02-BB-六西格玛案例之二.ppt

1、,LG Electronics / Digital Appliance Company,Contents,DC Inv. Multi. PF Improvement,研发中心,2004.10. 20,1.Theme Registration 2.Define 3.Measure 4.Analyze 5.Improve 6.Control,6 Project 登录/完了报告书,课 题 名,现水准,比较水准,目标,KPI,阶 段,定 义,测 定（Spec 明确化）,分 析（设计）,改 善（最适化）,管 理,活动期间,利用工具,课题选定背景,突破界限的Idea,类型,R&D,MFG,TQ,NWT,制

2、作人,LGETA （ R&D Center ）事业担当 （ 空调 ）部,R&D Center,Result,改善金额,登录日期,导入依据,( Big Y/TDR/月KPI追加/ 其它),8.158.24,8.259.11,9.1210.02,10.0310.15,10.1510.20,Logic tree,Gage R&R Capability analysis,One-way ANOVA,DOE,Xbar-R,DC Inverter Multi PF Improvement,0.91,0.92,0.93,0.936,2004-8-15,1/10,Fast & Profitable R&D,G

3、reat Company Great People,Background for factor selection, Power factor introduce,Where , I1 :effective current value of basic input wave Irms : effective value of input current =I1 /Irms :distortion modulus of input current Cos :phasic factor of basic wave voltage and current,rms,Define, Why we mus

4、t improve the power factor,1、Improve the equipments running efficiency. 2、Prolong the equipments using life. 3、Decrease the influence to the voltage network., Compare with competitive companies, Target,2/10,Fast & Profitable R&D,Great Company Great People,Circuit diagram,Three factors were selected

5、as a preliminary CTQ about phase control components.,Define,Preliminary CTQ,Logic tree,3/10,Fast & Profitable R&D,Great Company Great People,C,I,A,M,D,测量,Measure system,GPM-8212 AC digital power factor measure：,GPM-8212 AC digital power factor measure characteristic：1、Measure and display the power,t

6、he current and the voltage simultaneity.2、Amend the voltage,the current and the power automatically by connecting with the computer.,4/10,Fast & Profitable R&D,Great Company Great People,C,I,A,M,D,Measure,Two-Way ANOVA Table Without Interaction Source DF SS MS F P part 9 0.0002486 0.0000276 0.57177

7、0.809 operator 1 0.0000506 0.0000506 1.04782 0.314 Repeatability 29 0.0014011 0.0000483 Total 39 0.0017004 Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0000484 100.00 Repeatability 0.0000483 99.76 Reproducibility 0.0000001 0.24 operator 0.0000001 0.24 Part-To-Part 0.0000000 0.

8、00 Total Variation 0.0000484 100.00 Study Var %Study Var %Tolerance Source StdDev (SD) (0.9 * SD) (%SV) (SV/Toler) Total Gage R&R 0.0069592 0.0062633 100.00 12.53 Repeatability 0.0069509 0.0062558 99.88 12.51 Reproducibility 0.0003399 0.0003059 4.88 0.61 operator 0.0003399 0.0003059 4.88 0.61 Part-T

9、o-Part 0.0000000 0.0000000 0.00 0.00 Total Variation 0.0069592 0.0062633 100.00 12.53 Number of Distinct Categories = 1,Gage R&R,Total Gage R&R=12.53%20% ,the measure data is reliable.,5/10,Fast & Profitable R&D,Great Company Great People,C,I,A,M,D,Measure,USL 0.92 LSL 0.88,Process capability analys

10、is for measure data,P=0.2070.05， the data is accord with normal distribute.,6/10,Fast & Profitable R&D,Great Company Great People,Resistance R05S, Capacitance C09S & Reactor were verified significant factors,Resistance(R05S),Capacitance(C09S),Reactor,One-way ANOVA: R05S versus C2 Source DF SS MS F P

11、 C2 2 0.0012028 0.0006014 35.17 0.000 Error 12 0.0002052 0.0000171 Total 14 0.0014080 S = 0.004135 R-Sq = 85.43% R-Sq(adj) = 83.00% Individual 95% CIs For Mean Based on Pooled StDev Level N Mean StDev -+-+-+-+- 65k 5 0.90920 0.00259 (-*-) 71.5k 5 0.90040 0.00546 (-*-) 75k 5 0.88740 0.00385 (-*-) -+-

12、+-+-+- 0.8880 0.8960 0.9040 0.9120 Pooled StDev = 0.00414,One-way ANOVA: Reactor versus C6 Source DF SS MS F P C6 2 0.0141989 0.0070995 705.25 0.000 Error 12 0.0001208 0.0000101 Total 14 0.0143197 S = 0.003173 R-Sq = 99.16% R-Sq(adj) = 99.02% Individual 95% CIs For Mean Based on Pooled StDev Level N

13、 Mean StDev +-+-+-+- 20mh 5 0.85420 0.00192 (-*) 26.8mh 5 0.90180 0.00349 (-*) 31mh 5 0.92860 0.00378 (*-) +-+-+-+- 0.850 0.875 0.900 0.925 Pooled StDev = 0.00317,One-way ANOVA: C09S versus C4 Source DF SS MS F P C4 2 0.0060041 0.0030021 159.68 0.000 Error 12 0.0002256 0.0000188 Total 14 0.0062297 S

14、 = 0.004336 R-Sq = 96.38% R-Sq(adj) = 95.78% Individual 95% CIs For Mean Based on Pooled StDev Level N Mean StDev -+-+-+-+- 0.05uf 5 0.86320 0.00576 (-*-) 0.10uf 5 0.90120 0.00409 (-*-) 0.15uf 5 0.90900 0.00255 (-*-) -+-+-+-+- 0.870 0.885 0.900 0.915 Pooled StDev = 0.00434,7/10,5. Significant differ

15、ence verification,C,I,A,M,D,Analysis,Fast & Profitable R&D,Great Company Great People,Create an experiment of three factors (R05S, C09S, Reactor) and two levels related to power factor.,Levels of factor,Main effect plot,8/10,6. DOE,C,I,A,M,D,Improvement,Simulation Results,Interaction plot,Cube plot,

16、Fast & Profitable R&D,Great Company Great People,C,I,A,M,D,Improvement,9/10,1、Reactor has greatest influence upon the power factor. 2、Reactor and resistance has interact influence. 3、PF has improve to 0.936.,Factorial Fit: C8 versus Resistance, Capacitance, Reactor Estimated Effects and Coefficients

17、 for C8 (coded units) Term Effect Coef SE Coef T P Constant 0.87000 0.006000 145.00 0.004 Resistance -0.03850 -0.01925 0.006000 -3.21 0.192 Capacitance 0.02050 0.01025 0.006000 1.71 0.337 Reactor 0.10500 0.05250 0.006000 8.75 0.072 Resistance*Capacitance 0.00300 0.00150 0.006000 0.25 0.844 Resistanc

18、e*Reactor 0.02650 0.01325 0.006000 2.21 0.271 Capacitance*Reactor -0.01450 -0.00725 0.006000 -1.21 0.440 S = 0.0169706 R-Sq = 98.97% R-Sq(adj) = 92.80% Analysis of Variance for C8 (coded units) Source DF Seq SS Adj SS Adj MS F P Main Effects 3 0.0258550 0.0258550 0.0086183 29.92 0.133 2-Way Interactions 3 0.0018430 0.0018430 0.0006143 2.13 0.457 Residual Error 1 0.0002880 0.0002880 0.0002880 Total 7 0.0279860,Result:,Fast & Profitable R&D,Great Company Great People,Factors,10/10,C,I,A,M,D,Control,Design Spec.,Xbar-R Control Box,Next work: Go