【正文】 Z T Target 0 A 3? Process Problem Solving Approach Center Process Reduce Spread X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X OffTarget Unpredictable OnTarget 6? Helps us Identify and Reduce VARIATION due to: Insufficient Process Capability Unstable Parts Materials Inadequate Design Margin Define What do we want to know ? What is our problem ? What is our defect ? Practical Problem ? Project CTQ’s ? Solid Y, Spec Definition, and Defect Definition ? Building a Justifiable Business Case ? Approved Charter (R0) What did we learn ………Do we have a viable project ? 特性要因圖 The % Variation Due to the Measurement Method GAGE R R GAGE: The instrument used for making Measurements that we want to validate. REPEATABILITY: Does the same operator get the same results When measuring the same part several times? REPRODUCIBILITY: Do different operators get the same results when measuring the same part several times? CAUTION: A Calibration Sticker does not imply that Gage RR is acceptable! Measure What do we want to know ? Statistical Problem ? Project Y, Spec Definition, and Defect Definition ? Gage RR on Y Data ? Process Map ? L1 to Show Z Values with Link to Financials ? Rationalization for Focused Y ? Descriptive Statistics for Focused Y What did we learn ………Mean problem ? Variance ? Both ? 時(shí) 間 GOOD BAD 3 Sigma 6 Sigma Breakthrough Improvement SixSigma 突破 表現(xiàn) 如果我們充份瞭解與掌握 X, 為何我們要持續(xù)測試與檢驗(yàn) Y? ? Y ? 相依 (Dependent) ? 輸出 (Output) ? 結(jié)果 (Effect) ? 不良結(jié)果 (Symptom) ? 監(jiān)測 (Monitor) ? X1 . . . Xn ? 互相獨(dú)立 (Independent) ? 輸入 (InputProcess) ? 原因 (Cause) ? 問題 (Problem) ? 控制 (Control) 為了獲得好的結(jié)果 , 我們是否要專注於 Y 或 X 的行為 ? f (X) Y= 專注於 X 而非 Y Six Sigma焦點(diǎn) CTQ’s(成本 , 品質(zhì) , 交期 , 顧客滿意度 ) 每單位缺點(diǎn)數(shù) 複雜度 DPPM Rolled Thruput Yield SixSigma 分?jǐn)?shù) 流程底限 (Baseline) 流程標(biāo)竿 (Benchmarking) KPOV’s KPIV’s 偏移與漂移 (Shift Drift) SixSigma衡量指標(biāo) 現(xiàn)有衡量指標(biāo) 良率 RMA數(shù)量 返修數(shù)量 顧客抱怨數(shù) ? ? ? ? Leadership Must Ask the Right Questions What Gets Measured Gets Managed SixSigma 衡量指標(biāo) (Metrics) SixSigma 衡量指標(biāo) 定 義 ? CTQ’s: – 重要顧客滿意參數(shù) . 通常包括 品質(zhì) ,成本 ,交期等 . ? KPOV’s: – 關(guān)鍵流程輸出變數(shù) (Key Process Output Variables). 流程中由 KPIV’s反應(yīng)矯正措施之結(jié)果 ? KPIV’s: – 關(guān)鍵流程輸入變數(shù) (Key Process Input Variables). 直接與其他 KPIV’s相關(guān) , 影響改變流程輸出之變數(shù) Changing Focus From Output to Process Y Dependent Output Effect Symptom Monitor X1. . . XN Independent InputProcess Cause Problem Control Identifying and Fixing Root Causes Will Help us Obtain the Desired Output f (X) Y = Some Basic 6?Related Tools Scatter Diagram Over Slept Car Would Not Start Weather Family Problems Other Pareto Diagram Frequency of Occurrence Reasons for Being Late for Work Arrival Time at Work Time Alarm Went Off Analyze What do we want to know ? Statistical Problem Understood ? Link Process Map to Fishbone w/C, N, X Labeling ? Ensure Data is Collected for All Xs ? Drill Down to Vital Few Xs via ANOVA, GLM, Ttest, Ftest ? List of Vital Few X’s ? Quantified Financial Opportunities What did we learn ……… What were the causal Xs ? How did we identify them ? PM/CE/CNX/SOP Process Mapping Why? * Process visual foundation for current situation and analysis ? Aids in identifying bottlenecks, redundancies and waste ? Look for Non Value Add ? Look for Variables (CNX) How? ? Determine beginning and end of process to be mapped ? Involve people knowledgeable about the process ? Brainstorm steps group in major process areas ? Layout activities in sequence ? Validate by physically walking through process PM/CE/CNX/SOP CE: Cause Effect Sources of Variation Output(s) Specs People Material Machine X C C N C N X X Measurement Method Environment Every variable on the diagram should be labeled as either: C = Constant N = Noise X = Experimental variable or Factor PM/CE/CNX/SOP SOP: Standard Operating Procedures Standard Operating Procedure are rules that we define to ensure that we have Consistent processes in everything we do. ? Based on good judgment ? Common sense ? Engineering knowledge Remember ISO 9000! Make sure we have defined processes and that the rules are being obeyed by all. 數(shù)據(jù)分析 size risk ? Is the risk of say there is a difference when there really isn’t one(生產(chǎn)者冒險(xiǎn)率 ) ? Is the risk of not finding a difference when there really is one (消費(fèi)者冒險(xiǎn)率 ) ?/? is he magnitude or size of the difference been tested. This is sometimes called the test sensitivity. αδ / σ 20% 10% 5% 20% 10% 5% 20% 10% 5% 20% 10% 5% β0 . 2 225 328 428 309 428 541 392 525 650 584 744 8910 . 3 100 146 190 174 234 2890 . 4 56 82 107 98 131 1620 . 5 36 53 69 63 84 1040 . 6 25 36 48 44 58 720 . 7 18 27 35 32 43 530 . 8 14 21 27 25 33 410 . 9 11 16 21 19 26 321 9 13 17 略 16 21 26 略1 . 1 7 11 14 13 17 211 . 2 6 9 12 11 15 181 . 3 5 8 10 9 12 151 . 4 5 7 9 8 11 131 . 5 4 6 8 7 9 121 . 6 4 5 7 6 8 101 . 7 3 5 6 5 7 91 . 8 3 4 5 5 6 81 . 9 2 4 5 4 6 72 2 4 4 4 5 62 . 1 2 3 4 4 5 62 . 2 2 3 4 3 4 52 . 3 2 3 3 3 4 52 . 4 2 3 3 3 4 52 . 5 1 2 3 3 3 42 . 6 1 2 3 2 3 42 . 7 1 2 3 2 3 42 . 8 1 2 3 2 3 32 . 9 1 2 2 2 2 310%20% 5%