在更好的车身制造中实施六西格玛质量ImplementingSixSigmaQualityatBetterBodyManufacturing课件.ppt

1、D M AICDefineMeasure AnalyzeImprove ControlDDefineMMeasureAAnalyzeIImproveCControlImplementing Six Sigma Qualityat Better Body Manufacturing 2D M AICDefineMeasure AnalyzeImprove ControlDimensionDPMASM_7Y172475ASM_8Y85824ASM_3Y19786ASM_9Y3874ASM_10Y776ASM_6Y4OverviewABC Incorporated(ABC)is not achiev

2、ing Six Sigma quality levels for all critical Body-Side Sub-Assembly dimensions as requested by their customers.Ensure that all critical body-side subassembly dimensions are within Six Sigma quality levels of 935 to correct ASM_7Y and ASM_8Y Set clamp position to location 2 for ASM_9Y and ASM_10Y Re

3、-machine A-pillar die to correct A_3Y and ASM_3Y Determined the correlation between body side and assembly dimensions.Evaluated the significance of Tonnage 935 for ASM_7Y&ASM_8Y.Conducted a DOE for Clamp position for ASM_9Y&ASM_10Y.050000100000150000200000ASM_7YASM_8YASM_3YASM_9YASM_10YASM_6YDPM3D M

4、 AICDefineMeasure AnalyzeImprove ControlProblem Statement&The GoalABC Incorporateds customer wants ABC to apply Six Sigma problem solving methodology to insure that the body side subassembly is achieving Six Sigma quality levels of less than 3.4 defects per million for all critical body side subasse

5、mbly dimensions.ABC needs an improvement strategy that minimizes the rework costs while achieving the desired quality objective.ABCs goal is to produce module subassemblies that meet the customer requirements and not necessarily to insure that every individual stamped component within the assembly m

6、eets it original print specifications sub-system optimizations vs.local optimization.+A-PillarReinforcementB-PillarReinforcementBody Side Outer+A-PillarReinforcementB-PillarReinforcementBody Side OuterDDefine4D M AICDefineMeasure AnalyzeImprove ControlMeasure PhaseKey Variables:Assembly process vari

7、ables:Weld Pattern(density),Clamp Location,and Clamp Weld PressureStamping process variables(body side):Press Tonnage,Die Cushion Pressure,Material ThicknessBody Assembly Dimensions ASM_1Y through ASM_10YMMeasure477617247585824197863874050000100000150000200000ASM_7YASM_8YASM_3YASM_9YASM_10YASM_6YDPM

8、Assembly Dimensions with Highest Defects5D M AICDefineMeasure AnalyzeImprove ControlResolution alternatives(based upon past experience):1.Make adjustments to assembly process settings2.Reduce variation of components through better control of stamping process input variables3.Rework stamping dies to

9、shift component mean deviation that is off target and causing assembly defectsTarget Performance Level:All ten critical assembly dimensions at Six Sigma quality level of 3.4 DPM.Cp 2.0 and Cpk 1.67Fish Bone and P-Diagrams:Understanding potential causes of defects.From this we pick the assembly and c

10、omponent dimensions that require further analysisAnalyze Phase AAnalyze6D M AICDefineMeasure AnalyzeImprove ControlFor our analysis we will do a DOE to check for levels that contribute to better quality product.Weld Pattern(density)Clamp LocationOperatorMachineMaterialsMethodsClamp Weld PressurePres

11、s TonnageDie Cushion PressureMaterial ThicknessTrainingYield StrengthElastic LimitEnvironmentTemperatureHumidityQualityComponent VariabilityInspection ProcessGage R&RBody Assembly Analyze Phase AAnalyzeBody Side Sub-AssemblyStamping ProcessOutputsBody Side Sub-Assemblies atSix Sigma quality levelsCo

12、ntrol VariablesClamp Location Press TonnageWeld Density Die Pressure Clamp PressureError StatesDimensional defectsNoise VariablesEnvironmentInherent VariationInputsMaterial ThicknessYield Strength7D M AICDefineMeasure AnalyzeImprove ControlAnalysis of ASM_7Y and ASM_8Y 27120.00.51.0Subgroup NumberAS

13、M_7YNumber of runs about median:Expected number of runs:Longest run about median:Approx P-Value for Clustering:Approx P-Value for Mixtures:Number of runs up or down:Expected number of runs:Longest run up or down:Approx P-Value for Trends:Approx P-Value for Oscillation:4.000007.000005.000000.034640.9

14、65366.000007.666673.000000.107780.89222Run Chart for ASM_7Y27120.00.51.0Subgroup NumberASM_8YNumber of runs about median:Expected number of runs:Longest run about median:Approx P-Value for Clustering:Approx P-Value for Mixtures:Number of runs up or down:Expected number of runs:Longest run up or down

15、:Approx P-Value for Trends:Approx P-Value for Oscillation:4.000007.000005.000000.034640.965368.000007.666672.000000.597810.40219Run Chart for ASM_8YAnalyze Phase AAnalyzeConclusion:BS_7Y and ASM_7Y are following a similar trend.A correlation chart to study this further shows high correlation.(Pearso

16、n correlation,R of 0.701).0.00.51.00.00.51.0ASM_8YASM_7YXY Plot of ASM_8Y and ASM_7Y8D M AICDefineMeasure AnalyzeImprove ControlAnalyze Phase AAnalyze-0.8-0.6-0.4-0.20.00.20.40.60.8LSLU SLCapability Analysis of B_7YU SLTargetLSLM eanSam ple NStDev(W ithin)StDev(O verall)CpCPUCPLCpkCpmPpPPUPPLPpkPPM

17、U SLPPM TotalPPM U SLPPM TotalPPM U SLPPM Total 0.70 *-0.70 0.11360.07881220.07912152.962.503.432.50 *2.952.493.412.490.000.000.000.000.000.000.000.000.00Process DataPotential(W ithin)CapabilityO verall CapabilityO bserved Perform anceExp.W ithin Perform anceExp.O verall Perform anceW ithinOverallCa

18、pability of B_7Y-1.0-0.50.00.51.01.52.0LSLU SLCapability Analysis of BS_7YU SLTargetLSLM eanSam ple NStDev(W ithin)StDev(O verall)CpCPUCPLCpkCpmPpPPUPPLPpkPPM U SLPPM TotalPPM U SLPPM TotalPPM U SLPPM Total 0.700000 *-0.700000 0.899444360.1496400.383691 1.56-0.44 3.56-0.44 *0.61-0.17 1.39-0.17 0.006

19、66666.67666666.67 0.00908706.09908706.09 15.33698400.06698415.39Process DataPotential(W ithin)CapabilityO verall CapabilityO bserved Perform anceExp.W ithin Perform anceExp.O verall Perform anceW ithinOverall698416 DPM0 DPM0.51.01.50.30.40.50.60.70.80.91.01.11.21.3ASM_7YBS_7YXY Plot of ASM_7Y and BS

20、_7YConclusion:B_7Y has 0 ppm compared to 700K DPM in BS_7Y.Furthermore,BS_7Y shows strong correlation on dimension ASM_7Y.(Pearson correlation,R of 0.786).Capability of BS_7Y9D M AICDefineMeasure AnalyzeImprove Control9059159259359450.51.01.5TonnageBS_7YXY Plot of Tonnage vs.BS_7YXY Plot of Tonnage

21、vs.BS_7YConclusion:Tonnage values above 935 greatly improves BS_7Y and brings it closer to the mean.Lets see what impact this has on ASM dimensions 7Y,8Y,9Y,and 10Y by creating a subset of the data looking only at Tonnage 935.Analyze Phase AAnalyze10D M AICDefineMeasure AnalyzeImprove ControlAnalyze

22、 Phase AAnalyze-1.0-0.50.00.51.0L S LUS LC apability A nalysis of A S M _7Y at Tonnage 935US LTargetLS LM eanS am ple NS tD ev(W ithin)S tD ev(O verall)C pC P UC P LC pkC pmP pP P UP P LP pkP P M US LP P M TotalP P M US LP P M TotalP P M US LP P M Total 1.00 *-1.00 0.09120.1631740.1478552.041.862.23

23、1.86 *2.252.052.462.050.000.000.000.000.010.010.000.000.00P rocess D ataP otential(W ithin)C apabilityO verall C apabilityO bserved P erform anceE xp.W ithin P erform anceE xp.O verall P erform anceW ithinO verall-1.0-0.50.00.51.0L S LUS LC apability A nalysis of A S M _8Y at Tonnage 935US LTargetLS

24、 LM eanS am ple NS tD ev(W ithin)S tD ev(O verall)C pC P UC P LC pkC pmP pP P UP P LP pkP P M US LP P M TotalP P M US LP P M TotalP P M US LP P M Total 1.00000 *-1.00000-0.12833120.1018250.0891613.273.692.852.85 *3.744.223.263.260.000.000.000.000.000.000.000.000.00P rocess D ataP otential(W ithin)C

25、apabilityO verall C apabilityO bserved P erform anceE xp.W ithin P erform anceE xp.O verall P erform anceW ithinO verall-1.0-0.50.00.51.0L S LUS LC apability A nalysis of A S M _9Y at Tonnage 935US LTargetLS LM eanS am ple NS tD ev(W ithin)S tD ev(O verall)C pC P UC P LC pkC pmP pP P UP P LP pkP P M

26、 US LP P M TotalP P M US LP P M TotalP P M US LP P M Total 1.00000 *-1.00000 0.52083120.2060100.1770981.620.782.460.78 *1.880.902.860.90 0.00 0.00 0.00 0.0010010.7710010.77 0.00 3408.51 3408.51P rocess D ataP otential(W ithin)C apabilityO verall C apabilityO bserved P erform anceE xp.W ithin P erfor

27、m anceE xp.O verall P erform anceW ithinO verall-1.0-0.50.00.51.0L S LUS LC apability A nalysis of A S M _10Y at Tonnage 935US LTargetLS LM eanS am ple NS tD ev(W ithin)S tD ev(O verall)C pC P UC P LC pkC pmP pP P UP P LP pkP P M US LP P M TotalP P M US LP P M TotalP P M US LP P M Total 1.00 *-1.00

28、0.39120.2155410.1876631.550.942.150.94 *1.781.082.471.08 0.00 0.00 0.00 0.002326.722326.72 0.00 576.00 576.00P rocess D ataP otential(W ithin)C apabilityO verall C apabilityO bserved P erform anceE xp.W ithin P erform anceE xp.O verall P erform anceW ithinO verallConclusion:Setting Tonnage to greate

29、r than 935 resulted in ASM_7Y and ASM_8Y meeting the goal of 3.4 DPM.ASM_9Y and ASM_10Y require further analysis.Impact this has on ASM dimensions 7Y,8Y,9Y&10Y on Tonnage11D M AICDefineMeasure AnalyzeImprove ControlDOE for Response Variable ASM_9Y DOE factorial analysis shows Clamp Position is the o

30、nly significant factor in determining ASM_9Y dimension DOE Response Optimization for ASM_9Y Set Clamp Position to Location 2(level 1)Optimizer recommends setting Weld Density to 1.33 weld per inch(level 1),but this appears to be a robust parameter,which could be changed for the benefit of process wi

31、thout reducing quality if processing time or cost shows a benefit.Optimizer recommends setting Clamp Pressure to 2100 psi(level 1),but this appears to be a robust parameter,which could be changed for the benefit of process without reducing quality if processing time or cost shows a benefit.Run addit

32、ional tests at recommended settings to confirm results Weld Density and Clamp Pressure are robust parameters and can be set to optimize the process capability to maximum level and lowest cost.Analyze Phase AAnalyzeInput VariableProposed ASM_9Y SettingProposed ASM_10Y SettingClamp LocationLocation 2L

33、ocation 2Weld Density(welds per X inches)1.331.33Clamp Pressure2100 psi2100 psi12D M AICDefineMeasure AnalyzeImprove ControlAnalyze Phase AAnalyzeDOE for Response Variable ASM_10Y DOE factorial analysis shows Clamp Position is also the only significant factor in determining ASM_10Y dimension DOE Res

34、ponse Optimization for ASM_10Y Setting clamp to location 2 also improves ASM_10Y Recommend same settings used to improve ASM_9Y to improve process capability which also allows for no changes to machine setup and helps reduce possible process concerns Run additional tests at recommended settings to c

35、onfirm results Weld Density and Clamp Pressure are robust parameters and can be set to optimize the process capability to maximum level and lowest cost.13D M AICDefineMeasure AnalyzeImprove ControlDOE for Response Variable ASM_3Y DOE factorial analysis shows that no factors are significant Response

36、Optimization shows no solution for response optimizer Observe Process Capability of A_3Y and BS_3Y ASM_3Y and A_3Y have a similar mean shift in the-Y direction Correlation of Output Variables No dimensional correlations appear to exist between ASM_3Y and A_3Y or BS_3YStepwise Regression Analysis of

37、BS_3Y Tonnage and Die Pressure appear to be significant in determining dimension BS_3Y Tonnage values 920 may improve BS_3Y Die Pressure appears to have no clear correlation to BS_3YAnalyze Phase AAnalyze14D M AICDefineMeasure AnalyzeImprove ControlProcess Capability of BS_ 3Y and ASM_3Y at Tonnage

38、920 Created subset of body data looking only at dimensions with Tonnage 935 Tonnage 920 appears to improve the mean of BS_3Y slightly,but has no impact on improving the mean of ASM_3Y.-1.0-0.50.00.51.0LSLUSLCapability Analysis of ASM_3YUSLTargetLSLMeanSample NStDev(Within)StDev(Overall)CpCPUCPLCpkCp

39、mPpPPUPPLPpkPPM USLPPM TotalPPM USLPPM TotalPPM USLPPM Total 1*-1 0360.08514360.09717253.913.913.913.91 *3.433.433.433.430.000.000.000.000.000.000.000.000.00Process DataPotential(Within)CapabilityOverall CapabilityObserved PerformanceExp.Within PerformanceExp.Overall PerformanceWithinOverallDie rema

40、chined to move mean+0.80Capability of A_3Y and ASM_3Y with+0.80 mm mean offset Manipulate data for A_3Y and ASM_3Y by+0.80 mm to simulate re-machining Process capability shows 0 defects for A_3Y and ASM_3Y with this mean offsetAnalyze Phase AAnalyze15D M AICDefineMeasure AnalyzeImprove ControlAnalyz

41、e Phase AAnalyzeConclusions From the analysis of ASM_7Y and ASM_8Y we can conclude that:Setting tonnage 935 results in ASM_7Y and ASM_8Y meeting the goal Analyzing ASM_9Y and ASM_10Y helps determine that:Setting clamp position to location 2,weld density to 1 weld every 1.33”and clamp pressure to 200

42、0 psi helps with dimensions ASM_9Y and ASM_10Y Analyzing ASM_3Y helps us conclude that:Re-machine A-Pillar die to move A_3Y to nominal which could cause BS_3Y to shift towards nominal effectively shifting ASM_3Y to nominal16D M AICDefineMeasure AnalyzeImprove ControlWith the recommended changes the

43、process performance will improve significantlyDimension MeanStDev OverallDPM_Obsv DPM_Within DPM_ExpPpPpkCpCpkASM_1Y-0.0350.1650002.011.942.472.39ASM_2Y0.2590.1520012.201.632.311.71ASM_3Y0.0000.097000ASM_4Y0.0090.1150002.902.873.533.50ASM_5Y-0.3300.1450022.301.543.722.50ASM_6Y-0.2840.1600142.081.492

44、.241.60ASM_7Y0.0900.1480002.252.052.041.86ASM_8Y-0.1280.0890003.743.263.272.85ASM_9Y0.5210.180000ASM_10Y0.3950.191000AAnalyzeAnalyze Phase 17D M AICDefineMeasure AnalyzeImprove ControlRecommendations for improving the process:Set Tonnage to above 935 to improve ASM_7Y&ASM_8Y Set Clamp to Location 2

45、to improve ASM_9Y&ASM_10Y Re-machine the A-Pillar die to move the mean of A_3Y to nominal which in turn will move ASM_3Y to nominal Implement the above recommendations and run additional samples to verify results.IImproveImprove Phase 18D M AICDefineMeasure AnalyzeImprove ControlControl PhaseCContro

46、lRecommended controls:Implement a gauge on the body side component press to monitor tonnage Implement an alarm and shut-off feature on the body side press if tonnage falls below 935 tons Implement poke-yoke clamping fixture that ensures clamp is always in Position 2 Establish an affordable control p

47、lan for ongoing monitoring of the 10 critical assembly dimensions.19D M AICDefineMeasure AnalyzeImprove ControlSummaryABC Incorporated is not achieving Six Sigma quality levels for all critical Body-Side Sub-Assembly dimensions as requested by their customers.BBM needs to apply Six Sigma problem sol

48、ving methodology to establish an improvement strategy that minimizes rework costs,yet achieves the desired quality objective.Implement a gauge on the body side component press to monitor tonnage Implement an alarm&shut-off feature on body side press if tonnage falls below 935 Implement poke-yoke cla

49、mping fixture that ensures clamp is always in Position 2 Establish control plan for ongoing monitoring of the 10 critical assembly dimensions.Set Tonnage to above 935 to improve ASM_7Y&ASM_8Y Set Clamp to Location 2 to improve ASM_9Y&ASM_10Y Re-machine the A-Pillar die to move the mean of A_3Y to nominalBring the key process output variables within Six Sigma quality level of 3.4 DPM.Cp 2.0 and Cpk 1.67