SPC统计过程控制培训

统计过程控制StatisticalProcessControlforOperatorsWelcome欢迎培训目的

TrainingGoal目的--助你获得SPC的知识及技巧OurGoal--TohelpyougainrelevantSPCknowledge&skills.什么是SPC及SPC的益处

WhatisSPCandbenefits.数据的收集及测量

Datacollectionandmeasurement.使用反应计划解决问题

Troubleshootingusingreactionplans工序的稳定&能力(CP和CPK)

ProcessStabilityandCapability.(CPandCPK)培训内容

TrainingAgenda什么是SPC?

WhatisSPC?利用统计技术如控制图去分析工序或其产物,以采取适当的行动去达致及维持一个受统计技术控制的状态以及改善工序能力.Theuseof

statistical

techniquessuchascontrolchartstoanalyzea

process

or

itsoutputssoastotakeappropriateactionstoachieveandmaintainastateof

statisticalcontrol

andtoimprovetheprocesscapability.Outofcontrol失控Trends趋势Shifts偏移ControlChart控制图统计技术Statistical工序Process控制ControlLCLUCL什么是SPC?

WhatisSPC?Measurement测量

Cause—EffectDiagram

因果图（鱼骨图）Effect

果Machine机Environment环境Man人Material物料Methods方法

Cause因什么是SPC?

WhatisSPC?

ParetoDiagram柏拉图DefectivesScratchPlugholeOpenShort什么是SPC?

WhatisSPC?DetermineKeyProductCharacteristics介定关键的产品特性DetermineKeyVariables介定关键的变量PlantheMatrixofValidationTests计划确认测试的矩阵

DOE实验设计什么是SPC?

WhatisSPC?Functionaffected被影响的功能PotentialFailuremode潜在缺陷模式-PotentialEffect潜在影响-PotentialCause潜在原因-DesignControl设计控制

ActionPlan行动计划Result结果FMEA缺陷模式与后果分析什么是SPC?

WhatisSPC?什么是SPC?

WhatisSPC?SPC数据=工序的声音SPCdata=thevoiceoftheprocess!统计技术Statistical收集及整理数字化的事实数据Collection&arrangementofnumericalfacts.Data!控制Control

预防,预测,监管Prevention.Prediction.Regulation.工序Process执行一件工作的一连串步骤Seriesofstepstoperformatask是否一组图表?Isitasetofcharts?是否一个警告系统?Isitawarningsystem?是否一个预防性方法?Isitapreventivemethod?使用SPC目的

UsingSPCObjectives我们的SPC目的是为你提供一个有利于持续改善的工具:OurSPCobjectivesistoprovideyouwithatoolforcontinualimprovementthathelpsto:将工序变异减致最少 minimizeprocessvariation.消除流程的错败 eliminatefailuresinourprocesses.将产品能力尽量提升 maximizeproductcapability.加强客户满意程度 increasecustomersatisfaction.SPC价值

SPCValue

少报废Lessscarp

少返工Lessrework

少停机Lessdowntime

更佳利润Betterprofit

更佳市场信誉Goodreputationinmarketplace!SPC价值

SPCValue

更佳产品质量Betterqualityproduct

更多可靠产品Morereliabledelivery

可以信赖的供应商Asuppliertheycancounton客户CustomersSPC价值

SPCValue

少挫败感及无聊时间

Lessfrustration&downtime

更能控制工作Morecontrol

更能对工序及产品问题作正确决定Abilitytomaketherightdecisionaboutprocessofproductproblems

能生产更优值的产品Betterproductcomingfromtheareinfrontofme你YouSPC如何帮忙?

HowSPCCanHelp生产中DuringProduction发生问题时(特殊原因)SPC数据会发出讯号SPCdatasendasignalthatthere’saproblem(specialcause).我们采取纠正行动防止问题Wetakecorrectiveaction

topreventdefects.将来FortheFutureSPC数据提供一个工序变异的历史记录SPCdataprovideahistoryofthevariationintheprocess.我们改善工序以减少一般原因导致的变异Weimprovetheprocesstoreducecommoncausevariation.统计技术及控制图

StatisticsandControlCharts如何运用统计技术于控制图?Howdoweusethesestatisticsoncontrolcharts?收集数据--数目或量度某物Collectdata--countormeasuresomething.于控制图上画上数值Plotthedataonthecontrolchart.或...OR...计算统计数值于控制图上画上数值Calculateastatisticandplotthestatisticonthechart.SPC步骤:WWHWWW

SPCStep-WWHWWW什么数据需要收集?

Whatdatadoweneed?为什么需要收集数据?

Whydoweneedtocollectdata?如何得到数据?

How

willwegetthedata?何时收集数据;多久收集一次?

When

dowecollectit;howoften?流程中哪处收集数据?

Where

intheprocessdowegetthedata?谁收集数据?

Who

collectsthedata?收集数据Collectdata什么数据需要收集?

Whatdatadowecollect?收集数据Collectdata客户要求:功能;外观CustomerRequirementsFunctionalAesthetic产品特性（计数型）ProductFeatures工序参数（计量型）ProcessVariables为什么需要收集数据?

Whyshouldwecollectthedata?收集数据Collectdata监控变异Tomonitorvariation.尽早指出工序问题Toidentifyprocessproblemsasearlyaspossible.为什么?Why?如何收集数据?

Howdowecollectthedata?如何?How?收集数据Collectdata我们需要一个测量系统Weneedameasurementsystem.方法--技巧,工具,经培训的员工Method

--technique,tool,trainedpeople记录--数据收集表格,表达数据的格式(即控制图)Record--datacollectionsheet,formattopresentdata(i.e.,controlchart)计划--负责人,收集数据地点,频率,时间Plan--who,where,howoften,when何时及何处收集数据?

When&wheredowegetthedata?那一个比较好?Whichisbetter?工序中作测量Measureon-line最后检查Inspectatend何时收集数据?

Whendowecollectthedata?流程中作测量MeasureOn-line,DuringtheProcessSPCSPC预防性Preventionfocus避免浪费Avoidswaste提供质量一致的产品Deliversconsistentproducts减少变量Reducesvariation主动性Proactive于流程终点作检查InspectProductattheEndoftheProcess检查Inspection侦察性Detectionfocus容忍浪费Tolerateswaste返工Reworksproducts容忍变异Toleratesvariation被动性Reactive数据的种类

TypesofData计量的Variables可用连续性的单位Measureonacontinuousscale可以是流程或量度的特性Foraprocessorproduct例子:Examples:线宽linewidth板料厚度laminationthickness计数的Attributes数量,等级,类别Count,grade,categorize不能量度的Can’tmeasureit

一般是产品特性Usuallyforaproduct例子:Examples:坏品百分比%defectiveparts甩货百分比%orderslate控制图种类

TypesofControlCharts计量控制图VariablesCharts用于连续单位的量度Fordatawegetbymeasuringonacontinuousscale.例子Examples温度temperature线宽circuitwidth厚度pinheight分别监察两组统计数值的三对控制图Threepairsofchartsthatmonitortwostatistics.平均及范围(X-R)Average&R(averageandrange)平均及标准差(X-S)Average&S(averageandstandarddeviation)个别值移动范围(X-MR)X&MR(individualsandmovingrange)计数控制图AttributeCharts用于数量等级或分类的数据Fordatawegetbycounting,gradingorcategorizingthings.例子Examples甩货百分比#oflatedeliveries坏板百分比#ofdefectivecircuitboards计数控制图AttributeChartsNPPUC控制图种类

TypesofControlCharts规格

Specifications客户,供应商或内部工程要求Customer,supplierorinternalengineeringrequirements包括:Include:目标或中间值(最理想的)targetornominalvalue(theideal!)在目标值两旁可接受的变异allowablevariationoneithersideofthetargetvalue规格上限=目标值+可接爱的变异USL=target+allowablevariation规格下限=目标值-可接受的变异LSL=target-allowablevariation例子--酸浓度

Example--AcidConcentration规格是130克/升+/-30克升Specificationis130grams/liter+/-30grams/liter规格上限=目标值+可接受的变量USL=target+allowablevariation130+30=160规格下限=目标值-可接受的变异LSL=target-allowablevariation130-30=100可接受变异的总值=规格上限=规格下限Totalallowablevariation=USL-LSL160-100=60控制限--控制上,下限

ControlLimits--UCL,LCL若流程受到控制:Ifyourprocessisincontrol:99.7%的数据将会在控制上限及下限之间.99.7%ofthedatapointswillbebetweentheUCLandLCL.数据没有特定的图样=随机的.Datapointswillshownopattern=random.大部分数据会趋向平均值.Mostdatapointswillbeclosetotheaverage.数据应有一半在平均值以上及一半在以下.Datapointsbe50/50aboveandbelowaverage.控制限--好处

ControlLimits--Benefits减少两个可能的错误Minimizestwopossiblemistakes:忽略问题Ignoringaproblem.采取不必要的纠正行动Takingunnecessarycorrectiveaction.

曲线下的出现可能性已知Probabilitiesunderthecurveareknown.有利于预测和计划Goodforpredictionandplanning.有利于侦察不正常的数据Goodforspottingweirdpatternsofpoints.控制图及标准差

ControlCharts&StandardDeviation使用标准差决定控制上限及下限,如钟状曲线.TodetermineUCL&LCL,usestandarddeviation(s)--justlikethebellcurve!+3s-3sUCL=Average+3sAverageLCL=Average-3s-3s+3s利用变异的数值(标准差)去建立变异的一般范围(控制上限及下限之间的范围)是否合理?Doesn’titmakesensetouseameasureofvariation(standarddeviation)toestablishanormalrangeofvariation(areabetweenUCLandLCL)foraprocess?设定控制限

SettingControlLimitsAverage-3s+3s-2s+2s-1s+1sLCLUCL-3s+3s-2s+2s-1s+1sLCLUCLAverage-3s+3s-2s+2s-1s+1sLCLUCLAverage将钟状曲线转90度Flipthebellcurveonit’sside.设定控制限

SettingControlLimitsUCL=Average+3sLCL=Average-3s-3s+3s-2s+2s-1s+1sAverageLCLUCL这是什么意思?Whatdoesitallmean?生产中使用SPC

UsingSPCDuringProduction1.收集数据Collectdata3.理解数据Interpretthedata2.在图上记录数据Recorddataonchart4.特别原因SpecialCause?6.采取纠正行动

Takecorrectiveaction5.继续执行流程

Continuetoruntheprocess是Yes否No7.准备文件

Document使用SPC--例子

UsingSPC--AnExample88.18.28.38.48.58.68.78.88.99123456789101112131415mils是否有特别问题发生?Didanythingspecialhappen?1.收集数据

Collectdata3.理解数据Interpretthedata2.在图上记录数据

Recorddataonchart4.特别原因SpecialCause?基本控制图格式

BasicControlChartFormat一般原因导致的变异

Commoncausevariation特别原因导致的变异Specialcausevariation88.18.28.38.48.58.68.78.88.99123456789101112131415milsUCLLCLY轴-量度

y-axis-scaleformeasurementsX轴-时间

X-axis-timesequence

平均值(典形数值)Average(thetypicalvalue)平均年龄=(27+27+33+46+57)÷5=38岁Averageage=(27+27+33+46+57)÷5=38years2727334657Averageage=38统计技术--中间值倾向

Statistics--CentralTendency统计技术--分布

Statistics--Spread范围(R)--最大数字减最小数字Range(R)--highestnumberminuslowestnumberR=(57-27)=30岁R=(57-27)=30years幅度=30岁Range=30years2727334657统计技术--分布

Statistics--Spread标准差(S)=个别数值与平均值相差的平方Standarddeviation(S)--Howfaraway,onaverage,aretheindividualdatavaluesfromtheaverageage?S=13.2岁S=13.2yearsAverage=3811

years11

years19years8years5years2727334657例子--计数控制图

Example--AttributeChartPChart--VAASFastechFinalInspectionAverageLCLUCL0150003000045000600007500090000105000120000135000150000123456PPM流程稳定性

ProcessStability稳定的流程StableProcess一致的Consistent可预测的Predictable特别原因Nospecialcauses受控的Incontrol稳定性可用控制图量度Stabilityismeasuredusingcontrolcharts.流程可以是受控,但不符合规格的.Aprocesscouldbeincontrol,butnotmeetspecifications.??????什么是流程?

Whatisaprocess?完成一件工作的一连串步骤Aseriesofstepswefollowtoaccomplishatask.步骤Steps成品Outputs输入Inputs??????流程的内容

ThepartsofaProcess物料Materials人People机器/设备Machines方法Methods环境

Environment稳定,能力及质量

Stability,Capability&Quality为能做到优越的表现,工作流程必须:Toachieveperformanceexcellence,workprocessesmustbe:

稳定

Stable一致的,可预计的consistent,predictable

有能力

Capable持续符合规格continuallymeetsspecifications

持续改善

Continuallyimproved流程稳定及能力

ProcessStability&Capability有能力的流程CapableProcess流程有能力持续的满足规格要求Processhastheabilitytocontinuallymeetspecifications.工序必须处于受控状态(统计技术角度),才可被认为有能力Processmustbeinstatisticalcontrolbeforeitcanbeconsideredcapable.稳定

Stability稳定的工序Stableprocess受统计技术控制instatisticalcontrol无特别原因导致的变异nospecialcausesofvariation稳定工序的控制图Controlchartfromastableprocess无超越控制上限或下限的点nopointsoutsideUCLorLCL无偏移或走势noshiftsortrends工序可以说是于一定时间内受到控制,而只有一般原因导致的变异Suchaprocessissaidtobeincontroloveraseriesoftime,withonlycommoncausespresent.LCLUCLCL变异

Variation个别成品之间不可避免的分别Theinevitabledifferencesamongindividualoutputsofaprocess.一般原因导致的变异CommonCauseVariation正常,常见,可预计的-自然的normal,usual,expectedthings--natural特别原因导致的变异SpecialCauseVariation偶发性,不可预计的-特定的sporadic,unexpectedthings--assignable变异何时何地都会出现

VariationisEverywhere!物料变异:化学品浓度,混合比例及补料份量,不同供应商MaterialVariation:chemicalconcentration,mixratios&dosing;differentsuppliers设备变异:保养时间,损耗,调校过程MachineVariation:maintenanceschedules,wear&tear,calibrationprocess人为变异:技巧及经验,身材及体能,态度及纪律PeopleVariation:skill&experience,size&strength,attitude&disciplinea方法变异:程序文件,文件维持MethodVariation:documentationofprocedures,maintenanceofdocumentation环境变异:时间,天气,厂房位置,空气污染EnvironmentalVariation:time,weather,locationofplant,aircontamination变异结果

ConsequencesofVariation流程中太多一般原因导致的变异Toomuchcommoncausevariationinaprocess流程中出现特别原因导致的变异Anoccurrenceofspecialcausevariationinaprocess影响工作disruptioninwork生产力下降lostproductivity报废及返工scrapandrework甩交货期misseddeliverydates不稳定的产品表现variableproductperformance不稳定的产量erraticproductyields不稳定的产品特性variationsinproductfeaturesAAAAAAAAAAAAAACp及Cpk值

ValueofCpandCpk根据规格评估流程表现.Evaluateprocessperformanceagainstspecs.决定流程是否能满足新规格要求.Determineifprocesscanmeetnewspecs.根据Cpk及Cp值的距离制订改善目标.SetimprovementgoalbasedondistancebetweenCpkandCp.评估供应商.Evaluatesuppliers.用于销售过程的一部分.Useaspartofsalesprocess.Cpk--量度工序设定

Cpk-MeasuresProcessSetting比较工序参数中间值设定及目标.Comparessettingofprocesscenter(average)totarget.基本定律:Cpk要求最少1.33Generalrule--aimforCpkof1.33minimumUSLLSL目标Target工序参数中间值ProcessCenter偏离中间值OffCenter!!Cpk--例子

CpkExamplesCpk良好GoodCpkCpk差PoorCpkLSLUSLLSLUSLCp--量度流程分布

Cp-MeasuresProcessSpread比较可接受变异(A)及实际变异(B)Compareallowablevariation(B)toactualvariation(A).B=USL-LSLA=6标准差A=6standarddeviationsCp=B/ALSLUSLABCp必须大于1

CpShouldBeGreaterThan1显示于实际变异少于可接受变异Indicatesactualvariationislessthanallowablevariation.LSLUSLLSLUSLLSLUSLCp大于1Cpgreaterthan1Cp=1Cp小于1Cplessthan1Cp--总结

Cp-Conclusions数值越大越好!Thebiggerthenumber,thebetter!Cp的缺点--只能显示流程分布,但不能显示是否符合规格DeficiencyofCp--Itshowsonlythespreadofprocess,butnotthecompliancetospecification.例子：两流程的Cp一样。

Example:TwoprocesseswithsameCp.USLLSLTargetUSLLSLTarget工序能力不足的两种情况

TwoWaysaProcessIsNOTCapable1.实际工序变异超出可接受变异的总值

Actualprocessvariation(A-sixsigma)exceedstotalallowablevariation(B-spec)TargetBALSLUSL产品不符合规格Productsoutofspec产品不符合规格Productsoutofspec工序能力不足的两种情况

TwoWaysaProcessIsNOTCapable2.如工序表现不足处于规格的中间位置,并其中一边的控制限超越规格限.

Ifprocessisnotcenteredproperlyandoneofthecontrollimitsexceedsthespeclimit.LSLUSLLCLUCLTargetAverage产品不能符合规格Productsoutofspec!产品不是最佳Productsnotthebest.若工序能力不足如何办?

Whatifaprocessisn’tcapable?流程需要改善Theprocessneedsimprovement!首先,采取改善行动,减少变异,然后,按目标值将流程表现调至中间值.First,takeactiontoreducethevariation.Then,centertheprocessoverthetarget.表现不良Badnews!表现改善Gettingbetter进一步改善MuchbetterUSLLSLTargetUSLLSLTargetUSLLSLTarget你需要做什么?

Whatshouldyoudo?USLLSLCp<2andCpk<1采取预防行动清除不合格产品

Takeprecautionstoremove

non-conformingproducts持续努力减少变异

Continueeffortstominimizevariation将工序表现控制到中间值

Centertheprocess维持工序于控制限内Maintainprocesswithincontrollimits持续努力减少变异Continueeffortstominimizevariation将工序表现控制到中间值

CentertheprocessUSLLSLCp<2andCpk>1你需要做什么?

Whatshouldyoudo?USLLSLCp<2andCpk>1.5维持工序于控制限内

Maintainprocesswithincontrollimits持续努力减少变异

ContinueeffortstominimizevariationUSLLSLCp>2andCpk<1采取预防行动清除不合格产品

Takeprecautionstoremove

non-conformingproducts持续努力减少变异

Continueeffortstominimizevariation将工序表现控制到中间值

Centertheprocess你需要做什么?

Whatshouldyoudo?维持工序于控制限内

Maintainprocesswithincontrollimits将工序表现控制到中间值

CentertheprocessUSLLSLCp>2andCpk>1维持工序于控制限内

MaintainprocesswithincontrollimitsUSLLSLCp>2andCpk>1.5失控图样--第一定律

Out-ofControlPatterns--Rule1任何点超越控制限Anypointbeyondthecontrollimits控制上限以外OutsidetheUpperControlLimit8.08.18.28.38.48.58.68.7123456789101112131415LCLAverageUCL控制下限以外OutsidetheLowerControlLimit8.08.18.28.38.48.58.68.7123456789101112131415LCLAverageUCL失控图样--第二定律

Out-ofControlPatterns--Rule2连续七点向上或向下--走势Upwardordownwardrunof7consecutivepoints--trend连续七点向下Downwardrunofsevenconsecutivepoints连续七点向上Upwardrunofsevenconsecutivepoints8.08.18.28.38.48.58.68.7123456789101112131415LCLAverageUCL8.08.18.28.38.48.58.68.7123456789101112131415LCLAverageUCL失控图样--第三定