【正文】 measurement process P e r s o n n e lM a c h i n e sM a t e r i a l sM e t h o d sM e a s u r e m e n t sE n v i r o n m e n tC a u s e a n d E f f e c t D i a g r a mVariation in measurement System ? Measurement System and Measurement Error(2) Average m (Total) = m (Product) + m(Measurement) Variability s2 (Total) = s2 (Product) + s2(Measurement) Deflection of measurement system (To be decided by calibration) Variation of measurement system (To be decided by RR assessment) ? Process Variance Observed Process Variation Actual Process Variation Measurement Variation Long term process variation Short term process variation Variation within a sample Variation due to operators Variation due to gage Reproducibility Linearity Stability Repeatability Accuracy ? Gage RR Analysis ? Types of Gage RR Analysis Methodology ◎ X bar R Method ◎ ANOVA Types of Variation estimation by the Gage RR ◎ Equipment Variation: EV ◎ Appraiser (Operator): AV ? GRR Decision and Improvement Direction ? Gage RR Decision Criteria ? %GRR ? 10% (Good measurement system) ? 10% ? %GRR ? 30% (May be used) ? %GRR ? 30% (Can not used) ? Gage improvement direction For repeatability error ? reproducibility error ? (Need to taken an action to operator) For reproducibility error ? repeatability error ? (Need to taken an action to gage) ? M3 Identify Sigma Level ? M3 step covers the followings: ? Data stratification ? Graphical cause elimination ? Understand product capability and product performance ? Calculate current sigma level ? Graphical Analysis ◎ Run Chart ◎ Scatter Diagram ◎ Box Plot ◎ Histogram ? Changes to the process may be more easily recognized graphically than tabularly. ? Understanding Variation ? What is Variation? ◎ Different oute of a process or result of a product or service ? Measurement index scattered from center value ? Variation will be appeared in every process and the target of improvement is to reduce it’ s variations ? Why a variation might be occurred? ◎ By a mon cause ◎ By a special cause ◎ 5M1E ? What impacts will be happened if a variation bee big? ? Can not predict/ forecast outes ? Occur reinspection and/ or rework ? Delay schedule ◎ Increase customer dissatisfaction ? ShortTerm/LongTerm Relationships Inherent Capability of the ProcessShort Term Capability Sustained Performance of the ProcessLong Term Performance Over time, a “ typical” process will shift and drift by approximately ? ? Product Capability(Cp) ? Cp = |USLLSL| / 6?st ； Zst = 3 Cp ? Capability Index(Cpk) ? Cpu = min (Cpu, Cpl)， Where Cpu = (USL?)/3?st； Cpl = (?LSL)/3?st； Zst = 3 Cpk ? Performance Index(Cpk) ? Cpk = min (Cpu, Cpl)， Where Cpu = (USL?)/3?lt； Cpl = (?LSL)/3?lt； Zst = 3 Cpk . DMAIC Methodology 5 Stages DMAIC Methodology and Statistical Tools ? Phase: Analysis ? Steps。 Work Breakdown Tool ? A1 Set up Improvement Goal。 ? Benchmarking, Entitlement, KANO ? A2 Identify Potential Causes。 ? Pareto, Brainstorming, Cause Effect Diagram, Logic Tree ? A3 Verify Potential Causes。 ? Regression, Hypothesis Test, ANVOA, MultiVari Analysis ? A1 Set Up Improvement Goal ? In M3 the current product capabilities were defined. ? Step A1 provides the tools to define performance objectives. ? The purpose is to set objective to establish a balance between improving customer satisfaction and available resources. ? A1 step covers following topics: – Establish performance goals – Assess shortterm and longterm sigma in terms of measurement benefits (decrease in COPQ, increase in revenue) – Determine improvement direction by the gap analysis between goal and current level ? Paths to Performance Goals Performance Goals Process Improvement (Entitlement) Process Change (Breakthrough) Baseline Process Measurement ? Benchmarking Why Benchmark (1)? Innovation Continuous Improvement Breakthrough Improvement Continuous Improvement Time Performance ? Benchmarking Why Benchmark (2)? ? Develop and Improvement Strategic Goals ? Establish actionable objectives ? Provide sense of urgency ? Encourage breakthrough thinking ? Create a better understanding of your industry ? A2 Identify Potential Causes ? Finding main independent variables, and making the list Y = f (X) ? Object Make list of potential independent variables for changing