6sigma黑带培训教材(英文).ppt
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1、Process Capability Analysis(Measure Phase)Process Capability AnalysisProcess Capability Analysis2Scope of ModuleProcess VariationProcess CapabilitySpecification,Process and Control LimitsProcess Potential vs Process PerformanceShort-Term vs Long-Term Process CapabilityProcess Capability for Non-Norm
2、al DataCycle-Time(Exponential Distribution)Reject Rate(Binomial Distribution)Defect Rate(Poisson Distribution)Process Capability AnalysisProcess Capability Analysis3Process VariationProcess Variation is the inevitable differences among individual measurements or units produced by a process.Sources o
3、f Variationwithin 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 AnalysisProcess Capability Analysis4Types of VariationInhe
4、rent or Natural VariationDue to the cumulative effect of many small unavoidable causesA process operating with only chance causes of variation present is said to be“in statistical control”Process Capability AnalysisProcess Capability Analysis5Types of VariationSpecial or Assignable VariationMay be d
5、ue to a)improperly adjusted machine b)operator error c)defective raw materialA process operating in the presence of assignable causes of variation is said to be“out-of-control”Process Capability AnalysisProcess Capability Analysis6Process CapabilityProcess Capability is the inherent reproducibility
6、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.The frequency of d
7、efectives produced may be measured ina)percentage(%)b)parts per million(ppm)c)parts per billion(ppb)Process Capability AnalysisProcess Capability Analysis7Process CapabilityProcess Capability studies can indicate the consistency of the process outputindicate the degree to which the output meets spec
8、ificationsbe used for comparison with another process or competitorProcess Capability AnalysisProcess Capability Analysis8Process Capability vs Specification Limitsa)b)c)a)Process is highly capableb)Process is marginally capablec)Process is not capableProcess Capability AnalysisProcess Capability An
9、alysis9Three 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 processthe natural 6 limits of the measured characteristicCon
10、trol Limits (LCL and UCL)measures the variation of a sample statistic(mean,variance,proportion,etc)Process Capability AnalysisProcess Capability Analysis10Three Types of LimitsDistribution of Individual ValuesDistribution of Sample AveragesProcess Capability AnalysisProcess Capability Analysis11Proc
11、ess Capability IndicesTwo measures of process capabilityProcess PotentialCpProcess PerformanceCpuCplCpkProcess Capability AnalysisProcess Capability Analysis12Process PotentialThe Cp index assesses whether the natural tolerance(6)of a process is within the specification limits.Process Capability Ana
12、lysisProcess 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 Rate1.000.270%1.330.007%1.506.8 ppm2.002.0 ppbProcess
13、Capability AnalysisProcess Capability Analysis14Process Potentiala)b)c)a)Process is highly capable(Cp2)b)Process is capable(Cp=1 to 2)c)Process is not capable(Cp1.5)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 AnalysisProcess Cap
14、ability Analysis19Example 1Specification Limits:4 to 16 gMachineMeanStd Dev(a)10 4(b)10 2(c)7 2(d)13 1Determine the corresponding Cp and Cpk for each machine.Process Capability AnalysisProcess Capability Analysis20Example 1AProcess Capability AnalysisProcess Capability Analysis21Example 1BProcess Ca
15、pability AnalysisProcess Capability Analysis22Example 1CProcess Capability AnalysisProcess Capability Analysis23Example 1DProcess Capability AnalysisProcess Capability Analysis24Process CapabilityFor a normally distributed characteristic,the defective rate F(x)may be estimated via the following:For
16、characteristics with only one specification limit:a)LSL onlyb)USL onlyLSLUSLProcess Capability AnalysisProcess Capability Analysis25Example 2Specification Limits:4 to 16 gMachineMeanStd Dev(a)10 4(b)10 2(c)7 2(d)13 1Determine the defective rate for each machine.Process Capability AnalysisProcess Cap
17、ability Analysis26Example 2Mean Std Dev ZLSL ZUSL F(xUSL)F(x)10 4 -1.51.5 66,807 66,807133,614 10 2 -3.03.0 1,350 1,350 2,700 7 2 -1.54.5 66,807 3 66,811 13 1 -9.03.0 0 1,350 1,350Lower Spec Limit=4 gUpper Spec Limit=16 gProcess Capability AnalysisProcess Capability Analysis27Process Potential vs Pr
18、ocess Performance(a)Poor Process Potential(b)Poor Process PerformanceLSLUSLLSLUSLExperimental Design to reduce variationExperimental Design to center mean to reduce variationProcess Capability AnalysisProcess Capability Analysis28Process Potential vs Process Performance Process Potential Index (Cp)C
19、pk 1.0 1.2 1.4 1.6 1.8 2.0 1.02,699.9 1,363.3 1,350.0 1,350.0 1,350.0 1,350.0 1.2 318.3 159.9 159.1 159.1 159.1 1.4 26.7 13.4 13.4 13.4 1.6 1.6 0.8 0.8 1.8 0.1 0.0 2.0 0.0Defective Rate(measured in dppm)is dependent on the actual combination of Cp and Cpk.Process Capability AnalysisProcess Capabilit
20、y Analysis29Process Potential vs Process Performancea)Cp=2Cpk=2b)Cp=2Cpk=1c)Cp=2Cpk 1Cp Cpk Missed OpportunityProcess Capability AnalysisProcess Capability Analysis30Alternative Process Performance IndexProcess capability statistics measure process variation relative to specification limits.The Cp s
21、tatistic compares the engineering tolerance against the processs natural variation.The Cpk statistic takes into account the location of the process relative to the midpoint between specifications.If the process target is not centered between specifications,the Cpm statistic is preferred.Process Capa
22、bility AnalysisProcess Capability Analysis31Process StabilityA process is stable if the distribution of measurements made on the given feature is consistent over time.TimeStable ProcessTimeUnstable ProcessucllclucllclProcess Capability AnalysisProcess Capability Analysis32Within vs Overall Capabilit
23、yWithin Capability(previously called short-term capability)shows the inherent variability of a machine/process operating within a brief period of time.Overall Capability(previously called long-term capability)shows the variability of a machine/process operating over a period of time.It includes sour
24、ces of variation in addition to the short-term variability.Process Capability AnalysisProcess Capability Analysis33Within vs Overall CapabilityWithinOverallSample Size30 50 units 100 unitsNumber of Lotssingle lotseveral lotsPeriod of Timehours or daysweeks or monthsNumber of Operatorssingle operator
25、different operatorsProcess Potential Cp PpProcess Performance Cpk PpkProcess Capability AnalysisProcess Capability Analysis34Within vs Overall CapabilityWithin CapabilityOverall CapabilityThe key difference between the two sets of indices lies in the estimates for Within and Overall.Process Capabili
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