【文章內(nèi)容簡介】 process D M A I C Data(Y) Display 50 60 70 80 90 100LSL USLUSLLSLMeanStDev (Within)StDev (Overall)CpCPUCPLCpkPpPPUPPLPpk Process DataPotential (Within) CapabilityOverall CapabilityWithinOverall5 15 25607080Yield %Filling Yield Process Capability of Filling (Wastage 27%) Cpk: D M A I C Data(Y) Display 20230290280270260Individual and MR ChartObser.Individual ValueMean=UCL=LCL=151050Mov.RangeR=UCL=LCL=020230Last 22 Observations285280275270Observation NumberValues300275Capability PlotProcess ToleranceIIIIIIIISpecificationsWithinOverall285275265Normal Prob Plot290280270Capability HistogramWithinStDev:Cp:Cpk:OverallStDev:Pp:Ppk:Process Capability of Mixing (8% bulk wastage) (Cpk: ) Summary of Measurement Phase D M A I C ?Use Prioritization Matrix to select key data for further study ?FMEA analysis show risk in process change ?Gage RR study shows the gauge is products artwork eccentric measure. ?Most of material lost in filling and mixing process and those two process capability are quite low. Cause and Effect Analysis D M A I C People High waste of Tube line Material Seal temperature Adjust gap between clamp Drive system Tube position Sensor adjust Equipment Electrical adjust Mechanical transmit Holder speed Still fill while without tube Cooling system Six tubes always rejected when the machine start every time Tube deformation Untrained operator New mechanical Adjust position sensor or electrical Set the seal temperature Process Batch quantity is too small No special gauge testing eccentric Bulk was stored in small plastic bags Material remain in vessel bags Tube artwork center is different with the mark Melt point of tube unstable Seal unit unstable Mixing vessel too small RO water shortage Water pulled by vacuum pump Analyze XsOne way ANOVA D M A I C Operators Skill Analysis of Variance for Filling Source DF SS MS F PValue Operator 2 Error 22 Total 24 Individual 95% CIs For Mean Based on Pooled StDev Level N Mean StDev ++++ 1 9 (*) 2 9 (*) 3 7 (*) ++++ Pooled StDev = The filling yield was affected by different operators Analyze XsDot Plot D M A I C PumpManually29241914Bulk FeedWastageFilling wastage vs bulk feed(means are indicated by lines)Bulk was stored in small plastic bags and fed into the tube machine manually, a lot of bulk remained in bags and bags often broke before being fed into machine. Transfer the bulk into stainless steel tote from mixing vessel directly, install the membrane pump and electric control system to deliver the bulk to tube machine automatically. Way of bulk feed into Tube machine Mean: 25 Mean: Filling Wastage was reduced from 25% to 16% after bulk storing totes Analyze XsRegression D M A I C 120230100 90 80 70 6070605040302010 0Holder Speed Filling Wast95% PI95% CIRegressionThe holder searching mark speed is too fast. Action: Adjust electric board to reduce the speed. Tube Holder Speed Holder speed reduce from 120 to 60 rpm, the filling wastage reduced 15% Analyze XsBox plot D M A I C 1 2270280290processQty (kg