六西格玛046sigma工具其它未分类6project

6SIGMA BBProjectNOV-23-2000Page1FDD

Department主要内容6–SigmaProject

登录书

6–SigmaProject

步骤书

Measure-PhaseAnalyze-PhaseImprove

-

PhaseControl

-Phase6–SigmaProject

结束报告书NOV-23-2000Page2Head

Carriage(Nut

Miss)Spindle

Motor

Ass'yCarriage-UP

Ass'yHGA

Side0PCB-Main

Ass'y(FDD)Bezel

Ass'yOthers8814633.733.78042230.864.54769118.382.8174376.789.5101313.993.352382.095.4121374.6100.00100000200000020406080100DefectCountPercentCum

%PercentCountDefine–Project

选定事由D废弃金额最大NOV-23-2000Page3Pareto

Chart

for

Material

Des原材料不良废弃分析（10/1~10/31）6

SIGMA

Project

登录书效果金额单品在工材料费基准

材料费：

(5710-1000)*70000*(6.5+1)*27*12/10000000=801,171RMB

PROJECT

活动期间2000.10.3.~

2001.1.31.问题点(现水准)NUT

原材料尺寸不良；Carriage

Lower

Nut

组立Hole

设计问题；富钢NUT

组立工程压入不良；Main

Line

Carriage

Upper

组立不良。活动方向Nut

原材料改善；Carriage

Lower

Nut

Hole

设计变更；富钢相关作业者作业方法，组立设备改善Main

Line作业者教育。部门长推进事务局财会TEAM

长Champion朴夏律金英浩刘晓星Leader杨进活动Member邓常松周建良贺志才PROJECT名Carriage

Lower

NUT

脱落不良改善关联ProcessBond涂抹工程，Nut

熔着工程，Carrige

Upper

组立工程。指导BB部门长朴夏律PROJECT推进日程DMAIC9/3~9/209/21~9/3010/3~10/3011/1~12/112/1~12/30成果指标活动前现水准活动后向上率工程不良率5710PPM1000PPM82.50%Sigma水准4.03δ4.59δPROJECT

效果NOV-23-2000Page46

SIGMA

Project

步骤书PROJECT

选定事由工程不良率高，关联原材料浪费严重，

影响工程品质及生产性，且不良原因集中■现象确认(问题中心)WHAT(对象)Nut

&

Carriage

LowerWHERE(关联工程)Nut

熔着工程、S1

组立工程HOW(关联指标)Secew

组立不可■现象确认2(4M侧面)MAN

Nut

熔着工程人员，S1

组立工程人员MACHINE

Nut

熔着机S1

组立Drive*MATERIAL

Nut

&

Carriage

Lower■效果给部门带来的影响降低产品返修率，提高工程品质及生产性给顾客带来的影响提高产品信赖性，降低User

不良率，达到客户满足的要求。*METHODNut

熔着工程作业方法教育S1

组立工程作业方法教育SOLVE■最高目标GAP

分析■解决方案(对策)Sensor

原材料弹性增强；关联Jig

重新调整；相关作业者作业方法教育；为测定分析的适用方法Nut

熔着JIG

Gauge

R&R

评价

Line

别工程不良统计比较。

Driver

Torque

管理ImplementChartNOV-23-2000Page5Process

MappingNUT

press

&drillN-作业者N-设备偏差

C-Drive

TorqueC-S1组立JigN-作业者涂抹量N-Bond涂抹均匀性

C-Bond浇口大小C-Bond干燥时间

C-Bond

性能N-作业者Nut安放

C-压入Jig定位C-压入Jig

Air

pressC-压入Jig冲头行程

C-工作台异物S-压入Jig的润滑N-作业者S-设备预热

S-模具温度

C-模具尺寸

C-部品结构

C-成型毛刺

C-材料性质Nut

&

CarriageLowerAssemblyBond

涂抹工程S1

AssemblyS1

&CarriageLower组立Nut

外围Bond涂抹Nut

&

CarriageLower

组立Carriage

Lower成型C/L注塑成型Nut

PressNut

DrillN-作业者N-设备震动

C-模具精度

C-模具保养C-Drill

Macheine精度C-定位精度

C-材料性质

S-设备润滑MNOV-23-2000Page6作业不标准外观检查不良Bond涂抹不均或量少Nut

压入Jig

Air

不良Nut

压入Jig

不良Nut同心度不良Nut

drill不良C/L

内径尺寸不良Bond

粘度不良目视检查Nut

测试不良模具别偏差Bond

保管处温度高PersonnelMachinesMaterialsMethodsMeasurementsEnvironmentNut

脱落不良分析Cause

-

and

–

Effect

DiagramNut

脱落不良MMeasurementsMaterials

MenNut

外径尺寸不良Drive

Torque

过大

NUT

模具不良Methods

MachinesEnvironmentNOV-23-2000Page7XYMatrixM12345678910Rank%

Rank25212411423620519517814217015210414912.47%6.14%5.64%11.68%10.14%9.65%8.81%7.03%8.41%7.52%5.15%7.37%12345678910111213141516ViewResultsDeleteInstructionsOutputVariables

(Y's)Nut&C/L配合状况Bond

粘着力Nut压入状况Nut

脱落程度OutputRanking98710Input

Variables

(X's)Association

TableNut

外径尺寸91910Nut

Screw

同心度11110Nut

Screw破损1119C/L内径尺寸81810C/Lhole

外型6198Bond

涂布量21019Bond

粘性1919Bond涂布均匀度1717压入Jig

Air

Press1199压入Jig

定位2187Drive

Qurque1118组立作业方法31210DEMONOV-23-2000Page8Characteristic

Selection

MatrixResults60%50%40%30%20%10%0%70%80%100%90%Nut

外径尺寸Nut

Screw

同心度Nut

Screw破损C/L内径尺寸C/Lhole

外型Bond

涂布量Bond

粘性Bond涂布均匀度压入Jig

Air

Press压入Jig

定位Drive

Qurque组立作业方法Input

CharacteristicCharacteristic

Importance

(%)M【续上】改善必要!!!NOV-23-2000Page9Process

FMEAMPotential

Failure

Modesand

Effects

AnalysisProcess

Name:

Track00

AlignmentProcess

Responsibility:工程技术队Affected

Product(s):3.5''

Double

High

Density

FDDPFMEA

Key

Date:1999年12月20#ProcessFunction(Step)Potential

FailureModes

(processdefects)Potential

FailureEffects

(Y's)SEVClasPotentialCauses

ofFailure

(X's)OCCCurrentProcessControlsDETRPNRecommendActions1Nut

Press&Drill模具凹模尺寸不良Nut外径尺寸不良9模具不良6模具制造管理5270Nut

Drill

不良Nut

Screw

不良10Drill

Machine

不良2Drill

设备控制480Nut

Drill定位不良Nut

同心度不良10定位Jig

不良3Drill

定位Jig精度390材料不良Nut

尺寸变形9材料不良3QC抽检5135模具磨损Nut

尺寸不良10模具不良5定期保养42002CarriageLower模具凸模尺寸不良C/L尺寸不良10模具不良5模具制造管理4200注塑条件不良C/L尺寸变化8设备管理不良3标准操作者管理372模具型芯尺寸不良Nut

定位不良10模具不良5模具制造管理5250Resin

不良C/L尺寸变化7原材料不良3QC抽检242C/L

内异物C/L

压入变形85S管理不足4生产管理396NOV-23-2000Page10【续上】MRecommend#ProcessFunction

(Step)Potential

FailureModes

(processdefects)PotentialFailureEffects

(Y's)SEVClaPotentialCauses

ofFailure

(X's)OCCCurrentProcessControlsDETRPNActions3Nut&C/L

AssemblyNut

安放不好Nut

压入不良8作业者疏忽4外观检查100%目测396压入Jig

Air

Press未管理压力不足8设备管理不良6无管理7336压入Jig

定位不良C/L破损8设备不良5设备定期管理4160压入Jig冲头BendNut

压入变形9设备不良3设备定期管理4108压入Jig冲头行程不足Nut未压紧9设备不良4设备定期管理62164Bond涂布工程涂布不均匀Nut

粘着力不强7作业方法无标准化，作业者品质意识差6外观检查100%目测8336涂布量不足Nut

粘着力不强7作业方法无标准化，作业者品质意识差5外观检查100%目测7245Bond涂布器浇口不良Bond

涂量不足7作业工具无标准化5无管理8280Bond干燥状况Nut

粘着力不强8干燥环境差4自动干燥396Bond粘性Nut

粘着力不强9原材料不良3无管理8216点滴方法Nut

粘着力不强5作业方法无标准化，作业者品质意识差5无管理71755S1

AssemblyDrive

Torque

不良Nut

受力大6Torque

管理不足31

Time/2Shift

点检6108作业者方法Nut

受力方向不良5作业方法无标准化，作业者品质意识差4100%全检6120NOV-23-2000Page11Attribute

Gauge

R&R

EffectivenessSCORING

REPORTDATE:

2000-11-15Attribute

Legend5

(used

in

computations)1

pass

2

fail

NAME:

Allied

EmployeePRODUCT:

SFD-321B/***BUSINESS:Alloperatorsagree

within

andbetween

each

OtherAllOperatorsagree

with

standardNut脱落Nut正常Known

PopulationOperator

#1Operator

#2Operator

#3Y/NAgreeY/NAgreeSample

#AttributeTry

#1Try

#2Try

#1Try

#2Try

#1Try

#21234567891011121314passpasspasspasspasspasspassYYpasspasspasspasspasspasspassYYpasspasspasspasspasspasspassYYfailfailfailfailfailfailfailYYpasspasspasspasspasspasspassYYpasspasspasspasspasspasspassYYfailfailpassfailfailpass

已passfailfailpassfailfail知pa的ss

真passfailfailfailfailfailYYpasspasspasspassfailfailp检ass

查passfailpassfailfail结p果asspassfailYYfailfailfailYYfailfailfailYYpass值passpassYYpasspasspassYYfailfailfailYYpasspasspasspasspasspasspassYYMNOV-23-2000Page12SourceTotal

Inspected#

MatchedFalse

Negative

(operFalse

Positive

(operaMixed95%

UCLCalculated

Score95%

LCL%

Appraiser1Operator

#1

Operator

#2

Operator

#3%Score

vs

Attribute2Operator

#1

Operator

#2

Operator

#3141414141414141414141414ator

rejectedgoodproduct)tor

accepted

bad

product)000000000100.0%100.0%100.0%100.0%100.0%100.0%100.0%100.0%100.0%100.0%100.0%100.0%76.8%76.8%76.8%76.8%76.8%76.8%Screen

%

Effective

Score3Screen

%

Effective

Score

vs

Attribute414141414100.0%100.0%100.0%Total

Inspected#

in

Agreement95%

UCLCalculated

Score95%

LCL76.8%100.0%76.8%NotesOperator

agrees

with

him/herself

on

both

trialsOperator

agrees

on

both

trials

with

the

known

standardAlloperators

agreed

within

and

between

themselvesAll

operators

agreedwithin&

betweenthemselves

AND

agreedwith

theknownstandard%

Appraiser110.0%100.0%90.0%80.0%70.0%60.0%50.0%40.0%30.0%20.0%10.0%0.0%Operator

#1

Operator

#2

Operator

#3%

Efficiency95%

UCLCalculated

Score

95%

LCL%

Score

vs

Appraiser110.0%100.0%90.0%80.0%70.0%60.0%50.0%40.0%30.0%20.0%10.0%0.0%Operator

#1

Operator

#2

Operator

#3%

Efficiency95%

UCLCalculated

Score

95%

LCL【续上】检查人员一致性地评价的次数%Statistical

Report

-

Attribute

Gage

R&R

StudyDATE:

2000-11-15NAME:

Allied

EmployeePRODUCT:

SFD-321B/***BUSINESS:

1900-1-0检查人员与真值一致性地评价的次数%检查人员一致性地评价的次数%与真值一致性地评价的次数%

(检查者间)MNOV-23-2000Page13M-Phase

小结Nut

脱落不良重要影响因素Nut

Diameter尺寸；Carriage

Lower

内径尺寸及设计作业者作业方法；Nut

压入Jig

的压入情况Bond

涂抹量及涂抹均匀度重要因子NOV-23-2000Page143.903.954.004.054.10LSLUSLProcess

Capability

Analysis

for

Nut

DiameterUSLTarget

LSLMeanCp

CPU

CPLCpkCpmPp

PPUPPLPpkPPM

<LSL

PPM

>USLPPM

TotalPPM

<LSL

PPM

>USLPPM

TotalPPM

<LSL

PPM

>USLPPM

Total*3.900003.93856Sample

N

100StDev

(Within)

0.0135108StDev

(Overall)

0.01349282.473.980.950.95*2.473.990.950.950.000.000.002156.860.002156.862131.080.002131.08Process

Data4