改善企业质量流程管理的技术 6-sigma_trainiing(六西格码培训资料).ppt

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1、6-Sigma TrainingStatistical Technique to 6-Sigma Quality16-Sigma TrainingABOUT INSTRUCTORABOUT INSTRUCTORCurrent position:Sr.Officer,LCM Eng.Dept MPhif.(EE),BEng(Hons)Eng.Past working experience:HKUST:To fabricate OLED and design the related driving cicruits.CityU:To fabricate Polymeric Opto Wavegui

2、desPhilips:To develop LCM including B/W,Color STN,TFT and PLEDSolomon Systech:To develop the driver IC for B/W,Color STN,TFT and PDA products.26-Sigma TrainingCOURSE ABSTRACTCOURSE ABSTRACTThis course is to introduce the ways of Process Control System targeting to 6-sigma Quality in the manufacturin

3、g areas.The benchmark of Six Sigma will be shared during the course.In order to achieve it,series of measurement system capabilities,performance metrics and process control methodology will be discussed.36-Sigma TrainingCOURSE OBJECTIVESCOURSE OBJECTIVES Participants will learn:-*What is six Sigma *

4、Control Planning and Methodology *Measurement system capability *Process Capability Metrics *Continuous Process Improvement46-Sigma TrainingTraditional Process CapabilityTraditional Process Capability*99.73%of the total area within spec.limits.Defect rate will be 2,700 PPM.*Only 93.32%of the area un

5、der the curve and defect rate is 66,000PPM.56-Sigma TrainingSix Sigma CapabilitySix Sigma Capability*Defect rate-0.002 PPM*Defect rate-3.4 PPM66-Sigma Training Output VariablesManage the outputs.A Traditional ViewSales GrowthMarket ShareProfitability76-Sigma Training Output Variables Input Variables

6、Manage the inputs;respond to the outputs.A Non-traditional ViewSales GrowthMarket ShareProfitabilityCustomer SatisfactionProduct QualityOn-Time DeliveryCOQCredit TermsRelationshipsServiceCustomer Training86-Sigma TrainingWhat is 6-SigmaWhat is 6-SigmaMotorolas term to express a process capability th

7、at produces only 0.002 defects per each million units manufactured when the process is centered,or a maximum of only 3.4 defects for each million units when the process shifts up to 1.5 sigma to one side.The term“6 sigma”is becoming synonymous with“Quality Excellence”.96-Sigma Training The Concept o

8、f Six SigmaDifferent numbers of Opportunities.Manufacturing ProcessesCustomers or SuppliersAdministrative Areas6=A structural approach to continuous improvement1-Identify the product or service you provide2-Identify your customers&their requirements3-Determine your needs&suppliers4-Define the proces

9、s for doing work5-Eliminate defect sources/optimize the process6-Continuously improve the Sigma level(or“Six steps toward excellence”)A Bit of Statistics.A Bit of Statistics.-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0upper spec limitLower spec limit+1.5 Sigma-1.5 Sigma3.4 ppm or Zero+106-Si

10、gma TrainingCENSOREDNormal Distribution-Gaussian CurveSigma=Deviation(Square root of variance)-7-6-5-4-3-2-101234567Axis graduated in SigmaAxis graduated in Sigma68.27%95.45%99.73%99.9937%99.999943%99.9999998%result:317300 ppm outside(deviation)45500 ppm2700 ppm63 ppm0.57 ppm0.002 ppm between+/-1bet

11、ween +/-2between +/-3between +/-4between +/-5between +/-6=116-Sigma TrainingSix Sigma.And the Statistics -7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0+1.5 Sigma-1.5 Sigma3.4 ppmor ZeroUpper spec.limitLower spec.limit Reduce the variation:when =2 Cp =2 andand CpkCpk =1.5 =1.5Cp =2Cp =2126-Sigm

12、a TrainingSix Sigma.And Capability Cp=Design specification width6 3 Cpk=Min.Mean-Spec LimitWith a maximum process shift of+/-1.5 136-Sigma Training-Customers or Suppliers:One opportunity per product delivered or per component purchased.-Manufacturing process:Opportunities at each process step)-Admin

13、istrative areas:Number of opportunities for error for each activity performed The Opportunities.146-Sigma TrainingSome Examples of OpportunityCustomer Perspective:1 opportunity per product delivered ex.1 regulator=1 opportunity 1 controller=1 opportunity Production lines:Regulator =160 opportunities

14、 Controller=1200 opportunitiesForm(Payment,Purchase Order,.):Number of fields Expedite/Delivery:1 opportunity/packaging unit156-Sigma TrainingA quality level of A quality level of 6 6 corresponds to less corresponds to less than 3.4 defects per million than 3.4 defects per million OpportunitiesOppor

15、tunities(i.e.,correct(i.e.,correct 99.99966%99.99966%of the time)of the time)Number of DefectsNumber of DefectsNumber of UnitsNumber of Units=D.P.UD.P.U D.P.U x 1000000D.P.U x 1000000Number of OpportunitiesNumber of Opportunities =D.P.M.Op.=D.P.M.Op.Sigma and Opportunities1 Opportunity=1 Opportunity

16、=D.P.M.Op166-Sigma TrainingA Universal Measurement Scale.3 34 45 56 67 76681066810621062102332333.43.4 SigmaDPMOpDPMOpOn one condition:Calculate the defects and estimate the opportunitiesin the same way.176-Sigma TrainingMeasurement With SIGMA Is Simple!Estimate theOpportunitiesCount the Defects Fol

17、low the Indicator:Defects per million OpportunitiesConversion into Sigma canbe accomplished with the helpof a statistical table.6 6 =3.4=3.4 dpmodpmo186-Sigma TrainingConverting Defect Levels to.Sigma!175 defects are identified whileproducing 5000 controllers The manufacture of one controllerallows

18、for 1367 defect opportunities.D.P.Op=0.035/1367=0.0000256 An ExampleAn Example:D.P.U=175/5000=0.035 D.P.M.Op=25.6 Sigma level :5.55Sigma level :5.55196-Sigma TrainingSix Sigma:An Ambitious Objective?Accurate to 99.99966%(less than 3.4 defects for each millionopportunities)could appear excessive.!99.

19、9%is already VERY GOOD!But what could happen at a quality level of 99.9%(i.e.,1000 ppm),in our everyday lives(about 4.6)?4000 wrong medical prescriptions each yearMore than 3000 newborns accidentally falling from the hands of nurses or doctors each yearTwo long or short landings at American airports

20、 each day400 letters per hour which never arrive at their destination206-Sigma TrainingThe Impact of Quality:“6 Sigma Suppliers”n13 wrong drug prescriptions per yearn10 newborn babies dropped by doctors/nurses per yearnTwo short or long landings per year in all the airports in the U.S.nOne lost arti

21、cle of mail per hour216-Sigma TrainingDefect Reduction:“Peeling the Onion”Action NameDateACTION PLAN PROCEDURECONTINUOUS IMPROVEMENT MODEL TREND CHART GOAL T I M E 100%BRAINSTORMING/PARETO ANALYSIS/ROOT CAUSE IDENTIFICATION RESULTS AND INSTITUTIONALIZE MEASURE ANALYZE PROBLEM SOLVE Processstep 1Proc

22、essstep 3Processstep 2SUPPLIERSUPPLIERSUPPLIERCUSTOMERCUSTOMERCUSTOMERRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTSRECORDDEFECTS226-Sigma TrainingMeasurement Systems CapabilityMeasurement Systems CapabilityThe capability of the measurement system must be ensured before the system is used for

23、process control or for measurements used in capability studies.Gage Repeatability&Reproducibility(R&R):is a statistical study to investigate the gages ability to repeat a measurement on the same part(repeatability)an dthe ability to give the same reading on the same part when used by different peopl

24、e(reproducibility).Under 10%-acceptable10%-30%-May be acceptable depending on application.Effort should be made to improve the gaga capability.Over 30%-Not suitable to use.236-Sigma TrainingGage R&RGage R&R246-Sigma TrainingProcess Performance CapabilityProcess Performance CapabilityTo measure the a

25、bility of a machine or process to produce a product within specification.Potential Process Capability Index(Cp):-Ratio of specification width over the process spreadSpec WidthCp=Process SpreadUSL-LSL =6-Sigma256-Sigma TrainingProcess Performance CapabilityProcess Performance CapabilityProcess Capabi

26、lity Index(CpK):-an off-target process should be“penalized”for shifting from where it should be.CpK is the index to measure this real capability when the off-target penalty is taken into consideration.Target-Process MeanPenalty/Correction factor,k=1/2 Specification Width Mean-Closer spec limit Cpk=C

27、p(1-k)=3 sigma266-Sigma TrainingProcess Performance CapabilityProcess Performance Capability276-Sigma TrainingProcess Performance CapabilityProcess Performance Capability*Maximum customer satisfaction is achieved only when the product is right on target.286-Sigma TrainingProcess Performance Capabili

28、tyProcess Performance Capability296-Sigma TrainingTotal Process Control SystemTotal Process Control System1.Process/Product Failure Mode and Effects Analysis(FMEA)An analytical technique aimed at problem prevention through identification of potential problems.For each failure mode,the effect on the

29、total system is studied and actions to minimize the probability of failures are planned.FMEA will serve:a)Identifies known or potential process failure modesb)Assesses the potential risk effects of the failures to the customerc)Identifies the potential product or manufacturing process causes and con

30、trol actionsd)Identifies significant process variables to focus controls for detecting and reducing similar failures306-Sigma TrainingFMEAFMEA316-Sigma TrainingTotal Process Control SystemTotal Process Control System2.Process Control PlanA summary description of the procedures for controlling all si

31、gnificant characteristics of the processes used to manufacture a family of similar products.It identifies the important processes used to produce a product,the significant characteristics associated with each process and how to control each of those significant characteristics.Control Plan consists:

32、a)Processb)Equipmentc)Significant characteristicsd)Measurement methode)Minimum sample size and frequencyf)Analysis methodg)Out of control action326-Sigma TrainingControl PlanControl Plan336-Sigma TrainingTotal Process Control SystemTotal Process Control System3.Total Control MethodologyA set of docu

33、ments providing all necessary instructions on how to control each significant variable in a process.A Total Control Methodology is used at the individual process level,while a Control Plan is used for a product line that contains several processes.Total Control Methodology consists:a)Positrol Planb)

34、Positrol Log check listc)Control Chartsd)Out-of-Control Action Plan(OCAP)e)Process/Machine Setup Check Listf)P/M Schedule and Checklistg)P/M procedures346-Sigma TrainingAttribute ControlAttribute Control356-Sigma TrainingVariable ControlVariable Control366-Sigma TrainingStatistical Technique in Elec

35、trical Test AreaStatistical Technique in Electrical Test Area376-Sigma TrainingContinuous ImprovementContinuous Improvement386-Sigma TrainingContinuous ImprovementContinuous Improvement396-Sigma TrainingContinuous ImprovementContinuous Improvement406-Sigma Training=A structured approach to continuou

36、s improvement1-Identify the product or service you provide2-Identify the customer&their requirements3-Determine your needs&suppliers4-Define the process for doing work5-Eliminate defect sources/optimize the process6-Continuously improve the Sigma level(or”Six steps toward excellence)Six Sigma and Continuous ImprovementSupplierSupplierCustomerCustomerEnterNeeds ExitProduct/ServiceProcessActivity123456Feedback41