2-SPCSlidesRevisionNov2009[EF]3.pptx

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1、 Statistical Process Control统计过程控制Chen BoNov. 2009 Welcome 欢迎Section 1: SPC Introduction章节1： SPC介绍Section 2: SPC Use of Statistics章节2： SPC应用统计技术Section 3: Sampling Strategy for Process Control章节3： 过程控制抽样策略Section 4: Control Charts章节4： 控制图Section 5: Variable Data Control Charts章节5： 计量型数据控制图Section 6:

2、 Attribute Data Control Charts章节6： 计数型数据控制图Section 7: Process Capability章节7： 过程能力补充内容：SPC在产品生命周期中的应用 Section 1: SPC Introduction章节1：SPC介绍 Section Overview 章节概要This section will set the stage for this course by explaining the significance of SPC and how it is applied at Ford Motor Company.本章节通过解释SPC的

3、重要性和SPC怎样在福特汽车公司运用，使大家了解该课程的必要性。This section has three lessons:本章节有3部分课程：lLesson 1: Detection vs. Preventionl课程1：探测与预防lLesson 2: Process Control and Capabilityl课程2：过程控制和过程能力lLesson 3: SPC Use at Fordl课程3：SPC在福特的运用SPC Section 1, Lesson 1: Detection vs. Prevention Lesson Objectives 课程目标At the completi

4、on of this lesson, you will be able to:在本课程结束，您应该可以：lExplain the consequences of manufacturing and shipping products with no strategy in place for preventing defective products from reaching customersl解释如果没有预防缺陷产品的策略，产品制造并发运到顾客处的后果将是多么严重lExplain the Quality Loss Function (QLF) paradigm, including ho

5、w it differs from the traditional quality paradigml解释质量损失函数（QLF）形式，包括与传统质量形式的区别lEvaluate quality using the QLFl使用质量损失函数（QLF）评价质量lDifferentiate between detection and prevention strategiesl探测和预防策略的区别SPC Section 1, Lesson 1: Detection vs. Prevention Consequences of Bad Quality Control 不控制好质量的严重后果It is

6、more difficult to regain a lost customer than to keep a present customer重新赢得一个失去的客户比起维持一个现有的客户更加困难SPC Section 1, Lesson 1: Detection vs. Prevention Quality Loss Function (QLF)质量失效函数SPC Section 1, Lesson 1: Detection vs. Prevention Quality Paradigm 质量形式SPC Section 1, Lesson 1: Detection vs. Preventio

7、n QLF Example 质量失效函授例子SPC Section 1, Lesson 1: Detection vs. Prevention Quality Control Strategies 质量控制策略Quality control strategies can fall into one of two major categories: 质量控制策略可分为以下两类主要类型：lDetection 探测lPrevention 预防SPC Section 1, Lesson 1: Detection vs. Prevention Detection Strategy 探测策略SPC Sec

8、tion 1, Lesson 1: Detection vs. Prevention Prevention Strategy 预防策略SPC Section 1, Lesson 1: Detection vs. Prevention Lesson Complete 课程结束You have now completed Lesson 1: Detection vs. Prevention.您现在完成了课程1：探测与预防This lesson introduced the basic process for bringing products to customers and used the Q

9、LF to demonstrate the importance of quality control within this process. It also showed the advantages of a prevention quality strategy over a detection strategy.本课程介绍了为客户提供产品的基本过程，以及运用质量损失函数证明了过程中控制质量的重要性。同时展示了预防策略相比探测策略的优势。SPC Section 1, Lesson 1: Detection vs. Prevention Lesson Objectives 课程目标 At

10、 the completion of this lesson, you will be able to:在本课程结束，您应该可以：lDifferentiate between consistent and inconsistent processesl区别一致过程和非一致过程lDifferentiate between common cause and special cause variationsl区别普通原因变差和特殊原因变差lDifferentiate between process control and process capabilityl区别过程控制与过程能力lExplain

11、when to adjust a processl解释何时需要调整过程lExplain the steps to achieve high quality processesl解释达到高质量过程的步骤lDefine SPC and its role in improving process qualityl定义SPC及其在改善过程质量中的角色SPC Section 1, Lesson 2: Process Control and Capability Consistent vs. Inconsistent Processes一致过程和非一致过程SPC Section 1, Lesson 2:

12、Process Control and Capability Common Cause Variation 普通原因变差Common cause variations are natural variations that are part of a process. For example, common cause variations can be slight variation in the lengths of manufactured bolts (exaggerated in the graphic below).普通原因变差是过程固有的自然变差。例如，制造的螺栓之间轻微的长度

13、差异。SPC Section 1, Lesson 2: Process Control and Capability Special Cause Variation 特殊原因变差Special cause variations are due to unusual, or out-of-the-ordinary, events (i.e., events that are not a natural part of a process).特殊原因变差是由不寻常的，或者超出常规的事件引起的（事件不是某个正常过程的一部分）An example of special cause variation

14、could occur during the manufacture of a bolt. A broken bolt head indicates special cause variation. The broken head shown here represents a level of manufacturing performance that the customer will find unacceptable.如螺栓制造过程中一个螺栓的头部损坏，即是一种特殊原因变差。损坏的螺栓头部代表在制造过程层面出现了顾客不可接受的情况。SPC Section 1, Lesson 2: P

15、rocess Control and Capability Process Control vs. Process Capability 过程控制与过程能力SPC Section 1, Lesson 2: Process Control and Capability Process Adjustment 过程调整To adjust the process at the appropriate times, follow these steps:在适当的时间调整过程，可以按照如下步骤：lDetermine the expected amount of process variation (i.e

16、., the variation when the process is consistent, stable, and operating within its normal variation). l判定预期的过程变差量（当过程一致、稳定，并在正常变差内运行时的过程变差）lIdentify any unusual process output or measurement and find out what caused it. Unusual output indicates that variation has exceeded a normal, or expected, amoun

17、t and that a special cause is present.l识别任何不正常的过程输出或测量结果，并且找到原因。不正常的输出表明变差超出了正常的或预期的变差量，存在特殊原因lAdjust the process by removing the special cause for the unusual variation. This returns the process to a stable, in-control state. l通过移除造成不正常变差的特殊原因调整过程，使过程回到稳定受控的状态SPC Section 1, Lesson 2: Process Contro

18、l and Capability Steps to Achieve High Quality Processes达到高质量过程的步骤SPC Section 1, Lesson 2: Process Control and Capability Highest Quality 最高质量SPC Section 1, Lesson 2: Process Control and Capability SPC and Process Quality SPC与过程质量SPC Section 1, Lesson 2: Process Control and CapabilityThe AIAG SPC Ma

19、nual, 2nd Edition, defines SPC as: lThe use of statistical techniques such as control charts to analyze a process or its output so as to take appropriate actions to achieve and maintain a state of statistical control and to improve the process capability.l应用诸如控制图等统计技术来分析某一过程或其输出，以便采取适当的措施来达到并保持一种统计受

20、控的状态，从而提高过程能力。 Lesson Complete 课程结束You have now completed Lesson 2: Process Control and Capability. 您现在完成了课程2：过程控制和过程能力This lesson covered process consistency and two types of variation found in processes: common cause variation and special cause variation. It explained the difference between proces

21、s control and process capability. It also explained when to adjust a process and the high-level steps to achieve high quality processes. Finally, this lesson defined SPC and its role in improving process quality.本课程讲述了过程一致性，以及过程中的两类变差：普通原因变差和特殊原因变差。解释了过程控制和过程能力之间的区别。解释了何时需要调整过程，以及达到高质量过程的大致步骤。最后，课程定

22、义了SPC及其在改善过程质量中的角色。SPC Section 1, Lesson 2: Process Control and Capability Lesson Objectives 课程目标At the completion of this lesson, you will be able to:在本课程结束，您应该可以：lExplain SPCs purpose and applicationl解释SPC的目的和应用范围lExplain the need for SPC at Ford Motor Companyl解释SPC在福特汽车公司运用的必要性lIdentify the basic

23、 SPC process stepsl识别基本的SPC过程步骤SPC Section 1, Lesson 3: SPC Use at Ford SPCs Purpose and Application SPC的目的和应用范围The purpose of SPC:SPC的目的：lImprove quality and customer satisfactionl改善质量和客户满意lProvide process capability informationl提供过程能力信息lMonitor and control processesl监控和控制过程lStimulate continuous im

24、provementl刺激持续改进SPC Section 1, Lesson 3: SPC Use at Ford SPCs Purpose and Application SPC的目的和应用范围Industry SPC is used to monitor and control: Financial (Banking) Billing errors in the banks credit card operation Financial (Accounting) Flow time of accounts payable through a specific finance departme

25、nt Healthcare Delivery times of x-ray results at the radiology department Prescription errors in the hospitals pharmacy Shipping Shipment delivery times Here are examples of how various industries can use SPC:以下是不同行业应用SPC的例子：SPC Section 1, Lesson 3: SPC Use at Ford行业SPC用于监控和控制财务（银行）银行信用卡操作帐单错误财务（会计）

26、某财务部门应付帐目时间医疗放射科X光检查结果交付时间；医院药房处方错误物流发运交付时间 Need for SPCSPC的必要性lMaintain processes in a state of statistical controll维持过程统计受控lDistinguish between special cause and common cause variationl区别特殊原因和普通原因变差lUse reliable information to decide when or when NOT to take actionl使用可靠的信息用于决定是否及何时对过程采取措施lAssess p

27、rocess capabilityl评价过程能力lDetermine whether process improvements are successful (i.e., before and after)l判定过程改善是否成功（改善前和改善后）lUse a common language for communicating process control and capabilityl使用通用的语言用于沟通过程控制和过程能力SPC Section 1, Lesson 3: SPC Use at Ford SPC Basic StepsSPC的基本步骤 SPC Section 1, Lesso

28、n 3: SPC Use at Ford识别用于测量和监控的特性或参数开展量测系统分析(MSA)收集或测量数据做控制图解读控制图并采取适当措施评价过程质量开发抽样计划 Lesson Complete 课程结束You have now completed Lesson 3: SPC Use at Ford.您现在完成了课程3：SPC在福特的运用This lesson explained SPCs purpose and application and why SPC is needed at Ford. It also covered the basic SPC process steps.本课

29、程揭示了SPC的目的和应用范围，以及SPC在福特运用的必要性。同时介绍了SPC的基本步骤。SPC Section 1, Lesson 3: SPC Use at Ford Section Summary 本章小结You have completed Section 1: SPC Introduction.您完成了章节1：SPC介绍This section explained why Ford must employ a prevention strategy like SPC to achieve high quality processes and products. It also int

30、roduced SPCs application at Ford.本章节解释了福特为什么要采用像SPC这样的预防策略来达到高质量的过程和产品。同时介绍了SPC在福特的运用。SPC Section 1 Section 3: Sampling Strategy for Process Control章节3：过程控制抽样策略 Section Overview 章节概览This section has two lessons:本章有两部分课程：lLesson 1: Identifying Characteristics to Measurel课程1：识别用于测量的特性lLesson 2: Develo

31、ping Sampling Plansl课程2：开发抽样计划SPC Section 3, Lesson 1: Identifying Characteristics to Measure SPC Section 3, Lesson 1: Identifying Characteristics to Measure识别用于测量和监控的特性或参数 Lesson Objectives 课程目标At the completion of this lesson, you will be able to:在本课程结束，您应该可以：lIdentify who decides which characteri

32、stics to measurel识别谁来决定哪些特性被测量lIdentify when characteristics should be selectedl识别什么时候特性应该被选择lExplain how the process influences characteristic selectionl解释过程是如何影响特性选择的lExplain why variable data is preferred to attribute datal解释为什么计量型数据比计数型（属性）数据好lApply criteria for selecting characteristics to meas

33、urel选择测量特性的标准lDescribe sources used to determine which characteristics to measurel描述决定哪些特性被测量需用到的资源lExplain where identified characteristics to measure are documentedl解释识别的测量特性在哪里文件化SPC Section 3, Lesson 1: Identifying Characteristics to Measure Characteristic Selection: Who and When特性选择：谁、什么时候 At F

34、ord Motor Company, a cross-functional team identifies the process parameters, or characteristics, to measure and monitor. This cross-functional team includes:在福特汽车公司，跨功能小组识别用于测量和监控的过程参数或特性。该跨功能小组包括：lThe Manufacturing Engineer and the Product Design Engineerl制造工程师和产品设计工程师lEngineers from Facilities, T

35、ooling, Gauging, and Qualityl设备、工装、测量和质量工程师lThe production plant and suppliers (if necessary)l生产工厂和供应商人员（如有必要）SPC Section 3, Lesson 1: Identifying Characteristics to Measure Process Influence 过程影响The parameters, or characteristics, selected to measure will depend on the process.选择用于测量的参数或特性，取决于过程。Fo

36、r a manufacturing process, we can measure part characteristics or process parameters, such as diameter, pressure, time, or temperature. 例如针对制造过程，我们可以测量零件特性或过程参数，如直径、压力、时间或温度。Measuring and controlling appropriate process parameters results in a process that produces quality parts. Therefore, the pref

37、erred method is to understand and control process parameters rather than part characteristics.制造和控制适当的参数将导致过程产出相应质量的零件。因此，理解并控制过程参数优于直接测量和控制零件特性。SPC Section 3, Lesson 1: Identifying Characteristics to Measure Variable Data vs. Attribute Data计量型数据与计数型（属性）数据When feasible, the team should choose to mea

38、sure variable (i.e., continuous) data instead of attribute (i.e., discrete) data because variable data is more sensitive for detecting process changes. 如果可行，团队应该选用测量计量型数据（连续型）代替计数型数据（离散型），因为计量型数据用于探测过程变化更加敏感。SPC Section 3, Lesson 1: Identifying Characteristics to Measure Selection Criteria 选择标准SPC c

39、haracteristics, or variables, must be:SPC特性或变量应该满足：lIndependent process variables (i.e., unaffected by other characteristics or operations)l独立过程变量（不受其他特性或操作的影响）lFeasible to measure on the plant floor (i.e., measured the way they are machined)l尽可能在车间测量（按照加工的方式测量）SPC Section 3, Lesson 1: Identifying C

40、haracteristics to Measure Selection Criteria and GD&T 选择标准和GT&DGD&T callouts are often composites and include multiple error sources (e.g., size, form, location). Some of these error sources may be adjustable by machine operators, while others may not.GD&T常常混合并包含多个误差源（如：尺寸、形状、位置）。部分变差源可通过设备操作者调整，部分不

41、可以。GD&T feature measurement and calculation methods can also obscure what is happening in the process. This is particularly true for:GD&T属于测量和计算方法，会模糊过程事件，尤其对于：lTrue position l真实位置lProfilel形状lRunoutl跳动SPC Section 3, Lesson 1: Identifying Characteristics to Measure Selection Example 特性选择例子 Which one

42、of the following lists the independent measurements that could be SPC characteristics?以下哪个列出了可作为SPC独立测量的特性？a.A, B, and C onlyb.A, B, and D only c.A and C onlyd.A and D onlySPC Section 3, Lesson 1: Identifying Characteristics to Measure Sources for Characteristic Selection 特性选择用到的资源lCustomer inputl客户

43、输入lLessons learned from previous processes or productsl之前过程或产品的经验教训lBrainstormingl头脑风暴lCause and effect diagrams (i.e., fishbone diagrams)l因果图（鱼骨图）lDesign Failure Mode and Effect Analyses (DFMEAs)l设计FMEA (DFMEAs)lProcess Failure Mode and Effect Analyses (PFMEAs)l过程FMEA (PFMEAs)SPC Section 3, Lesson

44、1: Identifying Characteristics to Measure Control Plan 控制计划 SPC Section 3, Lesson 1: Identifying Characteristics to MeasureOnce the team identifies appropriate characteristics to measure and monitor, it documents them in the Control Plan.一旦团队识别出适当的测量和监控特性，就应该立即在控制计划中文件化。 Lesson Complete 课程结束This les

45、son covered the following information about characteristic selection for SPC:本课程介绍了SPC特性选择的相关信息：lWho is responsiblel谁负责lWhen selection occursl何时选择lSelection criterial选择标准lSources for characteristic selectionl选择特性需要的资源lWhere selected characteristics are documentedl选择的特性在哪里文件化SPC Section 3, Lesson 1:

46、Identifying Characteristics to Measure SPC Section 3, Lesson 2: Developing Sampling Plans开发抽样计划 Lesson Objectives 课程目标 At the completion of this lesson, you will be able to:在本课程结束，您应该可以：lExplain the purpose of samplingl解释抽样的目的lExplain the Central Limit Theorem and why sampling works for process cont

47、roll解释中心极限定理及为什么抽样可以用于过程控制lExplain why it is necessary to have a subgroup size of more than 1l解释为什么有必要取子组大小大于1lApply SPC sampling requirements for rational samples and stratificationl运用SPC抽样要求做合理的抽样和层化lIdentify a sampling plans major componentsl识别抽样计划的主要构成lDescribe considerations for determining app

48、ropriate sample size and frequencyl描述选取适当的抽样大小和频率的考虑原因lApply general rules for determining appropriate sample size and frequencyl运用通用的准则来选取适当的抽样大小和频率SPC Section 3, Lesson 2: Developing Sampling Plans Purpose of Sampling 抽样目的We use sampling to monitor process changes in:我们在以下方面运用抽样监控过程变化：lTargeting (

49、Has the process mean shifted away from the target?)l对中程度（过程均值是否偏离目标？）lVariability (Has the variability changed?)l变差（变差是否改变了？）lStability (Are the process mean and variation consistent over time?)l稳定性（过程均值和变差随着时间的推移是否一致？）SPC Section 3, Lesson 2: Developing Sampling Plans Central Limit Theorem: Propert

50、y 1中心极限定理：特性1 Property 1: The distribution of the sample means will become normally distributed as the sample size increases even if the population is non-normal.特性1：即使总体不符合正态分布，随着样本容量的增大，样本均值的分布将趋于正态分布SPC Section 3, Lesson 2: Developing Sampling Plans Central Limit Theorem: Property 2中心极限定理：特性2Prop