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1、講講 師：曾師：曾 明明 彬彬第三部分第三部分:統(tǒng)計過程控制統(tǒng)計過程控制Statistical Process Control規(guī)格規(guī)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(guī)格標(biāo)準(zhǔn)差圖規(guī)格標(biāo)準(zhǔn)差圖計數(shù)值：計數(shù)值：P不良率圖不良率圖C缺點數(shù)圖缺點數(shù)圖SPC&SQCPROCESS原料測量結(jié)果針對產(chǎn)品所做的仍只是在做SQC針對過程的重要控制參數(shù)所做的才是SPC預(yù)防或容忍?PROCESS原料人機(jī) 法環(huán) 測量測量結(jié)果好不好不要等產(chǎn)品做出來后再去看它好不好而是在制造的時候就要把它制造好00.20

2、.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大小預(yù)測時間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大小預(yù)測時間通常會牽涉到消除產(chǎn)生變異的特殊原因可以由制程人員直接加以改善大約能夠解決15%之制程上之問題通常必須改善造成變異的

3、共同問題經(jīng)常需要管理階層的努力與對策大約85%的問題是屬于此類系統(tǒng) K在內(nèi)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轉(zhuǎn)90。PLANDOSTUDYACTPLANDOSTUDYACTPLANDOSTUDYACT過程改進(jìn)循環(huán)1、分析過程本過程應(yīng)做些什么會出現(xiàn)什么錯誤達(dá)到統(tǒng)計控制狀態(tài)確定能力2.維讓過程

4、監(jiān)控過程性能查找偏差的特殊 原因并采取措施3.改進(jìn)過程改變過程從而更好 理解普通原因變差減少普通原因變差建立可解決問題之系統(tǒng)建立可解決問題之系統(tǒng)確認(rèn)關(guān)鍵制程及特性確認(rèn)關(guān)鍵制程及特性導(dǎo)入導(dǎo)入SPCSPC進(jìn)行關(guān)鍵進(jìn)行關(guān)鍵制程及特性之管制制程及特性之管制檢討制程能力檢討制程能力符合規(guī)格程序符合規(guī)格程序持續(xù)進(jìn)行制程改善計劃持續(xù)進(jìn)行制程改善計劃導(dǎo)入導(dǎo)入SPCSPC進(jìn)行關(guān)鍵進(jìn)行關(guān)鍵制程及特性之管制制程及特性之管制提報及執(zhí)行制提報及執(zhí)行制程改善計劃程改善計劃決定管制項目決定管制項目決定管制標(biāo)準(zhǔn)決定管制標(biāo)準(zhǔn)決定抽樣方法決定抽樣方法選用管制圖的格式選用管制圖的格式記入管制界限記入管制界限繪點、實施繪點、實施重新

5、檢討管制圖重新檢討管制圖處置措施處置措施管制圖判讀管制圖判讀管管 制制 圖圖 的的 選選 擇擇數(shù)據(jù)性質(zhì)？數(shù)據(jù)性質(zhì)？數(shù)據(jù)系不良數(shù)數(shù)據(jù)系不良數(shù)或缺點數(shù)或缺點數(shù)樣本大小樣本大小 n=?n=?n是否相等？是否相等？單位大小單位大小是否相關(guān)是否相關(guān)u管管制制圖圖C管管制制圖圖P P管管制制圖圖PnPn管管制制圖圖CL 性質(zhì)？性質(zhì)？X-Rm管管制制圖圖n=?=?X-X-管管制制圖圖X-RX-R管管制制圖圖X-RX-R管管制制圖圖計量值計數(shù)值 n 2 n=1不是缺點數(shù)是不是是 X X n 10 n=2 5 n=3或5 制品名稱：紫銅管 品質(zhì)特性：內(nèi)徑 測定單位：m/m 制造場所：XXX機(jī)械號碼：XXX 操

6、作 者：XXX 測 定 者：XXX 抽樣期限：自 年 月 日 樣組測定值XR樣組測定值XRX1X2X3X4X5X1X2X3X4X512345678910111213504746504650474850495150495053454848494950505150504949534949505250464951494949524548495451484951464652505150495250545251534850515550.449.647.449.649.651.249.248.850.649.049.250.450.4384485554553614151617181920212223242

7、553534650505250525550475348485052494947495454515147495349505250515152515152515149495353535150525051525349515052505049525150.250.650.649.849.851.250.451.052.251.050.651.21.2546573246455531201 1、將每樣組之、將每樣組之 X X 與與 R R 算出記入數(shù)據(jù)表內(nèi)。算出記入數(shù)據(jù)表內(nèi)。2 2、求、求 X X 與與 R R X=50.16 X=50.16 R=4.8 R=4.83 3、查系數(shù)、查系數(shù)A A2 2，D

8、D4 4，D D3 3 A A2 2=0.58 =0.58 ，D D4 4=2.11 =2.11 ，D D3 3=負(fù)值（以負(fù)值（以0 0代表）代表）XRnn1.2541202525=取樣數(shù)n平均數(shù)管制圖標(biāo)準(zhǔn)差管制圖全距管制圖中位數(shù)管制圖個別值管制圖最大值最小值管制圖X 圖管制界限中線管制界限中線管制界限管制界限管制界限管制界限界限 系數(shù)AA1A2C21/C2 B1B2B3B4d21/d2d3D1D2D3D4A3D5D6E2A9m3A2 C323456789101112131415161718192021222324252.1211.7321.5001.3421.2251.1341.0611.0

9、000.9490.9050.8660.8320.8020.7750.7500.7280.7070.6880.6710.6550.6400.6260.6120.6003.7602.3941.8801.5961.4101.2771.1751.0941.0280.9730.9250.8340.8480.8160.7880.7620.7380.7170.6970.6790.6620.6470.6320.6191.8801.0230.7290.5770.4830.4190.3730.3370.3080.2850.2660.2490.2350.2230.2120.2030.1940.1870.1800.1

10、730.1670.1620.1570.1530.56420.72360.79790.84070.86860.88820.90270.91390.92270.93000.93590.94100.94530.94900.95230.95510.95760.95990.96150.96380.96550.96700.96840.96961.77251.38201.25331.18941.15121.12591.10781.09421.08371.07531.06841.06271.05791.05371.05011.04701.04421.04181.03961.03761.03581.03421.

11、03271.03130.0000.0000.0000.0000.0260.1050.1670.2190.2620.2990.3310.3590.3840.4060.4270.4450.4610.4770.4910.5040.5160.5270.5380.5481.8431.8581.8081.7561.7111.5721.6381.6091.5841.5611.5411.5231.5071.4921.4781.4651.4541.4431.4331.4241.4151.4071.3991.3920.0000.0000.0000.0000.0300.1180.1850.2390.2840.321

12、0.3540.3820.4060.4280.4480.4660.4820.4970.5100.5230.5340.5150.5550.5653.2672.5682.2662.0891.9701.8821.8151.7611.7161.6791.6451.6181.5941.5721.5521.5341.5181.5031.4901.4771.4661.4551.4451.4351.1281.6932.0592.3262.5342.7042.8472.9703.0783.1733.2583.3363.4073.4723.5323.5883.6403.6893.7353.7783.8193.858

13、3.8953.9310.88650.59070.48570.42890.39460.36980.35120.33670.32490.31520.30690.29980.29350.28800.28310.27870.27470.27110.26770.26470.26180.25920.25670.25440.8530.8880.8800.8640.3480.3330.8200.8080.7970.7870.7780.7700.7620.7550.7490.7430.7380.7330.7290.7240.7200.7160.7120.7090.0000.0000.0000.0000.0000

14、.2050.3870.5460.6870.8120.9241.0261.1211.2071.2851.3591.4261.4901.5481.6061.6591.7101.7591.8043.6854.3584.6984.9185.0785.2055.3075.3945.4695.5345.5925.6465.6935.7375.7795.8175.8545.8885.9225.9505.9796.0066.0316.0580.0000.0000.0000.0000.0000.0760.1360.1840.2230.2560.2840.3080.3290.3480.3640.3790.3920

15、.4040.4140.4250.4340.4430.4520.4593.2672.5752.2822.1152.0041.9241.8641.8161.7771.7441.7161.6921.6711.6521.6361.6211.6081.5961.5861.5751.5661.5671.5481.5412.2241.2650.8290.7120.5620.5200.4410.4190.3690.0000.0000.0000.0000.0000.0780.1390.1870.2273.8652.7452.3752.1792.0551.9671.9011.8501.8092.6651.7721

16、.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 管制圖管制圖 CL =X=50.16 CL =X=50.16 UCL=X+A UCL=X+A2 2R=50.16+(0.58)(4.8)=52.93R=50.16+(0.58)(4.8)=52.93 LCL=X-A LCL=X-A2 2R=

17、50.16-(0.58)(4.8)=47.39R=50.16-(0.58)(4.8)=47.39 (2)R (2)R 管制圖管制圖 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)CLR(4.8)LCLR(0)超出控制界限的點：出現(xiàn)一個或多個點超出任何一個控制界限是該點處于失控狀態(tài)的主要證據(jù)UCLCLLCL異常異?？刂茍D的判讀控制圖的判讀

18、n鏈：有下列現(xiàn)象之一即表明過程已改變n連續(xù)7點位于平均值的一側(cè)n連續(xù)7點上升(后點等于或大于前點)或下降。UCLCLLCL控制圖的判讀n明顯的非隨機(jī)圖形：應(yīng)依正態(tài)分布來判定圖形，正常應(yīng)是有2/3的點落于中間1/3的區(qū)域。UCLCLLCL3 3、CpkCpk（制程能力）（制程能力）Cpk=Cpk=（1-|Ca|1-|Ca|）CpCp內(nèi)變差只考慮到固定變差或組單邊規(guī)格下規(guī)格界限單邊規(guī)格上規(guī)格界限雙邊規(guī)格2)(3)(3)(6dRLSLXCXUSLCLSLUSLCppp1 1、Ca=Ca=（準(zhǔn)確度（準(zhǔn)確度-雙邊規(guī)格）雙邊規(guī)格）X-X-T/2 T/2Ca=2、Cp=（精密度）（精密度）233),min(

19、dRSxCxSCCCClplupuplpupk(1)(1)公組樣本大小公組樣本大小 n n 相等時：相等時：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%時：時：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 (3)(3)n n不等，且相差大于不等，且相差大于20%20%時：時：CL=P CL=P UCL=P+3 P UCL=P+3

20、P（1-P1-P）/ni/ni LCL=P-3 P LCL=P-3 P（1-P1-P）/ni/nidn2 2、實例、實例 某工廠制造外銷產(chǎn)品，每某工廠制造外銷產(chǎn)品，每2 2小時抽取小時抽取100100件來檢查，將檢件來檢查，將檢 查所得之不良品數(shù)據(jù)，列于下表，利用此項數(shù)據(jù)，繪制查所得之不良品數(shù)據(jù)，列于下表，利用此項數(shù)據(jù)，繪制 不良率（不良率（P P）管制圖，控制其品質(zhì)。）管制圖，控制其品質(zhì)。組別ndp組別ndp組別ndp1234567891010010010010010010010010010010034385575560.030.040.030.080.050.050.070.060.050

21、.061112131415161718192010010010010010010010010010010036852362750.030.060.080.050.020.030.060.020.070.052122232425100100100100100584540.050.080.040.050.04合計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 （為負(fù)值，視為（為負(fù)值，視為0 0）1252500P（1-P）nP（1-P）n2

22、2、點繪管制圖、點繪管制圖 UCLCLLCLKCp不良率ppmKCp不良率ppm0.000.170.330.500.670.831.001.171.331.501.671.832.002.172.332.502.672.833.000.000.060.110.170.220.280.330.390.440.500.560.610.670.720.780.830.890.941.001000000.000867632.335738882.680617075.077504985.075404656.762317310.508243345.009182422.439133614.40395580.7

23、0566753.01545500.26430260.28019630.65812419.3317660.7614606.5322699.7963.333.503.663.834.004.164.334.504.664.835.005.165.335.505.665.836.006.166.331.111.171.221.281.331.391.441.501.551.611.671.721.781.831.891.942.002.052.11868.460471.110248.954128.14364.24131.36314.9116.9033.1111.3650.5830.2430.0980.0390.0150.0060.0020.0010.000謝謝觀看/歡迎下載BY FAITH I MEAN A VISION OF GOOD ONE CHERISHES AND THE ENTHUSIASM THAT PUSHES ONE TO SEEK ITS FULFILLMENT REGARDLESS OF OBSTACLES.BY FAITH I BY FAITH