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1、讲讲 师：曾师：曾 明明 彬彬第三部分第三部分: :统计过程控制统计过程控制Statistical Process Control規格規格 制程制程USLUCL SLCLLSLLCL s aCa Cp Cpk群體群體 樣本樣本 X bar xN n R計量值：計量值：均值極差圖均值極差圖規格標准差圖規格標准差圖計數值：計數值：P不良率圖不良率圖C缺點數圖缺點數圖SPC&SQCPROCESS原料测量结果针对产品所做的仍只是在做SQC針对过程的重要控制参数所做的才是SPC预防或容忍?PROCESS原料人机 法环 测量测量结果好不好不要等产品做出来后再去看它好不好而是在制造的時候就要把它制造好00.
2、20.71.62.31.60.70.2000.20.71.62.31.60.70.2000.20.71.62.31.60.70.2000.20.71.62.31.60.70.20大小预测时间00.10.537730.50.10000.020.050.10.170.250.350.450.450.350.20.0800.050.10.150.20.250.250.20.150.10.050.02000.20.71.62.31.60.70.2000.10.53730.50.10大小预测时间通常会牵涉到消除产生变异的特殊原因可以由制程人员直接加以改善大约能够解决15%之制程上之问题通常必须改善造成变
3、异的共同问题经常需要管理阶层的努力与对策大约85%的问题是属于此类系统 K在内之或然率在外之或然率0.6750.00%50.00%168.26%31.74%1.9695.00%5.00%295.45%4.55%2.5899.00%1.00%399.73%0.27%-30.2-20.7-11.62.3+11.6+20.7+30.20.05-3-2-1+1+2+399.73%95.45%68.26%-3+3UCLCLLCL转90。PLANDOSTUDYACTPLANDOSTUDYACTPLANDOSTUDYACT过程改进循环1、分析过程本过程应做些什么会出现什么错误达到统计控制状态确定能力2.维让
4、过程监控过程性能查找偏差的特殊 原因并采取措施3.改进过程改变过程从而更好 理解普通原因变差減少普通原因变差建立可解决问题之系统建立可解决问题之系统确认关键制程及特性确认关键制程及特性导入导入SPCSPC进行关键进行关键制程及特性之管制制程及特性之管制检讨制程能力检讨制程能力符合规格程序符合规格程序持续进行制程改善计划持续进行制程改善计划导入导入SPCSPC进行关键进行关键制程及特性之管制制程及特性之管制提报及执行制提报及执行制程改善计划程改善计划决定管制项目决定管制项目决定管制标准决定管制标准决定抽样方法决定抽样方法选用管制图的格式选用管制图的格式记入管制界限记入管制界限绘点、实施绘点、实施
5、重新检讨管制图重新检讨管制图处置措施处置措施管制图判读管制图判读管管 制制 图图 的的 选选 择择数据性质？数据性质？数据系不良数数据系不良数或缺点数或缺点数样本大小样本大小 n=? n=? n是否相等？是否相等？单位大小单位大小是否相关是否相关u管管制制图图C管管制制图图P P管管制制图图PnPn管管制制图图CL 性质？性质？X-Rm管管制制图图n =?=?X-X-管管制制图图X-RX-R管管制制图图X-RX-R管管制制图图计量值计数值 n 2 n = 1不是缺点数是不是是 X X n 10 n = 2 5 n = 3或5 制品名称：紫铜管 品质特性：内径 测定单位：m/m 制造场所：XXX
6、机械号码：XXX 操 作 者 ：XXX 测 定 者 ：XXX 抽样期限：自 年 月 日 样组测定值XR样组测定值XRX1X2X3X4X5X1X2X3X4X512345678910111213504746504650474850495150495053454848494950505150504949534949505250464951494949524548495451484951464652505150495250545251534850515550.449.647.449.649.651.249.248.850.649.049.250.450.438448555455361415161718
7、1920212223242553534650505250525550475348485052494947495454515147495349505250515152515152515149495353535150525051525349515052505049525150.250.650.649.849.851.250.451.052.251.050.651.21.2546573246455531201 1、将每样组之、将每样组之 X X 与与 R R 算出记入数据表内。算出记入数据表内。2 2、求、求 X X 与与 R R X = = = 50.16 X = = = 50.16 R = =
8、= 4.8 R = = = 4.83 3、查系数、查系数A A2 2，D D4 4，D D3 3 A A2 2 = 0.58 = 0.58 ，D D4 4 = 2.11 = 2.11 ，D D3 3 = = 负值（以负值（以0 0代表）代表）XRnn1.2541202525=取样数n平均数管制图标准差管制图全距管制图中位数管制图个别值管制图最大值最小值管制图X 图管制界限中线管制界限中线管制界限管制界限管制界限管制界限界限 系数AA1A2C21/C2 B1B2B3B4d21/d2d3D1D2D3D4A3D5D6E2A9m3A2 C32345678910111213141516171819202
9、1222324252.1211.7321.5001.3421.2251.1341.0611.0000.9490.9050.8660.8320.8020.7750.7500.7280.7070.6880.6710.6550.6400.6260.6120.6003.7602.3941.8801.5961.4101.2771.1751.0941.0280.9730.9250.8340.8480.8160.7880.7620.7380.7170.6970.6790.6620.6470.6320.6191.8801.0230.7290.5770.4830.4190.3730.3370.3080.2850
10、.2660.2490.2350.2230.2120.2030.1940.1870.1800.1730.1670.1620.1570.1530.56420.72360.79790.84070.86860.88820.90270.91390.92270.93000.93590.94100.94530.94900.95230.95510.95760.95990.96150.96380.96550.96700.96840.96961.77251.38201.25331.18941.15121.12591.10781.09421.08371.07531.06841.06271.05791.05371.0
11、5011.04701.04421.04181.03961.03761.03581.03421.03271.03130.0000.0000.0000.0000.0260.1050.1670.2190.2620.2990.3310.3590.3840.4060.4270.4450.4610.4770.4910.5040.5160.5270.5380.5481.8431.8581.8081.7561.7111.5721.6381.6091.5841.5611.5411.5231.5071.4921.4781.4651.4541.4431.4331.4241.4151.4071.3991.3920.0
12、000.0000.0000.0000.0300.1180.1850.2390.2840.3210.3540.3820.4060.4280.4480.4660.4820.4970.5100.5230.5340.5150.5550.5653.2672.5682.2662.0891.9701.8821.8151.7611.7161.6791.6451.6181.5941.5721.5521.5341.5181.5031.4901.4771.4661.4551.4451.4351.1281.6932.0592.3262.5342.7042.8472.9703.0783.1733.2583.3363.4
13、073.4723.5323.5883.6403.6893.7353.7783.8193.8583.8953.9310.88650.59070.48570.42890.39460.36980.35120.33670.32490.31520.30690.29980.29350.28800.28310.27870.27470.27110.26770.26470.26180.25920.25670.25440.8530.8880.8800.8640.3480.3330.8200.8080.7970.7870.7780.7700.7620.7550.7490.7430.7380.7330.7290.72
14、40.7200.7160.7120.7090.0000.0000.0000.0000.0000.2050.3870.5460.6870.8120.9241.0261.1211.2071.2851.3591.4261.4901.5481.6061.6591.7101.7591.8043.6854.3584.6984.9185.0785.2055.3075.3945.4695.5345.5925.6465.6935.7375.7795.8175.8545.8885.9225.9505.9796.0066.0316.0580.0000.0000.0000.0000.0000.0760.1360.18
15、40.2230.2560.2840.3080.3290.3480.3640.3790.3920.4040.4140.4250.4340.4430.4520.4593.2672.5752.2822.1152.0041.9241.8641.8161.7771.7441.7161.6921.6711.6521.6361.6211.6081.5961.5861.5751.5661.5671.5481.5412.2241.2650.8290.7120.5620.5200.4410.4190.3690.0000.0000.0000.0000.0000.0780.1390.1870.2273.8652.74
16、52.3752.1792.0551.9671.9011.8501.8092.6651.7721.4571.2901.1841.1091.0541.0100.9752.6951.8261.5221.3631.2631.1911.1431.1041.0721.8801.1870.7960.6910.5490.5090.4320.4120.3630.6030.4630.3870.3410.3080.2820.2620.2460.232 (1)X (1)X 管制图管制图 CL = X =50.16 CL = X =50.16 UCL = X+A UCL = X+A2 2R=50.16+(0.58)(4
17、.8)=52.93R=50.16+(0.58)(4.8)=52.93 LCL = X-A LCL = X-A2 2R=50.16-(0.58)(4.8)=47.39R=50.16-(0.58)(4.8)=47.39 (2)R (2)R 管制图管制图 CL = R =4.8 CL = R =4.8 UCL = D UCL = D4 4R =(2.11)(4.8)=10.13R =(2.11)(4.8)=10.13 LCL = D LCL = D3 3R =( 0 )(4.8)= 0R =( 0 )(4.8)= 0UCLX(52.93)CLX(50.16)LCLX(47.39)UCLR(10.15
18、)CLR(4.8)LCLR(0) 超出控制界限的点：出现一个或多个点超出任何一个控制界限是该点处于失控状态的主要证据UCLCLLCL异常异常控制图的判读控制图的判读n链：有下列现象之一即表明过程已改变n连续7点位于平均值的一侧n连续7点上升(后点等于或大于前点)或下降。UCLCLLCL控制图的判读n明显的非随机图形：应依正态分布来判定图形，正常应是有2/3的点落于中间1/3的区域。UCLCLLCL3 3、CpkCpk（制程能力）（制程能力） Cpk = Cpk = （1 - |Ca|1 - |Ca|）CpCp内变差只考虑到固定变差或组单边规格下规格界限单边规格上规格界限双边规格2)(3)(3)
19、(6dRLSLXCXUSLCLSLUSLCppp1 1、Ca=Ca=（准确度（准确度-双边规格）双边规格） X- X- T/2 T/2Ca =2、Cp=（精密度）（精密度）233),min(dRSxCxSCCCClplupuplpupk(1)(1)公组样本大小公组样本大小 n n 相等时：相等时：CL = P = CL = P = UCL= P +3 P UCL= P +3 P（1-P1-P）/n/n LCL= P -3 P LCL= P -3 P（1-P1-P）/n/n (2) (2)n n不等，且相差小于不等，且相差小于20%20%时：时： CL = P CL = P UCL= P +3
20、P UCL= P +3 P（1-P1-P）/n/n LCL= P -3 P LCL= P -3 P（1-P1-P）/n/n (3) (3)n n不等，且相差大于不等，且相差大于20%20%时：时： CL = P CL = P UCL= P +3 P UCL= P +3 P（1-P1-P）/ni/ni LCL= P -3 P LCL= P -3 P（1-P1-P）/ni/nidn2 2、实例、实例 某工厂制造外销产品，每某工厂制造外销产品，每2 2小时抽取小时抽取100100件来检查，将检件来检查，将检 查所得之不良品数据，列于下表，利用此项数据，绘制查所得之不良品数据，列于下表，利用此项数据，
21、绘制 不良率（不良率（P P）管制图，控制其品质。）管制图，控制其品质。组别ndp组别ndp组别ndp1234567891010010010010010010010010010010034385575560.030.040.030.080.050.050.070.060.050.061112131415161718192010010010010010010010010010010036852362750.030.060.080.050.020.030.060.020.070.052122232425100100100100100584540.050.080.040.050.04合计2500125平均1000.051 1、求管制界限、求管制界限 CL = P = = 0.05 = 5%CL = P = = 0.05 = 5% UCL = P +3 = 11.54% UCL = P +3 = 11.54% LCL = P -3 LCL = P -3 （为负值，视为（为负值，视为0 0）1252500P（1 - P）nP（1 - P）n2 2、点绘管制图、点绘管制图 UCLCLLCL