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1、SPC及及CPK實實 戰戰 篇篇11六西格碼在控制中的應用六西格碼在控制中的應用廣義的六西格碼是一個完善的管理工具是品質管理系統的一種說法單純的六西格碼控制應用是一種質量控制的目標請看以下說法正確與否? 我公司已經實施了六西格碼管理? 我公司達到了六西格碼的要求? 通過六西格碼管理公司品質上了一個台階一六西格碼一六西格碼22六西格碼與不良率六西格碼與不良率: Kr 百分比(%) 百萬分缺點數 1r 2r 3r 4r 5r 6r 68.26 95.45 99.73 99.9937 99.999943 99.9999998 317400 45500 2700 63 0.57 0.002(規格中心不
2、偏移規格中心不偏移)常態分配常態分配規格下限規格下限規格上限規格上限-6r-5r-4r-3r-2r-1r+6r+1r+2r +3r +4r +5rX423 Kr 合格百分比(%) 百萬分缺點數 1r 2r 3r 4r 5r 6r 30.23 69.13 93.32 99.3790 99.97670 99.999660 697700 308700 66810 6210 233 3.4規格中心值往左、右移動規格中心值往左、右移動1.5r常態分配常態分配規格下限規格下限規格上限規格上限-6r-5r-4r-3r-2r-1r+6r+1r+2r +3r +4r +5rX1.5r1.5r434n3控制方式与
3、6控制方式的比较：5? ? ? ? ?兩個影響量 6二二SPC與與CPK1區別與聯系區別與聯系CPK判定短期的制程能力可以用來解析目前的制程能力或用來檢驗制程能力是否在管制狀況下SPK長期的制程能力主要用在制程管制上。兩者配合使用應該做到短期=長期72影響量影響量-標准差標准差Sigma8樣173.673.672.076.576.872.076.873.673.673.673.673.670.470.472.0272.073.673.675.273.673.672.076.876.878.472.073.670.470.472.0 UCL UCLCLLCLLCL本376.875.272.076
4、.876.873.676.878.476.878.473.675.270.472.073.676.774.171.471.4測4 UCL UCLCLLCLLCL222.4 222.4 217.6 228.5 227.2 219.2 225.6 228.8 227.2230.4219.2 222.4211.2212.8217.66.62.60.00.074.174.172.576.275.773.175.276.375.776.873.174.170.470.972.5X=X=4.81.61.61.63.21.64.84.83.24.81.61.60.01.61.6R=R=X=R=1.960.6
5、90.85製 品名 稱TRX-7規格標準溫度時間群組數大小製 造部 門SMT期間49周上限 USL225803管制項目爐溫中心限CL22075總組數機 別回焊爐測溫板TRX-7-1實板測量單位&sec下限 LSL2157015測 定 者姜雲霞時時間間時 間 管 制日期 2004.11.29時間1110.838.4R時間74.12.6 R管制圖C P=預估不良率 (PPM)製程能力分析時間 Sigma=CPK=X圖R圖備注備注及原及原因追查因追查1時間的數據離散性較大Sigma=1.96因此要從測量儀器影響時間的設置來分析解決。時時間間X管缺制圖平均0.02.04.06.08.012345678
6、9101112131415UCLCLLCLR69717375777981123456789101112131415UCLCLLCLXUSLLSLSL實例實例(Sigma較大離散性問題較大離散性問題)3影響量影響量-中心偏移量中心偏移量10CPK實例分析實例分析(離散性較小中心偏移量影響離散性較小中心偏移量影響) 製 品R圖名 稱管制項目測量單位日期/時間批號1234567891011121314151617181920212223242515.8967樣10.1310.1350.1270.1270.1310.1350.1350.1270.1270.1310.1270.1310.1310.135
7、0.1270.1350.1310.1270.1380.1310.1310.1270.1310.1350.1270.241本20.1350.1310.1310.1240.1240.1310.1270.1310.1270.1350.1310.1240.1270.1310.1270.1270.1240.1240.1350.1240.1270.1270.1270.1310.131測30.130.1270.120.120.1240.1310.1270.1240.1240.1270.1310.1270.1240.1270.120.120.120.1240.1310.1270.1270.1240.120.1
8、310.131定40.1270.1270.1240.1310.1270.1350.1310.120.120.1270.1270.1310.1270.1310.120.1240.1240.1270.1270.1310.130.1270.1240.120.124值50.1240.1310.1240.1270.120.1270.1240.1160.120.120.1240.1270.1240.1240.120.130.1240.1240.120.1270.1310.1270.1240.1270.1310.6440.6510.6260.6290.6260.6590.6440.6180.6180.640
9、.640.640.6330.6480.6140.6330.6230.6260.6510.640.6470.6320.6260.6440.6440.1290.130.1250.1260.1250.1320.1290.1240.1240.1280.1280.1280.1270.1296 0.1230.1270.1250.1250.130.1280.1290.1260.1250.1290.1290.0110.0080.0110.0110.0110.0080.0110.0150.0070.0150.0070.0070.0070.0110.0070.0150.0110.0030.0180.0070.00
10、40.0030.0110.0150.0070.1272R=0.0101中心偏移量為0.0072Sigma值為0.0024通過計算SPC的管制范圍為0.011可見控制范圍已經相當小說明每次測量的數據都集中在一個區域波動很小。因此CPK值十分合理為1.812但管制上下限均在規格中心到規格上限的范圍內且管制下限還沒有達到規格中心。可以考慮調整規格并作進一步跟蹤。 R管制圖 Sigma= 0.0024CPK= 1.8112備註及原因追查: CP = 2.8242R 平平 均均X管制圖預估不良率 (PPM)製程能力分析 25合計量測數值的判定條件 USL 藍色1.67屬于制程能力充分的狀態下221.3計
11、算管制上下限上管制界限:UCL= Xbar +3*Sigma=0.139832+3*0.00312=0.149192下管制界限:LCL= Xbar - 3*Sigma =0.139832-3*0.00312=0.1304722312345678910111213141516171819202122232425USL0.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.16UCL0.1490.1490.1490.1490.1490.1490.1490.14
12、90.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.149SL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14Xi0.1430.140.1420.140.1450.1430.140.140.1350.1410.1370.140.1330.140.1360.1440.1370.140.140.1430.1370.1420.1430.1
13、420.1352CL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14LCL0.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.130LSL0.120.120.120.120.120.120.120.120.120.120.120.120.120.120.1
14、20.120.120.120.120.120.120.120.120.120.120.110.130.150.1712345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25USLUCLSLXiLCLLSLCL1.4管制圖241.5解析管制上下限上管制界限:UCL= 0.149192實際管制上限= 0.150 在實際解析中如果測量的點比較分散可以適當放寬解析上限再定期檢討縮緊管制上限到理論值。下管制界限:LCL= 0.130472實際管制下限= 0.130在實際解析中如果測量的點比較分散可以適當放寬解析下限再定期檢討縮緊管制下限到理論值。25
15、2SPC管制 將CPK解析的管制上下限作為SPC的管制上下線 定時對生產制程進行量測這個時間可以是每天或每班 檢查每次的量測結果是否在管控范圍內 量測點超出管控線需要立即檢討制程尋找出原因 定期(每月或每周)對近期的控制圖進行分析檢查是否有不收控制的趨勢(如周期變動連續7點連續11點等)。260.1250.1300.1350.1400.1450.1500.1551/11/21/31/41/51/61/71/81/91/101/111/121/131/141/151/16異常異常1/11/21/31/41/51/61/71/81/91/101/111/121/131/141/150.1480.1
16、40.1480.1440.1370.140.1320.1480.1370.1350.1490.1440.1440.1440.1370.1440.1330.1220.140.1390.1360.1550.140.140.1370.1330.1330.1330.1280.1330.1420.1390.1520.140.1370.140.1290.1440.1330.1290.1370.1440.140.1530.1440.140.1370.140.140.1480.1230.1410.1430.1370.1560.1430.1400.1410.1370.1400.1370.1270.1400.14
17、10.1370.1530.0080.0070.0110.0150.0110.0150.010.0150.0070.0050.007Date/Shift14235XR2.1SPC管制圖272.2管制圖的難點 CPK解析時存在中心偏移量較大的情況 CPK解析時數據離散性較大Sigma較大 SPC管制時管制上下限太嚴導致經常跑出管制線 量測點都在管制界限內是否代表制程良好283SPC & CPK管制的步驟管制的步驟四個步驟3.1 CPK改進3.2 CPK解析3.3SPC管制及改進3.4PDCA293.1CPK改進-中心偏移量12345678910111213141516171819202122232
18、425USL0.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.170.17UCL0.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.149SL0.150.150.150.150.150.150.150.150.150.150.150.150.150.150.150.15
19、0.150.150.150.150.150.150.150.150.15Xi0.1430.140.1420.140.1450.1430.140.140.1350.1410.1370.140.1330.140.1360.1440.1370.140.140.1430.1370.1420.1430.1420.1352CL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14LCL0.1300.1300.1300.1300.1300.1300.1300.13
20、00.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.130LSL0.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.130.150.1712345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25USLUCLSLXiLCLLSLCLSLCLCP=2.13675K=0.5084CPK
21、=1.05303.1CPK解析-消除中心偏移量0.110.130.150.1712345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25USLUCLSLXiLCLLSLCL12345678910111213141516171819202122232425USL0.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.160.16UCL0.1490.1490.1490.1490.1490.1490.1490.149
22、0.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.1490.149SL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14Xi0.1430.140.1420.140.1450.1430.140.140.1350.1410.1370.140.1330.140.1360.1440.1370.140.140.1430.1370.1420.1430.14
23、20.1352CL0.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.140.14LCL0.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.1300.130LSL0.120.120.120.120.120.120.120.120.120.120.120.120.120.120.12
24、0.120.120.120.120.120.120.120.120.120.12CL SLCP=2.13675K=0.0084CPK=2.1188313.1CPK解析-消除中心偏移量（圖）SL323.2CPK解析-穩定性離散性原則CPK解析時Sigma較大 CP 2 CPK 1.67具體解析過程可以用Xbar-R 管制分析法難難333.2CPK解析-Xbar-R 分析步驟 1計算XbarRXbar.barRbar 2計算R的管控線并判斷 3剔除異常的點(超出規格的)查找異常的原因 4重復123步驟直到全部在管控范圍內 5計算Xbar的管控線并判斷 6剔除異常的點(超出規格的)查找異常的原因 7
25、重復1到6步驟直到全部在管控范圍內 8落實查找出來的改善措施 9再次復驗。34n1計算XbarRXbar.barRbarR.UCL=D4*R.bar =2.12*0.0127=0.02694R.LCL=D3*R.bar =0*0.013=0NA2d2D4D321.881.133.27031.021.692.58040.732.062.28050.582.332.1201234567891011121314151617181920212223242510.1370.1190.1370.1330.1580.140.1480.1440.1370.1440.1440.1230.1330.140.133
26、0.140.1440.1290.1370.140.140.1440.1370.1330.13320.1440.1490.1480.1370.1510.1440.140.1330.1480.1480.1480.1280.1480.1480.1370.1480.140.140.1440.1370.1480.1510.1330.1370.13730.1510.1220.1440.140.1550.1480.1330.1370.1480.1510.1440.120.1480.1440.1370.140.1370.1440.1370.1440.140.140.1370.1330.1440.1370.12
27、40.140.1370.1490.140.1370.1330.1510.14830.1330.1310.1370.1370.1330.1370.1290.140.1330.140.1370.1440.140.1370.15150.140.1310.1440.140.1480.1440.140.1440.1480.1370.1440.1190.140.1370.140.1330.1370.140.140.1480.1480.1440.1440.140.144Xbar0.1420.1290.1430.1370.1520.1430.1400.1380.1460.1460.1430.1240.1410
28、.1410.1360.1400.1370.1390.1380.1420.1430.1450.1380.1360.141R0.0140.0300.0110.0070.0100.0080.0150.0110.0140.0140.0150.0120.0150.0110.0070.0150.0150.0150.0110.0110.0110.0110.0110.0070.018USL=CP=Rbar=Sigma=0.00545Rbar=0.16SL=0.14LSL=0.120.139970.0130.01271R.UCL=0.026942Xbar.bar=R.LCL=035n2計算R的管控線此時的X.b
29、ar圖0.000.010.010.020.020.030.030.0412345678910111213141516171819202122232425UCLRLCL異常點UCL0. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 1560. 156USL0. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1
30、600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 160SL0. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 140Xbar0. 1420. 1290. 1430. 1370. 1520. 1430. 1400. 1380. 1460. 1460. 1430. 1
31、240. 1410. 1410. 1360. 1400. 1370. 1390. 1380. 1420. 1430. 1450. 1380. 136LSL0. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 120LCL0. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1
32、240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1240. 1150. 1350. 15512345678910111213141516171819202122232425USLSLXbarLSLUCLLCL36n3重新計算-剔除R圖中的不合格點(第2點)134567891011121314151617181920212223242510.1370.1370.1330.1580.140.1480.1440.1370.1440.1440.1230.1330.140.1330.140.1440.1290.1370.1
33、40.140.1440.1370.1330.13320.1440.1480.1370.1510.1440.140.1330.1480.1480.1480.1280.1480.1480.1370.1480.140.140.1440.1370.1480.1510.1330.1370.13730.1510.1440.140.1550.1480.1330.1370.1480.1510.1440.120.1480.1440.1370.140.1370.1440.1370.1440.140.140.1370.1330.1440.1370.140.1370.1490.140.1370.1330.1510.1
34、4830.1330.1310.1370.1370.1330.1370.1290.140.1330.140.1370.1440.140.1370.15150.140.1440.140.1480.1440.140.1440.1480.1370.1440.1190.140.1370.140.1330.1370.140.140.1480.1480.1440.1440.140.144Xbar0.1420.1430.1370.1520.1430.1400.1380.1460.1460.1430.1240.1410.1410.1360.1400.1370.1390.1380.1420.1430.1450.1
35、380.1360.141R0.0140.0110.0070.0100.0080.0150.0110.0140.0140.0150.0120.0150.0110.0070.0150.0150.0150.0110.0110.0110.0110.0110.0070.018USL=CP=Rbar=Xbar.bar=R.LCL=00.01196R.UCL=0.025348Sigma=0.00505Rbar=0.16SL=0.14LSL=0.120.140430.012剔除后X.bar.bar及R.bar值均發生變化。R圖符合要求。0.000.010.010.020.020.030.03134567891
36、0111213141516171819202122232425UCLRLCL37n4計算Xbar的管控線134567891011121314151617181920212223242510.1370.1370.1330.1580.140.1480.1440.1370.1440.1440.1230.1330.140.1330.140.1440.1290.1370.140.140.1440.1370.1330.13320.1440.1480.1370.1510.1440.140.1330.1480.1480.1480.1280.1480.1480.1370.1480.140.140.1440.13
37、70.1480.1510.1330.1370.13730.1510.1440.140.1550.1480.1330.1370.1480.1510.1440.120.1480.1440.1370.140.1370.1440.1370.1440.140.140.1370.1330.1440.1370.140.1370.1490.140.1370.1330.1510.14830.1330.1310.1370.1370.1330.1370.1290.140.1330.140.1370.1440.140.1370.15150.140.1440.140.1480.1440.140.1440.1480.13
38、70.1440.1190.140.1370.140.1330.1370.140.140.1480.1480.1440.1440.140.144Xbar0.1420.1430.1370.1520.1430.1400.1380.1460.1460.1430.1240.1410.1410.1360.1400.1370.1390.1380.1420.1430.1450.1380.1360.141R0.0140.0110.0070.0100.0080.0150.0110.0140.0140.0150.0120.0150.0110.0070.0150.0150.0150.0110.0110.0110.01
39、10.0110.0070.018USL=CP=Rbar=Xbar.bar=R.LCL=01.312975UCL=0.01196R.UCL=0.0253481.320029K=0.005344CPK=Sigma=0.00505Rbar=0.16SL=0.14LSL=0.120.140430.0120.1252760.155579CL=0.140428LCL=UCL= Xbar.bar+A2*Rbar=0.14043+0.577*0.012=0.147354LCL= Xbar.bar -A2*Rbar =0.14043-0.577*0.012=0.13350638UCL0. 1470. 1470.
40、 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 1470. 147USL0. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 160SL0. 1400. 1400. 1400. 1400. 1400.
41、1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 140Xbar0. 1420. 1430. 1370. 1520. 1430. 1400. 1380. 1460. 1460. 1430. 1240. 1410. 1410. 1360. 1400. 1370. 1390. 1380. 1420. 1430. 1450. 1380. 136LSL0. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200.
42、 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 120LCL0. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1330. 1150. 1350. 1551345678910111213141516171819202122232425USLSLXbarLSLU
43、CLLCLn5剔除異常的點(超出規格的)查找異常的原因異常點異常點異常點異常點39n6重新計算-剔除第512點Xbar.barRbar都需要重新計算檢查R圖符合要求134678910111314151617181920212223242510.1370.1370.1330.140.1480.1440.1370.1440.1440.1330.140.1330.140.1440.1290.1370.140.140.1440.1370.1330.13320.1440.1480.1370.1440.140.1330.1480.1480.1480.1480.1480.1370.1480.140.140.
44、1440.1370.1480.1510.1330.1370.13730.1510.1440.140.1480.1330.1370.1480.1510.1440.1480.1440.1370.140.1370.1440.1370.1440.140.140.1370.1330.1440.1370.140.1370.140.1370.1330.1510.14830.1330.1370.1370.1330.1370.1290.140.1330.140.1370.1440.140.1370.15150.140.1440.140.1440.140.1440.1480.1370.1440.140.1370.
45、140.1330.1370.140.140.1480.1480.1440.1440.140.144Xbar0.1420.1430.1370.1430.1400.1380.1460.1460.1430.1410.1410.1360.1400.1370.1390.1380.1420.1430.1450.1380.1360.141R0.0140.0110.0070.0080.0150.0110.0140.0140.0150.0150.0110.0070.0150.0150.0150.0110.0110.0110.0110.0110.0070.018USL=XbbCP=UCLRbar=0.133627
46、0.147633CL=0.140630LCL=Sigma=0.00296Rbar=0.16SL=0.14LSL=0.120.140630.012R.LCL=02.2355480.01205R.UCL=0.0255412.253292K=0.007875CPK=0. 000. 010. 010. 020. 020. 030. 031346789101113141516171819202122232425UCLRLCL40n6重新計算-檢查X.bar是否符合管制要求UCL0. 1480. 1480. 1480. 1480. 1480. 1480. 1480. 1480. 1480. 1480. 1
47、480. 1480. 1480. 1480. 1480. 1480. 1480. 1480. 1480. 1480. 1480. 148USL0. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 1600. 160SL0. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 1400. 14
48、00. 1400. 1400. 1400. 1400. 1400. 140Xbar0. 1420. 1430. 1370. 1430. 1400. 1380. 1460. 1460. 1430. 1410. 1410. 1360. 1400. 1370. 1390. 1380. 1420. 1430. 1450. 1380. 1360. 141LSL0. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1200. 1
49、200. 120LCL0. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1340. 1150. 1200. 1250. 1300. 1350. 1400. 1450. 1500. 1550. 1600. 1651346789101113141516171819202122232425USLSLXbarLSLUCLLCL41n7落實改善措施及延長管制線 將第2點和第512點出現異常的原因進行
50、分析一定要追蹤落實改善 用以下公式得到管制用管制線UCL= Xbar +3*SigmaLCL= Xbar - 3*Sigma 423.3SPC管制及改進 3.1和3.2得到了管制上下限在批量生產中就可以用此管控線來管制檢驗制程是否處于正常狀況下 SPC管制一般會要求定期進行量測監控。發現異常及時處理0.1250.1300.1350.1400.1450.1500.1551/11/21/31/41/51/61/71/81/91/101/111/121/131/141/151/16異常異常433.4PDCA44結結 束束 語語n用CPK來解析制程得到制程管控的目標n用SPC來定期檢驗制程是否處于受控