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1、Process Capability Analysis(Measure Phase)Process Capability Analysis Process Capability Analysis2Scope of Module Process Variation Process Capability Specification,Process and Control Limits Process Potential vs Process Performance Short-Term vs Long-Term Process Capability Process Capability for N
2、on-Normal Data Cycle-Time(Exponential Distribution)Reject Rate(Binomial Distribution)Defect Rate(Poisson Distribution)Process Capability Analysis Process Capability Analysis3Process VariationProcess Variation is the inevitable differences among individual measurements or units produced by a process.
3、Sources of Variation within unit(positional variation)between units(unit-unit variation)between lots(lot-lot variation)between lines(line-line variation)across time(time-time variation)measurement error(repeatability&reproducibility)Process Capability Analysis Process Capability Analysis4Types of Va
4、riationInherent or Natural Variation Due to the cumulative effect of many small unavoidable causes A process operating with only chance causes of variation present is said to be“in statistical control”Process Capability Analysis Process Capability Analysis5Types of VariationSpecial or Assignable Var
5、iation May be due to a)improperly adjusted machine b)operator error c)defective raw material A process operating in the presence of assignable causes of variation is said to be“out-of-control”Process Capability Analysis Process Capability Analysis6Process CapabilityProcess Capability is the inherent
6、 reproducibility of a processs output.It measures how well the process is currently behaving with respect to the output specifications.It refers to the uniformity of the process.Capability is often thought of in terms of the proportion of output that will be within product specification tolerances.T
7、he frequency of defectives produced may be measured ina)percentage(%)b)parts per million(ppm)c)parts per billion(ppb)Process Capability Analysis Process Capability Analysis7Process CapabilityProcess Capability studies can indicate the consistency of the process output indicate the degree to which th
8、e output meets specifications be used for comparison with another process or competitorProcess Capability Analysis Process Capability Analysis8Process Capability vs Specification Limitsa)b)c)a)Process is highly capableb)Process is marginally capablec)Process is not capableProcess Capability Analysis
9、 Process Capability Analysis9Three Types of LimitsSpecification Limits(LSL and USL)created by design engineering in response to customer requirements to specify the tolerance for a products characteristicProcess Limits(LPL and UPL)measures the variation of a process the natural 6 limits of the measu
10、red characteristicControl Limits(LCL and UCL)measures the variation of a sample statistic(mean,variance,proportion,etc)Process Capability Analysis Process Capability Analysis10Three Types of LimitsDistribution of Individual ValuesDistribution of Sample AveragesProcess Capability Analysis Process Cap
11、ability Analysis11Process Capability IndicesTwo measures of process capability Process Potential Cp Process Performance Cpu Cpl CpkProcess Capability Analysis Process Capability Analysis12Process PotentialThe Cp index assesses whether the natural tolerance(6)of a process is within the specification
12、limits.Process Capability Analysis Process Capability Analysis13Process PotentialA Cp of 1.0 indicates that a process is judged to be“capable”,i.e.if the process is centered within its engineering tolerance,0.27%of parts produced will be beyond specification limits.Cp Reject Rate1.00 0.270%1.33 0.00
13、7%1.50 6.8 ppm2.00 2.0 ppbProcess Capability Analysis Process Capability Analysis14Process Potentiala)b)c)a)Process is highly capable(Cp2)b)Process is capable(Cp=1 to 2)c)Process is not capable(Cp1)Process Capability Analysis Process Capability Analysis15Process PotentialThe Cp index compares the al
14、lowable spread(USL-LSL)against the process spread(6).It fails to take into account if the process is not centered between the specification limits.Process is centered Process is not centeredProcess Capability Analysis Process Capability Analysis16Process PerformanceThe Cpk index relates the scaled d
15、istance between the process mean and the nearest specification limit.Process Capability Analysis Process Capability Analysis17Process PerformanceCpkReject Rate1.0 0.13 0.27%1.1 0.05 0.10%1.2 0.02 0.03%1.3 48.1 96.2 ppm1.4 13.4 26.7 ppm1.5 3.4 6.8 ppm1.6 794 1589 ppb1.7 170 340 ppb1.8 33 67 ppb1.9 6
16、12 ppb2.0 1 2 ppbProcess Capability Analysis Process Capability Analysis18Process Performancea)Process is highly capable(Cpk1.5)b)Process is capable(Cpk=1 to 1.5)c)Process is not capable(Cpk1)a)Cp=2Cpk=2b)Cp=2Cpk=1c)Cp=2Cpk 1Process Capability Analysis Process Capability Analysis19Example 1Specifica
17、tion Limits:4 to 16 gMachine Mean Std Dev(a)10 4(b)10 2(c)7 2(d)13 1Determine the corresponding Cp and Cpk for each machine.Process Capability Analysis Process Capability Analysis20Example 1AProcess Capability Analysis Process Capability Analysis21Example 1BProcess Capability Analysis Process Capabi
18、lity Analysis22Example 1CProcess Capability Analysis Process Capability Analysis23Example 1DProcess Capability Analysis Process Capability Analysis24Process CapabilityFor a normally distributed characteristic,the defective rate F(x)may be estimated via the following:For characteristics with only one specification limit:a)LSL onlyb)USL onlyLSL USLProcess Capability Analysis Process Capability Analysis25Example 2Specification Limits:4 to 16 gMachine Mean Std Dev(a)10 4(b)10 2(c)7 2(d)13 1Determine the defective rate for each machine.