯，杯盖)摆放高度控制,避免搬运时叠高运输,挤压产生不良通过此规定,目前小批量有较好改善,将在后续生产收集数据分析改善效果持续产品防护不当(产品只套PE袋保护)用干净PE胶袋包装,再套装气泡袋,每个胶框最上层用胶纸防护,避免灰尘工人操作刮花、刮伤对工人操作规程做培训,并将操作规程列入产品检验作业指导书，必要时关键工位戴手套作业，台面垫垫布工人操作防护意识逐渐形成,有一定改善,在平常工作中检查及监督,收集数据分析改善效果持续产品外观即时时改善DMAIC2022/12/7SixSigma62作业现场改善善作业现场改善善前作业现场改善善后DMAIC2022/12/7SixSigma63结构即时改善善改善前改善后经现场分析，，耐压不良80%由于发热盘边边口装配时刮刮伤内配线所所致。DMAIC2022/12/7SixSigma64裂口模具即时改改善水龙头裂口口模具改善善DMAIC2022/12/7SixSigma65现状能力力再分析析不良率控控制图,已受控SIGMA水平，已已初步提提升百万不良良数,降低了93477PPMDMAIC2022/12/7SixSigma66主要问题题分析DMAIC现状能力力再分析析2022/12/7SixSigma67二次FMEADMAIC通过RPN值，找出出8个还需改改善的因因子2022/12/7SixSigma68Y’S的确认LQC的MSA分析检查人员培培训宏观、微观观流程分析析现状能力分分析CE矩阵和FMEA分析制定即时改改善计划二次能力分分析，二次次FMEADMAIC测量阶级小小结2022/12/7SixSigma69分析阶段2022/12/7SixSigma70数据收集计计划DMAIC2022/12/7SixSigma71分析阶阶段MSADMAIC检测员员二人人，样样品十十个，，重复复三次次。电子数数显卡卡尺测测量系系统分分析2022/12/7SixSigma72GageR&RStudy-ANOVAMethodTwo-WayANOVATableWithInteractionSourceDFSSMSFP部件90.9423680.104708656.7030.000检测员员10.0002820.0002821.7670.217部件*检检测测员90.0014350.0001591.4720.192Repeatability400.0043330.000108Total590.948418GageR&R%ContributionSourceVarComp(ofVarComp)TotalGageR&R0.00012940.74Repeatability0.00010830.62Reproducibility0.00002110.12检测员员0.00000410.02检测员员*部部件0.00001700.10Part-To-Part0.017424799.26TotalVariation0.0175541100.00StudyVar%StudyVarSourceStdDev(SD)(6*SD)(%SV)TotalGageR&R0.0113770.0682648.59Repeatability0.0104080.0624507.86Reproducibility0.0045950.0275683.47检测员员0.0020180.0121111.52检测员员*部部件0.0041280.0247663.12Part-To-Part0.1320030.79201699.63TotalVariation0.1324920.794952100.00NumberofDistinctCategories=16分析阶阶段MSA结果GageR&R小于10%，可接受受分辨率等等级大于于5，非常好好ANOVA分析测量系统统可接受受2022/12/7SixSigma73DMAIC变量名称类型分析工具Y

水温高或低计量型ANOVA分析

1.正态性检验

2.One-WayANOVA3.残差分析X

温控器断开温度计量型Multi–Vari研究温控器断断开温度度水平：：78±20CA.760CB.780CC.800C2022/12/7SixSigma74DMAICY的正态性性检验Y的主影响响效果图图P>0.05,符合正态态分布ANOVA分析2022/12/7SixSigma75DMAICANOVA分析P>0.05方差相等等方差检验验2022/12/7SixSigma76One-wayANOVA:yversusxSourceDFSSMSFPx217.2988.64912.180.001Error1510.6520.710Total1727.949S=0.8427R-Sq=61.89%R-Sq(adj)=56.81%Individual95%CIsForMeanBasedonPooledStDevLevelNMeanStDev-------+---------+---------+---------+--1679.0170.783(------*------)2680.1501.093(------*-------)3681.4170.567(------*------)-------+---------+---------+---------+--79.080.081.082.0PooledStDev=0.843DMAICANOVA分析可以信赖ANOVA检验结果H0:温控器对水水温无影响响H1:温控器对水水温有影响响P值<0.05,拒绝原假设设说明温控器器对水温有有显著影响响2022/12/7SixSigma77DMAIC变量名称类型分析工具Y

水龙头漏水计数型1.PowerandSampleSize

2.TabulatedstatisticsX1

水龙头尺寸计量型X2水龙头胶塞硬度计量型水龙龙头头尺尺寸寸水水平平：：24.0+0.1mm1.24.0mm2.24.1mm水龙龙头头胶胶塞塞硬硬度度水水平平：：35--40度1.35度2.40度Multi–Vari研究2022/12/7SixSigma78水龙头头尺寸寸水龙头头尺寸寸水平平：24.0+0.1mm1.24.0mm2.24.1mm样本容容量PowerandSampleSizeTestforTwoProportionsTestingproportion1=proportion2(versusnot=)Calculatingpowerforproportion2=0.5Alpha=0.05SampleTargetProportion1SizePowerActualPower0.1200.80.813128Thesamplesizeisforeachgroup.DMAIC2022/12/7SixSigma79H0:水龙头头尺寸寸对水水龙头头漏水水无影影响H1:水龙头头尺寸寸对水水龙头头漏水水有影影响P值<0.05,拒绝原原假设设说明水水龙头头尺寸寸对水水龙头头漏水水有显显著影响列连表表检验验DMAICTabulatedstatistics:水龙头头尺寸寸,水龙头头漏水水Rows:水龙头头尺寸寸Columns:水龙头头漏水水NGOKAll24.0020200.00100.00100.000.0057.1450.000.0050.0050.0024.15152025.0075.00100.00100.0042.8650.0012.5037.5050.00All5354012.5087.50100.00100.00100.00100.0012.5087.50100.00CellContents:Count%ofRow%ofColumn%ofTotalPearsonChi-Square=5.714,DF=1,P-Value=0.017LikelihoodRatioChi-Square=7.648,DF=1,P-Value=0.006*NOTE*2cellswithexpectedcountslessthan52022/12/7SixSigma80水龙头头胶塞塞硬度度水龙头头胶塞塞硬度度水平平：35--40度1.352.40.样本容容量PowerandSampleSizeTestforTwoProportionsTestingproportion1=proportion2(versusnot=)Calculatingpowerforproportion2=0.5Alpha=0.05SampleTargetProportion1SizePowerActualPower0.1200.80.813128Thesamplesizeisforeachgroup.DMAIC2022/12/7SixSigma81列连表表检验验H0:水龙头头胶塞塞硬度度对水水龙头头漏水水无影影响H1:水龙头头胶塞塞硬度度对水水龙头头漏水水有影影响P值<0.05,拒绝原原假设设说明水水龙头头胶塞塞硬度度对水水龙头头漏水水有显显著影响DMAICTabulatedstatistics:水龙头头胶塞塞硬度度,水龙头头漏水水Rows:水龙头头胶塞塞硬度度Columns:水龙头头漏水水NGOKAll350202001001000.0058.8250.000505040614203070100100.0041.1850.00153550All634401585100100.00100.00100.001585100CellContents:Count%ofRow%ofColumn%ofTotalPearsonChi-Square=7.059,DF=1,P-Value=0.008LikelihoodRatioChi-Square=9.382,DF=1,P-Value=0.002*NOTE*2cellswithexpectedcountslessthan52022/12/7SixSigma82DMAIC变量名称类型分析工具Y

连接头漏水计数型1.PowerandSampleSize

2.TabulatedstatisticsX1

刀杆长度计量型X2

密封垫厚度尺寸计量型Multi–Vari研究刀杆长度