西格玛改善测量培训教材40408.pptx

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1、Time Based Management 2005 TBM Consulting Group,Inc.All Rights Reserved.2005 TBM Consulting Group,Inc.All Rights Reserved.SKBSKBTBM Consulting Group,Inc.is the sole licensee of LeanSigma,a service mark of Maytag Corporation.TBM Consulting Group,Inc.is the sole licensee of LeanSigma,a service mark of

2、 Maytag Corporation.西格玛改善测量西格玛改善测量西格玛改善测量西格玛改善测量Sigma KaizenSigma KaizenMeasureMeasure 1010-2 2 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB何谓精益西格玛何谓精益西格玛何谓精益西格玛何谓精益西格玛?WWhat is LeanSigma?hat is LeanSigma?改善突破的速度改善突破的速度,时效为本的战略时效为本的战略LeanSi

3、gma is a methodology aligned with a time-based strategy at the speed of Kaizen Breakthrough 聚焦于缩短前置时间及减少变化聚焦于缩短前置时间及减少变化Focused on lead-time&variability reduction 利用六西格玛及精益生产原理利用六西格玛及精益生产原理Utilizes both six sigma and lean principles 推动文化变革推动文化变革Drives cultural change 减少不良产品减少不良产品,减少产品及流程变化减少产品及流程变化

4、LeanSigma reduces defects and variation in product and processes 向向3.4PPM不良品迈进不良品迈进Strives for 3.4 defects per million 以测量为基础以测量为基础Measurement focused 现场数据和历史数据现场数据和历史数据Live and dead data 财务效益好财务效益好财务效益好财务效益好,所化时间少所化时间少所化时间少所化时间少Bottom Line Results in Substantially Less TimeBottom Line Results in Su

5、bstantially Less Time1010-3 3 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB西格玛改善西格玛改善精益西格玛模型精益西格玛模型精益西格玛模型精益西格玛模型 LeanSigma ModelLeanSigma Model6 Sigma(3.4 DPM)(3.4 DPM)5 Sigma(233 DPM)(233 DPM)4 Sigma(6,210 DPM)(6,210 DPM)3 Sigma(66,807 DPM

6、)(66,807 DPM)1-2 Sigma(308,537 DPM)(308,537 DPM)精益西格玛设计精益西格玛设计精益西格玛设计精益西格玛设计 Design for LeanSigmaDesign for LeanSigma制程能力制程能力制程能力制程能力 Process Capability Process Capability 优化制程优化制程优化制程优化制程 Process OptimizationProcess Optimization创建流线创建流线创建流线创建流线 Create FlowCreate Flow消除浪费消除浪费消除浪费消除浪费 Waste Eliminati

7、onWaste Elimination逻辑与直觉逻辑与直觉逻辑与直觉逻辑与直觉 Logic&IntuitionLogic&Intuition1010-4 4 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB找出不良品找出不良品 Determine the DefectY制定流程表现制定流程表现 Establish Process PerformanceY评审测量系统评审测量系统 Evaluate Measurement SystemY评

8、审标准化操作评审标准化操作 Evaluate Standard OperationsY识别根本原因识别根本原因 Identify Root CausesXs提出解决方案提出解决方案 Develop SolutionsXs排列及实施解决方案排列及实施解决方案 Prioritize&Implement Solutions主要的主要的X Vital Few Xs测试解决方案测试解决方案,验证结果验证结果 Test Solutions&Verify Results主要的主要的X Vital Few Xs完善标准化操作完善标准化操作 Refine Standard Operations主要的主要的X V

9、ital Few Xs验证测量系统验证测量系统 Validate Measurement System主要的主要的X Vital Few Xs实施控制系统及评审计划实施控制系统及评审计划 Implement Control System&Audit Plan主要的主要的X Vital Few Xs确定制程能力确定制程能力 Determine Process CapabilityY测量测量测量测量 MeasureMeasure分析分析分析分析 AnalyzeAnalyze改善改善改善改善 ImproveImprove控制控制控制控制 ControlControl精益西格玛项目阶段精益西格玛项目阶

10、段精益西格玛项目阶段精益西格玛项目阶段 LeanSigma Project Phases LeanSigma Project Phases1010-5 5 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB项目实施项目实施项目实施项目实施 Project ImplementationProject Implementation西格玛改善西格玛改善SM测量阶段测量阶段 5天改善天改善Sigma KaizenSM Measure Phase

11、5 day Kaizen第第5天天 Day 5第第4天天 Day 4第第3天天 Day 3第第2天天 Day 2第第1天天 Day 1精益西格玛简介精益西格玛简介LeanSigma Overview 改善突破法改善突破法Kaizen Breakthrough Methodology 精益西格玛测量精益西格玛测量工具工具LeanSigma Measure Tools 识别缺陷、识别缺陷、“Y”及项目范围及项目范围Identify defect,“Y”,&project scope 详细的现场行详细的现场行走示意图走示意图Enhanced Spaghetti Map 质量图质量图Quality M

12、ap 验证标准化操验证标准化操作作Verify Standard Operations 比较分析比较分析Comparative Analysis 收集历史资料收集历史资料Collect Historical Data 传授传授&行动行动Teach&Do 传授传授&行动行动Teach&Do 培训培训&范围范围Training&Scope 比较分析比较分析Comparative Analysis 测量系统分析测量系统分析Measurement System Analysis 必要时必要时,改善测改善测量系统量系统Improve measurement system,if necessary 确定制

13、程能力确定制程能力Determine Process Capability 收集现场数据收集现场数据Collect Live data 快速解决快速解决Quick kills 比较分析比较分析Comparative Analysis 基本质量工具基本质量工具Basic Quality Tools 因果图因果图Cause&Effect Chart 必要时必要时,收集更收集更多数据多数据Gather Additional Data if Required 测量阶段展示测量阶段展示Presentation of Measure Phase 西格玛改善实施西格玛改善实施西格玛改善实施西格玛改善实施 S

14、igma Kaizen ImplementationSigma Kaizen Implementation传授传授&行动行动Teach&Do 1010-6 6 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB项目实施项目实施项目实施项目实施 Project ImplementationProject Implementation精益西格玛测精益西格玛测量回顾量回顾LeanSigma Measure Review 用另外收集的用另外收集的

15、数据更新资料数据更新资料Update Information w/Additional Data Collection 精益西格玛分精益西格玛分析析/改善工具改善工具LeanSigma Analyze/Improve Tools 基本分析工具基本分析工具Basic Analytical Tools 假设性试验假设性试验Hypothesis Testing 确定根本原因确定根本原因Identify Root Cause 观察工场观察工场Shop Floor Observations 培训培训&范围范围Training&Scope 风险评估风险评估Risk Assessment 实施改善实施改善I

16、mplement Improvements 防错防错Mistake Proofing 数据收集数据收集Collect Data 通过假设性试验通过假设性试验,验证改善验证改善Verify Improvements through Hypothesis Testing 完善标准化操作完善标准化操作Refine Standard Operations 分析分析/改善阶段改善阶段展示展示Presentation of Analyze/Improve Phase 西格玛改善西格玛改善SM分析分析/改善阶段改善阶段 5天改善天改善Sigma KaizenSM Analyze/Improve 5 day

17、Kaizen西格玛改善实施西格玛改善实施西格玛改善实施西格玛改善实施 Sigma Kaizen ImplementationSigma Kaizen Implementation传授传授&行动行动Teach&Do 传授传授&行动行动Teach&Do 传授传授&行动行动Teach&Do 第第5天天 Day 5第第4天天 Day 4第第3天天 Day 3第第2天天 Day 2第第1天天 Day 11010-7 7 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Rese

18、rved.SKBSKB控制控制（30天跟催天跟催)Control(30 day follow up)改善公报改善公报Kaizen newspaper 鉴察使用统计制程控制鉴察使用统计制程控制Monitor using statistical process control 鉴察坚持标准化操作鉴察坚持标准化操作Monitor adherence to standard operations 借力其它地区借力其它地区Leverage to other areas 精益西格玛辩论精益西格玛辩论LeanSigma report out 庆祝项目结束庆祝项目结束Celebrate 项目实施项目实施项目实

19、施项目实施 Project ImplementationProject Implementation1010-8 8 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKBPease Shield定义定义Pease Shield产品为节省成本之产品产品为节省成本之产品 Position Pease shield product line to contribute to bottom line不良品率降低不良品率降低50%50%reducti

20、on in quality defectsDavid BealArvin PleimaMatt Goesling缩水线及模糊缩水线及模糊 Shrink lines&fog预计预计 Estimated实际实际 Actual$1,050,000开始开始 Started完成完成 Completed实施实施 ImplementedJuly 18,2000July 21,2000July 21,2000LeanSigma CharterLeanSigma Charter描述描述 Description:业务业务目标目标 Business Objective:结果结果 Deliverable:项目项目 Y

21、/缺陷缺陷 Project Y/Defect:财财务效果务效果 Financial:时间时间 Timing:发起发起人人 Sponsors:项目项目组长组长 Project Leader:指指导导 Mentor:流流程主人程主人 Process Owner:1010-9 9 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB精益西格玛团队精益西格玛团队精益西格玛团队精益西格玛团队 LeanSigma TeamLeanSigma Team核

22、心团队核心团队 Core team对流程有深刻认识的人士对流程有深刻认识的人士,例如工人、品质工程师、流程工例如工人、品质工程师、流程工程师、设计工程师等程师、设计工程师等Individuals who have in depth knowledge of the process,i.e.operators,quality engineers,process engineers,design engineers 参加过所有改善活动的人士参加过所有改善活动的人士Team members participate throughout all the kaizen events 其它人士其它人士 R

23、esources需要时才召集的人士需要时才召集的人士Individuals who are required on an as needed basis 改善活动期间或之后动员起来的人士改善活动期间或之后动员起来的人士Mobilized during kaizen and/or between kaizen weeks 1010-1010 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB零件或流程照片零件或流程照片零件或流程照片零件或流

24、程照片 Picture of Part or ProcessPicture of Part or Process1010-1111 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB三种图三种图三种图三种图 3 3 Types of MapsTypes of Maps质量图质量图QualityMap业务流程图业务流程图BusinessProcessFlow Map制造制造制造制造ManufacturingManufacturing业务业务

25、业务业务 /办公室办公室办公室办公室Business/OfficeBusiness/Office 详细的现场详细的现场行走示意图行走示意图EnhancedSpaghetti Map1010-1212 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB详细的现场行走示意图详细的现场行走示意图详细的现场行走示意图详细的现场行走示意图 Enhanced Spaghetti MapEnhanced Spaghetti Map显示物料流程显示物料流

26、程Shows material flow 显示工人流程显示工人流程Shows operator flow 观察实际布置观察实际布置,找出浪费活动找出浪费活动Aids in identifying wasteful activities by viewing it from the basis of physical layout 显示实际发生的事与想像会发生的事显示实际发生的事与想像会发生的事Shows what is actually happening versus what people think happens 每人都要熟悉流程每人都要熟悉流程Familiarizes everyon

27、e with the process 找出物料搬运找出物料搬运/储存方面的变化储存方面的变化Identifies variations in material handling/storage 1010-1313 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB步骤步骤 Step1.丝攻 Tapper2.玻璃清洗Glass washer3包裹 Wrapper4浇注 Pourer1.5凝固 Cure7脱模 Demold8 检验 Inspe

28、ct问题问题 Problems2.玻璃不干净Glass not clean3.工模不方,工模准备 Mold not square,mold prep 4.锁模位置,移开模锁,模锁跌落Clamp location,clamp removal,clamps fall off5.凝固时间、温度、湿度 Cel time,temp.,humidity6.边缘/表面干净 Edge/face clean 浇注浇注 PourerPourer凝固台凝固台Cure TableCure Table检验检验InspectorInspector脱模脱模 DeMolderDeMolder玻璃清洗玻璃清洗 Glass Wa

29、sherGlass Washer黄色丝攻黄色丝攻 Yellow TapperYellow Tapper 模具加工模具加工Mold MakerMold Maker包裹包裹 WrapperWrapper树脂防护罩Resin Shield送生产部送生产部To Production开始开始开始开始 StartStart结束结束结束结束 EndEndLTWRevised:7/01 2001 TBM Consulting Group,Inc.All Rights Reserved.详细的现场行走示意图详细的现场行走示意图详细的现场行走示意图详细的现场行走示意图 Enhanced Spaghetti Map

30、Enhanced Spaghetti Map1010-1414 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB质量图质量图质量图质量图 Quality MapQuality Map确定流程之所有步骤确定流程之所有步骤Identifies all the steps in the process 清楚显示每个步骤之所有规格清楚显示每个步骤之所有规格Clearly shows all specifications of each step

31、 确定每个步骤所用之测量仪器。用测量系统分析来测试确定每个步骤所用之测量仪器。用测量系统分析来测试这些系统这些系统Identifies the measurement devices used in each step.These systems will be tested using a measurement systems analysis.流程控制的理解与实际变得显然流程控制的理解与实际变得显然Perception of the control versus the reality of the control becomes apparent 全力以赴于一个变革步骤全力以赴于一个变

32、革步骤,找出已知问题找出已知问题Total focus on one transformation step to identify known problems 1010-1515 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB质量图质量图产品产品流程流程日期日期流程步骤流程步骤规格规格/质量标准质量标准测量控制方法测量控制方法模具模具/工夹具工夹具发现发现缺陷缺陷/已知已知问题问题缺陷原因缺陷原因差距分析差距分析1010-1616

33、 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB质量图质量图质量图质量图 Quality MapQuality Map流程步骤流程步骤规格规格/质量质量标准标准测量测量控制控制方法方法模具模具/工夹具工夹具发现发现缺陷缺陷/已知已知问题问题缺陷缺陷原因原因差距差距分析分析后拉伸生后拉伸生产线产线3后拉伸生后拉伸生产线产线1输送带末端宽167mm拉伸机出口宽164mm收缩率一般811%,无规格;宽都变化+/-3%,有规格张力控制:7每1

34、,200英尺测量一次10英寸针孔记号测量线性收缩;钢尺测量产品宽都5分钟后,10英寸样板变成8.5”;宽度为170mm产品在直带上往一个方向弯曲,在另一直带上往相反方向弯曲产品应力;方在聚脂薄膜上时会弯曲冷却槽温度差异;水没有冷却;没有压滚机;张力为7正确吗?产品在鼓轮上还在收缩;产品明显弯曲,但无法测量输送带末端宽170mm拉伸机出口宽169mm收缩率一般2%,无规格;无规格每1,200英尺测量一次张力控制:7输送带在运转时测量为10”10英寸针孔记号测量线性收缩;钢尺测量产品宽都最后线性长度收缩只有0.2”1010-1717 2005TBM Consulting Group,Inc.All

35、 Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB质量图质量图质量图质量图 Quality MapQuality Map流程步骤流程步骤工具工具加工前加工前加工后加工后管尾张开表示工具完全插入管尾张开表示工具完全插入;满足回程弯曲插入之设计标准满足回程弯曲插入之设计标准图纸上的设计规格图纸上的设计规格张开工具张开工具长度不等长度不等,张开不对称张开不对称工人变化性工人变化性张开大小无测量数据张开大小无测量数据;没有最打最小管长小于张开尺寸没有最打最小管长小于张开尺寸;可用红色工具定义长度可用红色工具定

36、义长度规格规格/质量质量标准标准测量测量控制控制方法方法模具模具/工夹具工夹具发现发现缺陷缺陷/已知已知问题问题缺陷缺陷原因原因差距差距分析分析1010-1818 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB柏拉图柏拉图柏拉图柏拉图 ParetoPareto比较原因出现频率比较原因出现频率,按照递降顺序排列按照递降顺序排列Compares how frequently different causes occur and puts

37、them in decreasing order of occurrence 过滤资料过滤资料,重点改善重点改善Used to filter data to focus improvement efforts 柏拉图原理柏拉图原理柏拉图原理柏拉图原理 Pareto PrinciplePareto Principle:20%20%的原因造成的原因造成的原因造成的原因造成80%80%的问题的问题的问题的问题20%of the causes account for 80%of the problem20%of the causes account for 80%of the problem数量数量柏

38、拉图柏拉图标签标签_1喉管泄漏接线错误脏污其它零件损坏擦伤1010-1919 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB树脂防护罩历史资料树脂防护罩历史资料树脂防护罩历史资料树脂防护罩历史资料Historical Data collected on Resin ShieldHistorical Data collected on Resin Shield数量数量柏拉图柏拉图缺陷数量缺陷数量缺陷柏拉图缺陷柏拉图收缩收缩模糊模糊气泡气

39、泡比例比例累计累计%1010-2020 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB何谓测量系统分析何谓测量系统分析何谓测量系统分析何谓测量系统分析?What is Measurement System Analysis“MSA”?What is Measurement System Analysis“MSA”?识别测量系统变量识别测量系统变量,量化如何影响流程量化如何影响流程It identifies and quantifies

40、 how much of the overall process variability is due to the measurement system 测量数据是测量过程的输出测量数据是测量过程的输出,可能发生变化可能发生变化Measurements are outputs of a measurement process,which are subject to variation.离离散型散型/特特征征型型数据数据Discrete/Attribute Data 专家重评专家重评Expert Reevaluation 鉴定人同意鉴定人同意Appraiser Agreement连续性数据连

41、续性数据Continuous Data仪器重复性及再现性仪器重复性及再现性Gage R&R 立即评估测量变异立即评估测量变异,确定如何影响流程确定如何影响流程Measurement variation must be assessed immediately to determine impact on process1010-2121 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB连续性数据连续性数据连续性数据连续性数据 Conti

42、nuous DataContinuous Data规格下限规格下限 LSL规格上限规格上限 USL流程变异流程变异 Process Variation流程变异流程变异 Process VariationX1 X2 X3Xn测量过程变异测量过程变异 Measurement Process Variation仪表变异仪表变异Gage Variation鉴定人变异鉴定人变异Appraiser VariationX1 X2 X3Xn重复性重复性Repeatability校对校对Calibration稳定性稳定性Stability线性度线性度Linearity灵敏度灵敏度Discrimination10

43、10-2222 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB再现性再现性再现性再现性 ReproducibilityReproducibility鉴定人鉴定人AAppraiser A鉴定人鉴定人CAppraiser C鉴定人鉴定人BAppraiser B由不同鉴定人使用同一测量同一测量系统系统对同一项目同一项目进行测量之平均测量值差异Variation in the average of the measurements made

44、by different appraisers using the same measuring system when measuring the identical characteristic on the same item 测量系统导致的差异测量系统导致的差异 Variation due to the measuring system 1010-2323 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB重复性重复性重复性重复性

45、 RepeatabilityRepeatability由同一鉴定人使用同一测量装置同一测量装置对同一项目同一项目之同一特性同一特性进行多次测量之测量值差异The variation in measurements obtained with one measurement device when used several times by an appraiser while measuring the same characteristic on the same item 第第1次测量次测量Measurement 1第第3次测量次测量Measurement 3第第2次测量次测量Measur

46、ement 2测量设备导致的差异测量设备导致的差异测量设备导致的差异测量设备导致的差异 Variation due to the measuring deviceVariation due to the measuring device1010-2424 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB仪器重复性及再现性仪器重复性及再现性仪器重复性及再现性仪器重复性及再现性 Gage R&RGage R&R规格规格 Spec规格上限规格

47、上限 USL规格下限规格下限 LSL差异差异 Variability一般经验一般经验一般经验一般经验 Rule of ThumbRule of Thumb:30%,不接受不接受,必须改善必须改善Over 30%Reject Improvement Mandatory贵司的原则是什么贵司的原则是什么贵司的原则是什么贵司的原则是什么?)?)What are your companys guidelines?What are your companys guidelines?(GRR%)仪器差异仪器差异 X100总差异总差异1010-2525 2005TBM Consulting Group,Inc

48、.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.SKBSKB数据世界数据世界数据世界数据世界 Data WorldsData Worlds不良品不良品:不能满足客户要求的产品不能满足客户要求的产品Defective:The unit either meets or does not meet customer requirements 不良次数不良次数一个产品不能满足客户要求的次数一个产品不能满足客户要求的次数Defect:The number of times a unit fails to meet

49、 requirements 连续性连续性能够呈现任何数值的可测量特性能够呈现任何数值的可测量特性Continuous:A measurable characteristic that can take on any value 数据世界决定所用的分析工具数据世界决定所用的分析工具The Data World dictates what analytical tools to use1010-2626 2005TBM Consulting Group,Inc.All Rights Reserved.2005TBM Consulting Group,Inc.All Rights Reserved.

50、SKBSKB制程能力制程能力制程能力制程能力 Process CapabilityProcess Capability将制程能力、将制程能力、平均平均偏差偏差及及标准偏差标准偏差与与Relate process capability,mean and standard deviation 制程能力制程能力 Process CapabilityZ值值 Z Value规格极限相联系规格极限相联系,用一个用一个Z值即西值即西格玛值来表示格玛值来表示to specification limits and express them as a single Z value a.k.a.Sigma leve