【正文】 2023年 3月 23日星期四 下午 12時 6分 54秒 12:06: ? 1最具挑戰(zhàn)性的挑戰(zhàn)莫過于提升自我。 2023年 3月 23日星期四 12時 6分 54秒 12:06:5423 March 2023 ? 1空山新雨后，天氣晚來秋。 , March 23, 2023 ? 很多事情努力了未必有結果，但是不努力卻什么改變也沒有。 :06:5412:06Mar2323Mar23 ? 1故人江海別，幾度隔山川。 ? Optimizing DOE(RSM), Solution Selection Matrix ? I3 Set Up Operating Window。 ? Anything that results in nonconformance) ? DPO: Defect per Opportunity ? DPMO: Defect per Million Opportunities ? Example of Sigma calculation: Discrete Data ? Case (1): Over the last several years, you have collected data on trips to the airport. Of the 100 trips sampled, you have missed only 5 flights. If you indicate this situation as Sigma level, what will it be? ? Sol. DPU = DPO =5/100 = ? = , Z = ? ? level = Z + = + = Case (2). An accounting term conducted an internal audit for the financial report of year 2023 and they observed 25 nonconforming record. There were 2 steps of probable incorrect entry identified in the process and the total observation was 25,000 records. What is DPO? What is DPMO? What is Sigma level of financial reporting process? ? Sol. DPU = 25/25000, DPO = 25/(2*25000) =, DPMO = *10^6 =2023 ? 1 = , Z = ? ? level = Z + = + = ? Example of Sigma calculation: ? Continuous Data(1) 1 ? Mean Median Mode 70 80 90 100 110 120 130 + ? ? Normal Distribution with mean = 100 and std. = 10 ? Continuous Data(2) (1) Mathematical Model； (2) Continuous； (3) Smooth；(4) Symmetrical。 CTQ係任何會直接影響顧客對產品 /服務品質觀感之因素 。 ? VOC, VOB, QFD ? D3 Project Planning。 ? 在 3?水準， 由 1000個零件組成的產品中 ，每 15個產品中只有 1個產品是好的。 在 19701989年間美國的市場佔有率 ： ＊電視機從 50%降至 2% ＊收音機從 50%降至 2% ＊汽車從 78%降至 28% ＊影印機從 90%降至 20% ＊照相機從 90%降至 5% ＊鋼鐵從 40%降至 30% ? ※ 其結果造成美國貿易赤字每月高達 80100億美元 美國與日本製程能力之比較 ? 年代 美國 日本 ? 製程能力 品質水準 製程能力 品質水準 ? 1970 2? ? 3? ? 1980初 4? ? 1980中 4 ~ 5? ? 1980末 ? ~ 1990初 Motorola ? 6?方法： ? 不合格率 ? 相當於 6? ? 美國企業(yè)競爭力衰退的原因 ? 美國管理文化中含有 不信任的氣氛 ， 這種表現(xiàn)在嚴格的審核 、 管制 、 檢查的管理制度上 ， 無形造成過度的管理成本上漲 。 ? . 由需求的觀點 ? 在 70年代，產品達到 2?便達到標準。 ? 6 ? Activity ? 6? activity is to find out critical factors to quality (CTQ) at customer’ s point of view and to reduce the defects less than DPMO(PPM). LSL USL ? ？ ? Defect M 6? in RD 6? in MFG. Company Customer Customer CTQ VOC VOB 6? DPMO New Std. 3? 66800 DPMO Past Std. ? How Do We Improve Process Capability? ? ? Increase the tolerance ? ? Decrease the spread or variation of the process ? ? Shift the average by: ? ? ? Centering the average if the spec. has two limits ? ? ? Decrease or increase the average for spec. with one limit ? The Cost Opportunity ? 2? 3? 4? 5? 6? 0 5 10 15 20 25 30 About 15% of Sales, Cost Opportunity on 3? Company Cost of Failure (% of Sales) ? The Cost of Poor Quality (COPQ) Long Cycle Times, More Setups, Expediting Costs, Lost Sales, Engineering Change order, Overtime, Late delivery, Lost Opportunity, Lost Customer Loyalty, Excess Inventory Rejects, Warranty, Inspection, Scrap, Rework ? Who is Implementing 6 ? ? Motorola 1987 ? Texas Instrument 1988 ? ABB (Asea Brown Boveri) 1993 ? Allied Signal 1995 ? General Electric 1995 ? Kodak 1995 ? Siemens, Nokia, Sony 1997 ? 6 ? Benefits(Case 1) Motorola over 12 yrs ? Increase productivity an average of % per year ? Reduced the cost of poor quality by more than 84% ? Eliminated % of in process defects ? Save more than $11billion in manufacturing cost ? Realized an average annual pounded growth rate of 17% in earnings ? 6 ? Benefits(Case 2) General Electric (Million Dollars) Cost Profit 1996 240, 200 1997 400, 700 1998 450, 1200 1999 520, 2520 2023 600, 3000 ? 6 ? Benefits( Case 3) Texas Instruments Before (1988) After (1993) COPQ 30% 7% DPMO 104000 9000 Scrap $3M $ Yield % % Cycle Time (Week) 11 4 Inventory Cost $ $ ? The Focus of 6 ? If we are perfectly control X, should we constantly test and inspect Y? Y = f (X) Y X1 X2 X3 X4 X X …Xn ◎ Independent ◎ InputProcess ◎ Cause ◎ Problem ◎ Control Y ◎ Dependent ◎ Output ◎ Effect ◎ Symptom ◎ Monitor ? 6 ? is Applying Overall Business System RD 6? Transaction Mfg Design SS Manufacturing SS Transactional SS ? 6 ? Methodology Measure Analyze Design Verify Measure Analyze Improve Control Define Translate Y N New Process/ Product ?