六西格瑪測度品質(zhì)培訓(xùn)教材

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1、Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Click to edit Master text styles,Second Level,Third Level,Fourth Level,Fifth Level,Click to edit Master title style,Proprietary to Samsung Electronics Company,Six Sigma,測度,-,*,Rev.

2、2.0,Six Sigma,測度,(,Metrics),Measure,Define,Analyze,Improve,Control,方法論,Measure,概要,Project Y,基礎(chǔ)統(tǒng)計(jì),測定,System,分析,Six Sigma,測度,工程能力分析,Process Map,&,特性要因圖,FDM,Six Sigma,測度,學(xué)習(xí)目標(biāo),理解,Six Sigma,的主要測度,DPU,DPO,DPMO,FTY,RTY,Y,NOR,理解,水準(zhǔn)計(jì)算方法,DPU,與,DPMO,DPO(Defects per Opportunity),每機(jī)會缺陷數(shù),DPU(Defects per Unit),每單位

3、缺陷數(shù),為了消除缺陷的基準(zhǔn),工廠單位改善中使用,DPMO(Defects per Million Opportunities),每百萬機(jī)會缺陷數(shù),考慮制品復(fù)雜度的比較基準(zhǔn),企業(yè)內(nèi)或企業(yè)之間,Benchmarking,手段,Opportunity,Defects,DPO,=,Unit,Defects,DPO,=,制品,部品,2,部品,1,組裝品,A,組裝品,B,特性,B,特性,A,機(jī)會,(Opportunity),有可能發(fā)生缺陷的檢查或試驗(yàn)對象,發(fā)生缺陷的機(jī)會在特性、部品、組裝品等制品任何階段 都可能存在。,復(fù)雜度,(,Complexity),總機(jī)會數(shù)與制品或,Process,復(fù)雜度正比。,部品

4、,特性,材料,機(jī)械,工具,次序,制品,Process,復(fù)雜度,相關(guān)部品、特性或材料越多，,成為越復(fù)雜的制品。,相關(guān)機(jī)械、工具或次序越多，,成為越復(fù)雜的,Process.,DPU/DPO/DPMO,以下,Drilling,加工的例中計(jì)算,DPU,與,DPMO,.,Data,類型是,?,Unit,?,Defect,?,Opportunity,?,DPU,?,DPMO,?,DPU,計(jì)算,總生產(chǎn)單位數(shù),總?cè)毕輸?shù),=,DPU,DPU,不能考慮一個單位里有多少缺陷機(jī)會。,DPU,=,=,=,DPMO,總?cè)毕莅l(fā)生機(jī)會數(shù),總?cè)毕輸?shù),1,000,000,=,DPMO,=,DPMO,計(jì)算中心,一般表示,6,水準(zhǔn)時

5、，比不良率,3.4,ppm,更恰當(dāng)?shù)氖?3.4,DPMO,DPU/DPO/DPMO,事例,使用互相不同的,Process、,制品之 間或制造領(lǐng)域和非領(lǐng)域之間比較時更 恰當(dāng)。,DPMO,計(jì)算例,缺陷數(shù),某個,PCB,以,800,個焊接點(diǎn)和,200,個部品構(gòu)成。在這,PCB,中發(fā)現(xiàn)焊接不良,6,處和不良部品,2,個。,DPMO,是,?,DPMO=(6+2)/(800+200),*,百萬,=8,000,DP(M)O,計(jì)算時注意事項(xiàng),例,),某部品的生產(chǎn)工程中不良發(fā)生機(jī)會數(shù)是,100,000,次，但正常作業(yè),過程中只對其中,1,000,次機(jī)會進(jìn)行評價，結(jié)果一個部品里發(fā)現(xiàn),10,個,缺陷，以下計(jì)算中哪個

6、正確？,DPO=10/100,000,DPO=10/1,000,機(jī)會是有缺陷發(fā)生的可能性，以檢查及試驗(yàn)對象被評價時,Count,Yield,在工程的各階段中包括再作業(yè)或部品的廢棄等不良的管理指標(biāo)，,是良品率的概念。,初期數(shù)率,(,FTY,First Time Yield):,決定各別工程的品質(zhì)水準(zhǔn)時使用。再作業(yè),/,不修理的,Process,中適用。,累計(jì)數(shù)率,(,RTY,Rolled Throughput Yield):,表現(xiàn)全體工程的品質(zhì)水準(zhǔn)時使用的指標(biāo)中的一個。,表現(xiàn)為初期數(shù)率的倍。,標(biāo)準(zhǔn)化數(shù)率,(,Y,Nor,Normalized Yield):,表現(xiàn)全體工程的品質(zhì)水準(zhǔn)時使用的指標(biāo)中的

7、一個，,在,Process,中初期數(shù)率適用幾何平均概念。,Yield(,數(shù)率,),的種類,Yield(,數(shù)率,),45,000,ppm,浪費(fèi),30,000,ppm,浪費(fèi),56,000,ppm,浪費(fèi),95.5%,數(shù)率,97%,數(shù)率,94.4%,數(shù)率,RTY=0.955*0.97*0.944=87.4%,不但是最終階段，其它各階段的能力,RTY,都重視。,Hidden,Factory:,再作業(yè),/,廢棄,Yield,RTY,計(jì)算,已知的,DATA,是缺陷,DATA,時,是意味著泊松分布中,PX=0(,沒有一個缺陷的概率,).,-,e,DPU,已知的,DATA,是不良率或數(shù)率,DATA,時,Yiel

8、d,RTY=FTY,1,FTY,2,FTY,3,Y,Nor,計(jì)算,Y,Nor,=FTY,1,FTY,2,FTY,n,n,RTY,計(jì)算的檢討,生產(chǎn)一個單位部品所需,3,個工程，各工程的初期數(shù)率為,FTY,i,.,各單位工程中發(fā)生的缺陷數(shù)，跟隨著擁有以下概率函數(shù)的泊松分布。,DPU,dpu,dpu,dpu,e,e,-,+,+,-,=,=,),(,3,2,1,-,但,為,單位工程,i,的,平均缺陷數(shù),因此各單位工程的數(shù)率是在工程中一個缺陷都不發(fā)生的概率，如下。,i,dpu,e,X,P,-,=,=,=,0,按以上的結(jié)果，可以確認(rèn)下面的等式。,3,RTY,=,FTY,i,i,=1,Yield,想想下面的

9、工程。,收入檢查,100%,數(shù)率,SMD,檢查,95.5%,數(shù)率,PBA,檢查,97.0%,數(shù)率,ICT,94.4%,數(shù)率,RTY =1.00,0.955 0.970 0.944,=0.874=87.4%,Y,%,7,.,96,967,.,0,874,.,0,RTY,4,1,4,Nor,=,=,=,=,Yield(,數(shù)率,),Yield,例,1),現(xiàn)場某一位機(jī)士對特定類型,Defect,觀察結(jié)果,346,個生產(chǎn)單位中發(fā)現(xiàn),1,個。對這特性,(,Characteristic),的,RTY,?,0.00289,346,1,=,=,DPU,00289,.,0,=0.99711,=,=,-,-,e,e

10、,RTY,DPU,計(jì)算,),例,2),有,3,個工程組成的生產(chǎn),Line，,各工程通過數(shù)率為,98%,時,Line,的,RTY,?,計(jì)算,),0.98,0.98,0.98,RTY=0.98,0.98 0.98=0.941192,RTY,計(jì)算 例,Yield,水準(zhǔn),水準(zhǔn),:,規(guī)格中心和規(guī)格上限或下限距離是標(biāo)準(zhǔn)偏差的幾倍？,水準(zhǔn)的概念,品質(zhì)特性值隨正態(tài)分布時，從規(guī)格中心到規(guī)格界限為止距離相當(dāng)于標(biāo)準(zhǔn)偏差幾倍的測度，,Process,散布越小，,水準(zhǔn)越大。,m,1,s,3,s,平均,規(guī)格界限,測定,Process,可以生產(chǎn)多少均一品質(zhì)制品能力的測度。,1,s,m,1,s,發(fā)生不良限度,3,s,平均,記

11、號前數(shù)值,(,Z),越大，不良發(fā)生,的概率越小。,6,s,規(guī)格界限,3,水準(zhǔn)的,穩(wěn)定工程,6,水準(zhǔn)的,穩(wěn)定工程,由于作業(yè)者倒班、原材料,LOT,變化、設(shè)備的保,養(yǎng)、模具交換等現(xiàn)實(shí)性的變化要素而規(guī)格中心和,P,rocess,平均常時間維持一致狀態(tài)是很難。,根據(jù)經(jīng)驗(yàn)隨著時間過,去，一般,Process,平均離中心約,1.5,左右變動,。,Process dynamics,LSL,USL,起點(diǎn),1,起點(diǎn),2,起點(diǎn),3,起點(diǎn),4,Process,固有能力,長期,Process,能力,目標(biāo)值,水準(zhǔn)和,DPMO,考慮,Process,現(xiàn)實(shí)變化，計(jì)算對應(yīng),水準(zhǔn)的缺陷率或不良率時，,Process,平均離規(guī)格

12、中心標(biāo)準(zhǔn)偏差的,1.5,倍變動為前提計(jì)算。,在,6,水準(zhǔn),Process,中，,100,萬次機(jī)會中能發(fā)生,3.4,次左右缺陷，這相當(dāng)于,3.4,DPMO,.,USL,LSL,規(guī)格中心,3.4,DPMO,4.5,.st,1.5,.st,999,999.6,999,995,999,991,999,987,999,979,999,968,999,952,999,928,999,892,999,841,999,767,999,663,999,517,999,313,999,032,998,650,998,134,997,445,996,533,995,339,993,790,991,802,989,2

13、76,良品數(shù),3.4,5,9,13,21,32,48,72,108,159,233,337,483,687,968,1,350,1,866,2,555,3,467,4,661,6,210,8,198,10,724,6.0,5.9,5.8,5.7,5.6,5.5,5.4,5.3,5.2,5.1,5.0,4.9,4.8,4.7,4.6,4.5,4.4,4.3,4.2,4.1,4.0,3.9,3.8,.,st,4.5,4.4,4.3,4.2,4.1,4.0,3.9,3.8,3.7,3.6,3.5,3.4,3.3,3.2,3.1,3.0,2.9,2.8,2.7,2.6,2.5,2.4,2.3,.,lt

14、,986,097,977,250,971,284,964,070,955,435,945,201,933,193,919,243,903,199,884,930,864,334,841,345,815,940,788,145,758,036,725,747,691,462,655,422,617,911,579,260,539,828,500,000,460,172,良品數(shù),13,903,22,750,28,716,35,930,44,565,54,799,66,807,80,757,96,801,115,070,135,666,158,655,184,060,211,855,241,964,

15、274,253,308,538,344,578,382,089,420,740,460,172,500,000,539,828,3.7,3.5,3.4,3.3,3.2,3.1,3.0,2.9,2.8,2.7,2.6,2.5,2.4,2.3,2.2,2.1,2.0,1.9,1.8,1.7,1.6,1.5,1.4,.,st,2.2,2.0,1.9,1.8,1.7,1.6,1.5,1.4,1.3,1.2,1.1,1.0,0.9,0.8,0.7,0.6,0.5,0.4,0.3,0.2,0.1,0.0,-0.1,.,lt,420,740,382,089,344,578,308,538,274,253,2

16、41,964,211,855,184,060,158,655,135,666,115,070,96,801,80,757,66,807,54,799,44,565,35,930,28,716,22,750,17,864,13,903,10,724,8,198,良品數(shù),579,260,617,911,655,422,691,462,725,747,758,036,788,145,815,940,841,345,864,334,884,930,903,199,919,243,933,193,945,201,955,435,964,070,971,284,977,250,982,136,986,097,989,276,991,802,1.3,1.2,1.1,1.0,0.9,0.8,0.7,0.6,0.5,0.4,0.3,0.2,0.1,0.0,-0.1,-0.2,-0.3,-0.4,-0.5,-0.6,-0.7,-0.8,-0.9,.,st,-0.2,-0.3,-0.4,-0.5,-0.6,-0.7,-0.8,-0.9,-1.0,-1.1,-1.2,-1.3,-1.4,-1.5,-1.6,-