【正文】 YFT 和 YRT 42 線 過程 缺陷 個體 DPU 機會 DPMO s+ 合格率1 容器線 10,166 17,671 35 16,437 %2 噴漆線 3,992 20,292 30 6,558 %3 芯 2,096 38,397 25 2,184 %4 絕緣 120 18,924 10 634 %7 芯/線圈 302 15,757 8 2,396 %9 灌注容器 720 14,874 35 1,383 %10 安裝載運 895 13,598 28 2,351 %11 配組和銅焊 379 17,307 16 1,369 %12 容器存儲 461 11,386 22 1,840 %13 工程 775 18,924 28 1,463 %14 採購 11,747 18,924 25 24,830 %合計 31,653 18,924 262 6,384 滾動生産合格率 % 系統(tǒng)動態(tài) 確保評審每個過程的成本和對顧客的影響 驅動工廠廣泛 改善的焦點 驅動 SBU 廣泛的 同業(yè)基準 缺陷資料驅動 工程隊改善 43 減少缺陷 50% 線 過程 缺陷 個體 DPU 合格率 s+ 合格率容器線 5,083 17,671 35 8,218 %噴漆線 1,996 20,292 30 3,279 %芯 1,048 38,397 25 1,092 %絕緣 60 18,924 10 317 %芯/線圈 151 15,757 8 1,198 %灌注容器 360 14,874 35 692 %安裝載運 447 13,598 28 1,174 %配組和銅焊 189 17,307 16 683 %容器存儲 230 11,386 22 918 %工程 387 18,924 28 730 %採購 5,873 18,924 25 12,414 %合計 15,824 18,924 262 3,192 滾動生産合格率 %對於要改善 4倍，將生産線合格 (直通 )率從 %提高到 %,而標準偏差 σ的改善則從 。 ? 通過瞭解和控制 X， 就可以減少 Y的變異性， 從而減少缺陷數，改善 YRT和周期等，還能消除或減少檢查、核對和返工。 One Taste Unit Validate Measurements 60 Step 4.....Establish Product Capability for Y (Taste) This is a 3s Process! 7 Defects (ratings below 7) 24 Ratings (from our panel) = .292 292,000 Defects per 1,000,000 Loaves OR 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 of Ratings Rating 6 4 3 2 1 1 4 3 Defects 7 Target = 8 Analyze Measurements How Do We Approach This? ? Bake Several Loaves Under “Normal” Conditions ? Have Taster Panel Again Do the Rating ? Average Rating is ? But Variation is too Great for a 6s Process 3 x 10 + 4 x 9 + 6 x 8 + 4 x 7 + 3 x 6 + 2 x 5 + 1 x 4 + 1 x 3 1 + 1 + 2 + 3 + 4 + 6 + 4 + 3 61 Step 5.....Define Improvement Objectives for Y (Taste) How do we Define Improvement? ? Benchmark the Competition ? Focus on Defects ( . taste rating 7) ? Determine What is an “Acceptable Sigma Level” ? Set Improvement Objectives Accordingly Maybe a 5s Process Will Suffice! 1,000,000 100,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3 4 5 6 7 “ BETTER BREAD” Baking Process Best Competitor Range for Improvement Defects Per Million Sigma Scale Freihofer WONDER Pepperidge Farm Sunbeam Analyze Your Objective 62 Step 6.....Identify Sources of Variation in Y (Taste) How do we Determine the Potential Sources of Variation (Xs)? ? Have the Chefs Brainstorm ? Some Likely Ones Might be: Amount of Salt Used Brand of Flour Baking Time Baking Temperature Brand of Yeast YEAST FLOUR Multiple Sources: Chefs, Suppliers, Controls Synthesis possible solutions 胖妹 小胖妹 大胖妹 小小胖妹 63 Step 7.....Screen Potential Causes of Variation (Xs) How do we Screen for Causes of Variation (Xs)? ? Design an Experiment ? Use Different Sources of Potential Variation ? Have Panel Rate the Bread Used in the Experiment ? Results Lead to the “Vital Few” Causes YEAST FLOUR Source Conclusion Negligible Major Cause Negligible Major Cause Negligible Focus on The “Vital Few” Evaluate possible solutions 64 Step 8.....Discover Variable Relationships Between “Vital Few” (Xs) and Y How do we Find the Relationship Between the “Vital Few” (Xs) and Taste (Y)? ? Conduct a More Detailed Experiment ? Focus: Oven Temperature from 325 to 375 and 3 Brands of Flour ? RUN TEMP BRAND 1 325 A 2 325 B 3 325 C 4 350 A 5 350 B 6 350 C 7 375 A 8 375 B 9 375 C FLOUR FLOUR FLOUR Brand A Brand B Brand C Evaluate solutions Results: 350 Brand A is Best Combination of Temperature Flour 176。 177。 20:17:5520:17:5520:171/20/2023 8:17:55 PM 1以我獨沈久，