SPC统计过程控制培训ppt课件.ppt

SPCSPCImplement in work shopIntroduction to SPC SPC简介 SPC is the basic tool for studying variation and using statistical signals to monitor and/or improve process performance. This tool can be applied to ANY area: Manufacturing, Finance, Sales, etcSPC是研究过程变化的基本工具，它使用统计信号来监测和/或提高过程性能。该工具可应用于任何领域：制造，财务，销售等。 SPC is an acronym for Statistical Process Control. Most applications perform SPC on product characteristics (Ys), rather than process characteristics (Xs)SPC是“Statistical Process Control(统计过程控制）”的首字母缩写。SPC大部分被用于控制产品的特性而不是过程的特性 The first step is to use statistical techniques to control our process outputs. However, it is not until we focus our efforts on controlling those inputs (Xs), rather than control our outputs (Ys), that we realize the full gain of our efforts to increase quality, productivity, and lower costs.第一步就是用统计技术去控制过程输出。然而，如果只控制过程的输出，而不控制过程的输入，我们就无法体验到SPC在提高质量，提高生产力及降低成本等方面的诸多好处。What is Statistical Process Control什么是统计过程控制？ All processes have natural (expected) variability (due to common causes) and sometimes unexpected variability (due to special causes). We use SPC to monitor (and improve) our processes. Use of SPC allows us to DETECT special cause variation through OUT-OF-CONTROL signals. These out of control signals CAN NOT tell us WHY the process is out of control, only that it is.所有过程都具有自然的(预料中的）变化（由普通原因造成）和临时发生的意料之外的变化（由特殊原因造成）。可以使用SPC来监控（并改善）我们的过程。使用SPC能够通过失控信号来检测出特殊原因变量。这些失控信号仅能告诉我们过程失控，并不能告诉我们为什么过程会失控。 CONTROL CHARTS are the means through which process and product parameters are tracked statistically over time. Control charts incorporate upper and lower control limits that reflect the natural limits of random variability in the process. These limits should NOT be compared to customer specification limits.控制图是一种随时间从统计学角度跟踪过程及产品参数的方法。控制图中的上、下控制界限能够反映过程中随机变化的内在界限。控制界限不能与顾客要求的规格界限相比较。 Based on statistical principles, control charts allow for the identification of unexpected (nonrandom) patterns in process variation. When the control chart signals a unexpected pattern, we know special cause variation has changed the process. The actions we take to change the process to a more desirable state are the keys to successful SPC usage.控制图是基于统计学原理建立的，能够识别过程变量中非预期（非随机）模式。当控制图信号是一个非预期模式时，我们就可以判断出是特殊原因变量导致过程发生了变化。要想将过程改变到一个更理想状态，我们所采取的措施对成功地使用SPC是至关重要的。 Control limits are based on establishing 3 sigma limits for the Y or X statistic being measured.采用3倍标准偏差作为Y或X观测值的控制界限。What is Statistical Process Control什么是统计过程控制？Measures of Variability: 变差的测量标准 Range:极差 Numerical distance between the highest and the lowest values in a data set.一组数中最大数和最小数的差值叫极差。 Variance (s2 ):方差(s2 ): The average squared deviation of each individual data point from the mean.方差是单个值与平均值的差值的平方和的均值。 Standard Deviation (s):标准偏差(s): The square root of the variance.方差的平方根就是标准偏差。 most commonly used measurement to quantify variability 标准偏差多用于测量可量化的变差。Range = = max min1)(1_22=nXXSnii1)(1_2=nXXSnii Proven technique for improving productivity是已被证明了的提高生产力的技术手段。 Effective in defect prevention能有效地进行缺陷预防 Prevent unnecessary process adjustments防止不必要的过程调整。 Provide diagnostic information能提供诊断问题的信息。 Provide information about process capability能提供有关过程能力的信息。Benefits of Control Chart Systems使用控制图系统的好处Control Methods 控制方法 SPC on Xs or Ys without proper training = WALL PAPER进行SPC控制，如果没进行合适的培训=只做表面文章 Warning Signal Used to attempt to detect defects. Operators will learn to ignore or disconnect the warning signals once production becomes #1 priority. PEOPLE ACT ON WHAT THEY ARE MEASURED ON!如果试图用报警信号来检测缺陷。一旦生产变成1优先权，操作者就得学会忽视或断开报警信号。人们应对他们所测量到的东西采取措施。 S.O.P is implemented to attempt to detect defects. This action is not sustainable short-term or long-term.执行S.O.P是为了试图检测缺陷。这一措施并不支持短期或长期项目。 SPC on Xs or Ys with fully trained operators. The operators have been trained and understand the rules of SPC, but management will not empower them to stop or investigate.用经过全面培训的操作者来完成SPC控制。操作者已经过培训并理解了SPC规则，但管理者并没授权操作者可停止过程操作或对过程进行研究。 Type 3 Corrective Action = Inspection: Implementation of a short-term containment action which is likely to detect the defect caused by the error condition. Containments are typically audits or 100% inspection.第三类纠正措施=检查：实施一个短期临时措施有可能检测出由过失条件造成的缺陷。差差好好 SPC on Xs or Ys with fully trained operators and staff who respects the rules. Once a chart signals a problem everyone understands the rules of SPC and agrees to shut down for special cause identification and elimination.用经过全面培训的操作者和重视SPC规则的全体员工来进行SPC控制。一旦控制图出现异常，每个人都能理解SPC规则并同意停止操作，找出造成异常的特殊原因并排除。 Type II Corrective Action = Flag: Improvement made to the process which will detect when the error condition has occurred. This flag will shut down the equipment so that the defect will not move forward.第二类纠正措施=旗帜：实施了过程改进，这样当由过失条件造成的缺陷发生时就能检测出来。这面旗帜可以停止设备操作，使缺陷不至于进一步扩散。 Type I Corrective Action = Countermeasure: Improvement made to the process which will eliminate the error condition from occurring. The defect will never be created. This is also referred to as a long-term corrective action in the form of mistake proofing or design changes第一类纠正措施=对策：对过程实施第一类纠正措施可以消除出错环境，防止缺陷发生。缺陷将永远不会出现。这类纠正措施也指以防错或设计更改形式出现的长期纠正措施。Control Methods 控制方法差差好好Analysis of data measured by operator现场得到X-bar & R图数据分析1098765432160.6060.5860.5660.5460.52样样本本样样本本均均值值_X =60.5612LCL=60.51733UCL=60.60507109876543210.160.120.080.040.00样样本本样样本本极极差差_R=0.0761UCL=0.1608LCL=0O Op pe er ra at to or r2 2 的的 X Xb ba ar r- -R R 控控制制图图25232119171513119753160.6060.5560.50样样本本样样本本均均值值_X =60.5301UCL=60.5671LCL=60.49302523211917151311975310.150.100.050.00样样本本样样本本极极差差_R=0.0642UCL=0.1358LCL=01111111111B Bo ot th h o op pe er ra at to or r1 1& &2 2 的的 X Xb ba ar r- -R R 控控制制图图客户规格上限：客户规格上限：61.00Upper specifications客户规格下限：客户规格下限：60.00Lower specifications15141312111098765432160.5660.5460.5260.5060.48样样本本样样本本均均值值_X =60.5093UCL=60.5412LCL=60.47751514131211109876543210.1000.0750.0500.0250.000样样本本样样本本极极差差_R=0.0553UCL=0.1169LCL=011O Op pe er ra at to or r1 1 的的 X Xb ba ar r- -R R 控控制制图图特殊原因Special cause特殊原因Special cause1.测量标准是否统一？Is Measurement uniform or not?2.特殊原因是否分析？Has special cause been analyzed or not?3.操作过程是否标准化？Does the process follow the standardization?What should we do?我们应该怎么做1.每个操作人员有责任及时准确的测量并记录尺寸数据Each operator is responsible for measuring and recording data in time2.每个操作人员有责任及时的将计算所得数据在图中描点Each operator is responsible for plotting on SPC chart in time 3.每个操作人员有责任对出现特殊波动的点作出解释Each operator is responsible for giving explanation for special variation 4.车间主任有责任指导和管理操作人员完成SPC控制图Department manager should monitor the whole process 5.巡检人员有责任指导现场操作人员完成检验并绘制SPC控制图Inspector should coach the operator to accomplish inspection and SPC chart6. 加工同一零件出现换班时需使用不同颜色的签字笔记录The operator should use another color of pen when shift happens7. 统一测量和检验标准Unify the measurement and inspection criteria谢谢大家Thanks