制程能力研究-CPK与PPK课件.ppt

1、测量测量(Measure)阶段阶段流程能力流程能力 -1-流程能力研究流程能力研究(Capability Study )流程能力流程能力 -2-DefineMeasureAnalyzeImproveControlStep 4- 确定项目确定项目Ys Step 5- 确认确认Y的现水准的现水准Step 6-发掘潜在的原因发掘潜在的原因 变量变量(X)q 基础统计学基础统计学q Minitab简介简介q 测量系统分析测量系统分析q Y的表现水平的表现水平 及目标及目标q 确定改进目标确定改进目标路径位置路径位置流程能力流程能力 -3-目目 录录q 流程能力介绍流程能力介绍q 计数型流程能力计数型流

2、程能力 q 计量型流程能力计量型流程能力 q 流程能力指数流程能力指数q 短期短期/长期流程能力分析长期流程能力分析q 流程能力练习流程能力练习 流程能力流程能力 -4-2308,537366,80746,210523363.4s sPPM流程能力流程能力每百万机会的每百万机会的缺陷数缺陷数 流程能力介绍流程能力介绍流程能力流程能力 -5-当我们继续收集该流程的数据时当我们继续收集该流程的数据时, ,我们会有如下疑问：我们会有如下疑问： “这个流程有能力不产生不良吗这个流程有能力不产生不良吗?”?”要求数据收集分析要求数据收集分析. . “ “流程能力研究流程能力研究” ”USLLSL流程能力

3、是流程能力是 ? ?q 流程在管理状态时所表现出的产品或服务的品质变动程度流程在管理状态时所表现出的产品或服务的品质变动程度流程能力流程能力 -6-流程能力研究流程能力研究 q 研究流程的能力研究流程的能力 - 流程可以充分满足目标吗流程可以充分满足目标吗 ? ? - - 流程是处于可接受的散布水平吗流程是处于可接受的散布水平吗 ? ?q 使用可能的工具使用可能的工具 - 流程能力分析流程能力分析q 主要考虑事项主要考虑事项 - 要求要求流程是在可控制状态流程是在可控制状态. - 合理的子群合理的子群 (Rational Subgroup)q 最终结果物最终结果物 - -明确反映当前明确反映当

4、前ProcessProcess的短期及长期流程能力的报告书的短期及长期流程能力的报告书流程能力流程能力 -7-l额外的散布源于：额外的散布源于： -制造流程和测量系统制造流程和测量系统 -供给的材料散布供给的材料散布 -不合理的过窄的规格不合理的过窄的规格 ( (为了强化的设计，比顾客的要求更窄为了强化的设计，比顾客的要求更窄) )不适当的设计容限不适当的设计容限 不稳定的部不稳定的部件和材料件和材料 不充分的不充分的流程能力流程能力 流程能力流程能力 -8-LSLUSL不良不良流程能力流程能力多少材料脱离了规格？多少材料脱离了规格？ 短期的短期的/ /长期的长期的? ?不适当的不适当的设计容

5、限设计容限不适当的不适当的流程能力流程能力 供应材料供应材料的散布的散布 不适当的不适当的测量能力测量能力 流程能力流程能力 -9-你的数据是你的数据是什么类型的什么类型的计量型计量型记数型记数型从流程里从流程里收集数据收集数据从流程里从流程里收集数据收集数据用用 MinitabMinitab分析数据分析数据用用 ExcelExcel 分析数据分析数据流程能力表述流程能力表述DPU, PPMCp, Cpk, Pp, Ppk流程能力表述流程能力表述DPU, PPM流程能力流程能力 -10-“缺陷缺陷”(x(x44) ) 1 2 3 4 5 6 7 1 2 3 4 5 6 7 错误数错误数“缺陷缺

6、陷”( (x 130 Min)x 130 Min)“无缺陷无缺陷”( (x 130 Min)x 130 Min) 15 110 115 120 125 130 135 140 15 110 115 120 125 130 135 140 装配时间装配时间 ( (Min)Min) “无缺陷无缺陷”(x(x33) )顾客的要求顾客的要求顾客的要求顾客的要求记数型记数型计量型计量型流程能力流程能力 -11-寻找计量型数据寻找计量型数据太难了！太难了！流程能力流程能力 -12-生产的产品总数缺陷总数=DPU 000,000, 1 / =DPMOx单位产品机会单位产品缺陷数流程能力流程能力 -13- 4

7、.67 4.67 SigmaSigma清洁器个缺陷/3=DPUppmx750000,000, 1/ 4000DPU 3=DPMO冰箱机会流程能力流程能力 -14-流程能力流程能力 -15-l#1 #1 不良的洗衣机不良的洗衣机-工厂刚生产完一批共工厂刚生产完一批共4040,000,000台洗衣机台洗衣机, ,其中发现其中发现100100台洗衣机有缺台洗衣机有缺陷。陷。 l#2 #2 不良性批号不良性批号 在在3 3月份月份, ,有有12,41212,412台台A A型电机被组装到干燥机中型电机被组装到干燥机中, ,每台电机每台电机有有3 3个被正确制造的机会个被正确制造的机会( (分别是功率、

8、振动和总重分别是功率、振动和总重) )。在在本月中，发现了本月中，发现了200200个不良发生。个不良发生。 l#3 #3 不良性批量不良性批量-工厂刚生产出一批共工厂刚生产出一批共400400台冰箱（每台冰箱有台冰箱（每台冰箱有134134个部件）。在生个部件）。在生产中，发现了产中，发现了12,31212,312个不良（错组装或损坏）部件。个不良（错组装或损坏）部件。 DPU, DPMO, 和和 Sigma 是多少是多少?流程能力流程能力 -16-l#1 #1 有缺陷的购买定单有缺陷的购买定单 -在在3 3月中月中, ,共有共有764764份购买定单交付份购买定单交付, ,其中其中3213

9、21份有缺陷。份有缺陷。 l#2 #2 迟到的出货迟到的出货-在在20002000年年, ,共出货共出货42,100 42,100 批更换部件批更换部件, ,其中有其中有4,1004,100批晚到批晚到l#3 #3 不正确购买单据不正确购买单据-在在3 3月份月份, ,交付了交付了764764份购买单据份购买单据, ,每份单据要填每份单据要填8 8处信息处信息, ,共发共发现现12341234处不正确信息。处不正确信息。 流程能力流程能力 -17-计量型数据等于计量型数据等于.力量力量!流程能力流程能力 -18-l一般形式一般形式: :l这个变换产生的值来自一个平均值这个变换产生的值来自一个平

10、均值=0 =0 和和= 1= 1的分布的分布 。这个值以标这个值以标准偏差为单位显示了原来的数值离平均值有多远。准偏差为单位显示了原来的数值离平均值有多远。 -例如例如, , 如果如果 Z = 2, Z = 2, 说明问题中的数值偏离平均值说明问题中的数值偏离平均值2 2个标准偏差个标准偏差 l用这种方法，我们能在那个产品的输出平均值和用这种方法，我们能在那个产品的输出平均值和的基础上计算产品的基础上计算产品脱离规格的比例脱离规格的比例。s s)x-(x=Z流程能力流程能力 -19-l为了估计流程的良品率为了估计流程的良品率, ,我们用规格下限我们用规格下限( (LSL)LSL)和规格和规格上

11、限上限( (USL)USL)替代替代x x s)x-(SL=ZZ =(x-x)s这个结果将告诉我们流程的平均值以这个结果将告诉我们流程的平均值以sigmasigma为单位离规格限有多远为单位离规格限有多远 流程能力流程能力 -20-Avg平均平均 = 50标准偏差标准偏差 = 10正态分布正态分布流程能力流程能力 -21-SL -z = s s2.5s-s-= s s=2.5-s-s-s-s-s-sssssss-s-s-s-s-s-sssssss流程能力流程能力 -22-尾部面积是多少？尾部面积是多少？-s-s-s-s-sssssss-s-s-s-s-sssssss我们从Z表获得尾部的面积.或

12、者我们可以使用Minitab!流程能力流程能力 -23-s-s-s-s-sssssssZ Z 表表Z Table - Tail Area Probability0.000.010.020.030.040.050.060.070.080.090.00.500000.496010.492020.488030.484050.480060.476080.472100.468120.464140.10.460170.456200.452240.448280.444330.440380.436440.432510.428580.424650.20.420740.416830.412940.409050.4

13、05170.401290.397430.393580.389740.385910.30.382090.378280.374480.370700.366930.363170.359420.355690.351970.348270.40.344580.340900.337240.333600.329970.326360.322760.319180.315610.312070.50.308540.305030.301530.298060.294600.291160.287740.284340.280960.277600.60.274250.270930.267630.264350.261090.25

14、7850.254630.251430.248250.245100.70.241960.238850.235760.232700.229650.226630.223630.220650.217700.214760.80.211860.208970.206110.203270.200450.197660.194890.192150.189430.186730.90.184060.181410.178790.176190.173610.171060.168530.166020.163540.161091.00.158660.156250.153860.151510.149170.146860.144

15、570.142310.140070.137861.10.135670.133500.131360.129240.127140.125070.123020.121000.119000.117021.20.115070.113140.111230.109350.107490.105650.103830.102040.100270.098531.30.096800.095100.093420.091760.090120.088510.086920.085340.083790.082261.40.080760.079270.077800.076360.074930.073530.072150.0707

16、80.069440.068111.50.066810.065520.064260.063010.061780.060570.059380.058210.057050.055921.60.054800.053700.052620.051550.050500.049470.048460.047460.046480.045511.70.044570.043630.042720.041820.040930.040060.039200.038360.037540.036731.80.035930.035150.034380.033620.032880.032160.031440.030740.03005

17、0.029381.90.028720.028070.027430.026800.026190.025590.025000.024420.023850.023302.00.022750.022220.021690.021180.020680.020180.019700.019230.018760.018312.10.017860.017430.017000.016590.016180.015780.015390.015000.014630.014262.20.013900.013550.013210.012870.012550.012220.011910.011600.011300.011012

18、.30.010720.010440.010170.009900.009640.009390.009140.008890.008660.008422.40.008200.007980.007760.007550.007340.007140.006950.006760.006570.006392.50.006210.006040.005870.005700.005540.005390.005230.005080.004940.004802.60.004660.004530.004400.004270.004150.004020.003910.003790.003680.003572.70.0034

19、70.003360.003260.003170.003070.002980.002890.002800.002720.002642.80.002560.002480.002400.002330.002260.002190.002120.002050.001990.001932.90.001870.001810.001750.001690.001640.001590.001540.001490.001440.001393.00.001350.001310.001260.001220.001180.001140.001110.001070.001040.001003.10.000970.00094

20、0.000900.000870.000840.000820.000790.000760.000740.000713.20.000690.000660.000640.000620.000600.000580.000560.000540.000520.000503.30.000480.000470.000450.000430.000420.000400.000390.000380.000360.000353.40.000340.000320.000310.000300.000290.000280.000270.000260.000250.000243.50.000230.000220.000220

21、.000210.000200.000190.000190.000180.000170.000173.60.000160.000150.000150.000140.000140.000130.000130.000120.000120.000113.70.000110.000109.964E-059.577E-059.204E-058.844E-058.498E-058.165E-057.844E-057.535E-053.87.237E-056.951E-056.675E-056.409E-056.154E-055.908E-055.671E-055.444E-055.225E-055.014E

22、-053.94.812E-054.617E-054.429E-054.249E-054.076E-053.909E-053.749E-053.595E-053.447E-053.305E-054.03.169E-053.037E-052.911E-052.790E-052.674E-052.562E-052.455E-052.352E-052.253E-052.158E-054.12.067E-051.979E-051.895E-051.815E-051.738E-051.663E-051.592E-051.524E-051.458E-051.396E-054.21.335E-051.278E

23、-051.222E-051.169E-051.118E-051.070E-051.023E-059.780E-069.351E-068.940E-064.38.546E-068.169E-067.807E-067.461E-067.130E-066.812E-066.508E-066.217E-065.939E-065.672E-064.45.417E-065.173E-064.939E-064.716E-064.502E-064.297E-064.102E-063.914E-063.736E-063.564E-064.53.401E-063.244E-063.095E-062.952E-06

24、2.815E-062.685E-062.560E-062.441E-062.327E-062.218E-064.62.115E-062.015E-061.921E-061.830E-061.744E-061.661E-061.583E-061.508E-061.436E-061.368E-064.71.302E-061.240E-061.181E-061.124E-061.070E-061.018E-069.692E-079.223E-078.776E-078.350E-074.87.944E-077.556E-077.187E-076.836E-076.501E-076.181E-075.8

25、77E-075.588E-075.312E-075.049E-074.94.799E-074.560E-074.334E-074.118E-073.912E-073.716E-073.530E-073.353E-073.184E-073.024E-075.02.871E-072.726E-072.588E-072.456E-072.331E-072.213E-072.100E-071.992E-071.890E-071.793E-075.11.701E-071.614E-071.530E-071.451E-071.376E-071.305E-071.237E-071.173E-071.112E

26、-071.053E-075.29.983E-089.460E-088.964E-088.492E-088.045E-087.620E-087.217E-086.835E-086.472E-086.128E-085.35.802E-085.493E-085.199E-084.921E-084.657E-084.407E-084.170E-083.946E-083.733E-083.531E-085.43.340E-083.158E-082.987E-082.824E-082.670E-082.524E-082.386E-082.256E-082.132E-082.015E-085.51.904E

27、-081.799E-081.699E-081.605E-081.516E-081.432E-081.352E-081.277E-081.206E-081.138E-085.61.075E-081.014E-089.574E-099.035E-098.526E-098.045E-097.590E-097.160E-096.754E-096.370E-09Z Table - Tail Area Probability0.000.010.020.030.040.050.060.070.080.090.00.500000.496010.492020.488030.484050.480060.47608

28、0.472100.468120.464140.10.460170.456200.452240.448280.444330.440380.436440.432510.428580.424650.20.420740.416830.412940.409050.405170.401290.397430.393580.389740.385910.30.382090.378280.374480.370700.366930.363170.359420.355690.351970.348270.40.344580.340900.337240.333600.329970.326360.322760.319180

29、.315610.312070.50.308540.305030.301530.298060.294600.291160.287740.284340.280960.277600.60.274250.270930.267630.264350.261090.257850.254630.251430.248250.245100.70.241960.238850.235760.232700.229650.226630.223630.220650.217700.214760.80.211860.208970.206110.203270.200450.197660.194890.192150.189430.

30、186730.90.184060.181410.178790.176190.173610.171060.168530.166020.163540.161091.00.158660.156250.153860.151510.149170.146860.144570.142310.140070.137861.10.135670.133500.131360.129240.127140.125070.123020.121000.119000.117021.20.115070.113140.111230.109350.107490.105650.103830.102040.100270.098531.3

31、0.096800.095100.093420.091760.090120.088510.086920.085340.083790.082261.40.080760.079270.077800.076360.074930.073530.072150.070780.069440.068111.50.066810.065520.064260.063010.061780.060570.059380.058210.057050.055921.60.054800.053700.052620.051550.050500.049470.048460.047460.046480.045511.70.044570

32、.043630.042720.041820.040930.040060.039200.038360.037540.036731.80.035930.035150.034380.033620.032880.032160.031440.030740.030050.029381.90.028720.028070.027430.026800.026190.025590.025000.024420.023850.023302.00.022750.022220.021690.021180.020680.020180.019700.019230.018760.018312.10.017860.017430.

33、017000.016590.016180.015780.015390.015000.014630.014262.20.013900.013550.013210.012870.012550.012220.011910.011600.011300.011012.30.010720.010440.010170.009900.009640.009390.009140.008890.008660.008422.40.008200.007980.007760.007550.007340.007140.006950.006760.006570.006392.50.006210.006040.005870.0

34、05700.005540.005390.005230.005080.004940.004802.60.004660.004530.004400.004270.004150.004020.003910.003790.003680.003572.70.003470.003360.003260.003170.003070.002980.002890.002800.002720.002642.80.002560.002480.002400.002330.002260.002190.002120.002050.001990.001932.90.001870.001810.001750.001690.00

35、1640.001590.001540.001490.001440.001393.00.001350.001310.001260.001220.001180.001140.001110.001070.001040.001003.10.000970.000940.000900.000870.000840.000820.000790.000760.000740.000713.20.000690.000660.000640.000620.000600.000580.000560.000540.000520.000503.30.000480.000470.000450.000430.000420.000

36、400.000390.000380.000360.000353.40.000340.000320.000310.000300.000290.000280.000270.000260.000250.000243.50.000230.000220.000220.000210.000200.000190.000190.000180.000170.000173.60.000160.000150.000150.000140.000140.000130.000130.000120.000120.000113.70.000110.000109.964E-059.577E-059.204E-058.844E-

37、058.498E-058.165E-057.844E-057.535E-053.87.237E-056.951E-056.675E-056.409E-056.154E-055.908E-055.671E-055.444E-055.225E-055.014E-053.94.812E-054.617E-054.429E-054.249E-054.076E-053.909E-053.749E-053.595E-053.447E-053.305E-054.03.169E-053.037E-052.911E-052.790E-052.674E-052.562E-052.455E-052.352E-052

38、.253E-052.158E-054.12.067E-051.979E-051.895E-051.815E-051.738E-051.663E-051.592E-051.524E-051.458E-051.396E-054.21.335E-051.278E-051.222E-051.169E-051.118E-051.070E-051.023E-059.780E-069.351E-068.940E-064.38.546E-068.169E-067.807E-067.461E-067.130E-066.812E-066.508E-066.217E-065.939E-065.672E-064.45

39、.417E-065.173E-064.939E-064.716E-064.502E-064.297E-064.102E-063.914E-063.736E-063.564E-064.53.401E-063.244E-063.095E-062.952E-062.815E-062.685E-062.560E-062.441E-062.327E-062.218E-064.62.115E-062.015E-061.921E-061.830E-061.744E-061.661E-061.583E-061.508E-061.436E-061.368E-064.71.302E-061.240E-061.18

40、1E-061.124E-061.070E-061.018E-069.692E-079.223E-078.776E-078.350E-074.87.944E-077.556E-077.187E-076.836E-076.501E-076.181E-075.877E-075.588E-075.312E-075.049E-074.94.799E-074.560E-074.334E-074.118E-073.912E-073.716E-073.530E-073.353E-073.184E-073.024E-075.02.871E-072.726E-072.588E-072.456E-072.331E-

41、072.213E-072.100E-071.992E-071.890E-071.793E-075.11.701E-071.614E-071.530E-071.451E-071.376E-071.305E-071.237E-071.173E-071.112E-071.053E-075.29.983E-089.460E-088.964E-088.492E-088.045E-087.620E-087.217E-086.835E-086.472E-086.128E-085.35.802E-085.493E-085.199E-084.921E-084.657E-084.407E-084.170E-083

42、.946E-083.733E-083.531E-085.43.340E-083.158E-082.987E-082.824E-082.670E-082.524E-082.386E-082.256E-082.132E-082.015E-085.51.904E-081.799E-081.699E-081.605E-081.516E-081.432E-081.352E-081.277E-081.206E-081.138E-085.61.075E-081.014E-089.574E-099.035E-098.526E-098.045E-097.590E-097.160E-096.754E-096.37

43、0E-09.00621or 6210 ppm-s-s-s-s-sssssss-s-s-s-s-sssssss流程能力流程能力 -24-MINITAB MINITAB 分析方法分析方法l用用Minitab,Minitab,到到 然后点然后点 l把把Z-Z-值填入值填入输入常量输入常量 选项选项, ,然后然后 Minitab Minitab 会算出概率。会算出概率。流程能力流程能力 -25-MINITAB MINITAB 结果结果1 - .9938 = .0062或 6200 ppm-s-s-s-s-sssssss-s-s-s-s-sssssss累积分布函数累积分布函数 正态分布，平均值正态分布，

44、平均值 = 0 和标准差和标准差 = 1 x P( X = x ) 2.5 0.993790流程能力流程能力 -26-如果某个流程的规格限是1.030，流程的平均值是0.995，标准偏差是0.010，尾部面积将是多少？SL -z = s1.030-.995= = 3.5 0.010Z Z变换练习变换练习 1 1流程能力流程能力 -27-s-s-s-s-sssssssZ Z 表表Z Table - Tail Area Probability0.000.010.020.030.040.050.060.070.080.090.00.500000.496010.492020.488030.484050

45、.480060.476080.472100.468120.464140.10.460170.456200.452240.448280.444330.440380.436440.432510.428580.424650.20.420740.416830.412940.409050.405170.401290.397430.393580.389740.385910.30.382090.378280.374480.370700.366930.363170.359420.355690.351970.348270.40.344580.340900.337240.333600.329970.326360.

46、322760.319180.315610.312070.50.308540.305030.301530.298060.294600.291160.287740.284340.280960.277600.60.274250.270930.267630.264350.261090.257850.254630.251430.248250.245100.70.241960.238850.235760.232700.229650.226630.223630.220650.217700.214760.80.211860.208970.206110.203270.200450.197660.194890.1

47、92150.189430.186730.90.184060.181410.178790.176190.173610.171060.168530.166020.163540.161091.00.158660.156250.153860.151510.149170.146860.144570.142310.140070.137861.10.135670.133500.131360.129240.127140.125070.123020.121000.119000.117021.20.115070.113140.111230.109350.107490.105650.103830.102040.10

48、0270.098531.30.096800.095100.093420.091760.090120.088510.086920.085340.083790.082261.40.080760.079270.077800.076360.074930.073530.072150.070780.069440.068111.50.066810.065520.064260.063010.061780.060570.059380.058210.057050.055921.60.054800.053700.052620.051550.050500.049470.048460.047460.046480.045

49、511.70.044570.043630.042720.041820.040930.040060.039200.038360.037540.036731.80.035930.035150.034380.033620.032880.032160.031440.030740.030050.029381.90.028720.028070.027430.026800.026190.025590.025000.024420.023850.023302.00.022750.022220.021690.021180.020680.020180.019700.019230.018760.018312.10.0

50、17860.017430.017000.016590.016180.015780.015390.015000.014630.014262.20.013900.013550.013210.012870.012550.012220.011910.011600.011300.011012.30.010720.010440.010170.009900.009640.009390.009140.008890.008660.008422.40.008200.007980.007760.007550.007340.007140.006950.006760.006570.006392.50.006210.00