6-sigma trainiing(六西格码培训资料)

6-SigmaTraining1StatisticalTechniqueto6-SigmaQuality6-SigmaTraining2ABOUTINSTRUCTORCurrentposition:Sr.Officer,LCMEng.DeptMPhif.(EE),BEng(Hons)Eng.Pastworkingexperience:HKUST:TofabricateOLEDanddesigntherelateddrivingcicruits.CityU:TofabricatePolymericOptoWaveguidesPhilips:TodevelopLCMincludingB/W,ColorSTN,TFTandPLEDSolomonSystech:TodevelopthedriverICforB/W,ColorSTN,TFTandPDAproducts.6-SigmaTraining3COURSEABSTRACTThiscourseistointroducethewaysofProcessControlSystemtargetingto6-sigmaQualityinthemanufacturingareas.ThebenchmarkofSixSigmawillbesharedduringthecourse.Inordertoachieveit,seriesofmeasurementsystemcapabilities,performancemetricsandprocesscontrolmethodologywillbediscussed.6-SigmaTraining4COURSEOBJECTIVESParticipantswilllearn:-*WhatissixSigma*ControlPlanningandMethodology*Measurementsystemcapability*ProcessCapabilityMetrics*ContinuousProcessImprovement6-SigmaTraining5TraditionalProcessCapability*99.73%ofthetotalareawithinspec.limits.Defectratewillbe2,700PPM.*Only93.32%oftheareaunderthecurveanddefectrateis66,000PPM.6-SigmaTraining6SixSigmaCapability*Defectrate-0.002PPM*Defectrate-3.4PPM6-SigmaTraining7•OutputVariablesManagetheoutputs.ATraditionalViewSalesGrowthMarketShareProfitability6-SigmaTraining8•OutputVariables•InputVariablesManagetheinputs;respondtotheoutputs.ANon-traditionalViewSalesGrowthMarketShareProfitabilityCustomerSatisfactionProductQualityOn-TimeDeliveryCOQCreditTermsRelationshipsServiceCustomerTraining6-SigmaTraining9Whatis6-SigmaMotorola’stermtoexpressaprocesscapabilitythatproducesonly0.002defectspereachmillionunitsmanufacturedwhentheprocessiscentered,oramaximumofonly3.4defectsforeachmillionunitswhentheprocessshiftsupto1.5sigmatooneside.Theterm“6sigma”isbecomingsynonymouswith“QualityExcellence”.6-SigmaTraining10TheConceptofSixSigmaDifferentnumbersofOpportunities...ManufacturingProcessesCustomersorSuppliersAdministrativeAreas6=Astructuralapproachtocontinuousimprovement1-Identifytheproductorserviceyouprovide2-Identifyyourcustomers&theirrequirements3-Determineyourneeds&suppliers4-Definetheprocessfordoingwork5-Eliminatedefectsources/optimizetheprocess6-ContinuouslyimprovetheSigmalevel(or“Sixstepstowardexcellence”)ABitofStatistics...-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0upperspeclimitLowerspeclimit+1.5Sigma-1.5Sigma3.4ppmorZero+6-SigmaTraining111)(2nxxiNormalDistribution-GaussianCurveSigma==Deviation(Squarerootofvariance)-7-6-5-4-3-2-101234567AxisgraduatedinSigma68.27%95.45%99.73%99.9937%99.999943%99.9999998%result:317300ppmoutside(deviation)45500ppm2700ppm63ppm0.57ppm0.002ppmbetween+/-1between+/-2between+/-3between+/-4between+/-5between+/-6=6-SigmaTraining12SixSigma...AndtheStatistics-7.0-6.0-5.0-4.0-3.0-2.0-1.00.01.02.03.04.05.06.07.0+1.5Sigma-1.5Sigma3.4ppmorZeroUpperspec.limitLowerspec.limitReducethevariation:when=Designspecificationwidth/12Stabilizetheprocess,withoutaffectingthevariance,tolimitthemaximumprocessshiftto+/-1.5Undertheseconditions,andintheworstcase,therewillbenomorethana3.4ppmdefect(reject)level,withspecificationlimitsat4.5ononesideand7.5ontheother.Note:Onecanseethatthepointcorrespondingto6onthegraduatedperformancescaleaboveismeasuredin”Sigma’s”(with6correspondingtoa3.4ppmdefectlevel).Cp=2andCpk=1.5Cp=26-SigmaTraining13SixSigma...AndCapability12345678Cp0.330.6611.331.6622.332.66Cpk-0.160.160.50.831.161.51.832.16Cp=Designspecificationwidth63Cpk=Min.Mean-SpecLimitWithamaximumprocessshiftof+/-1.56-SigmaTraining14DifferentNumbersofOpportunities...ManufacturingProcessCustomersorSuppliersAdministrativeAreas6-CustomersorSuppliers:Oneopportunityperproductdeliveredorpercomponentpurchased.-Manufacturingprocess:Opportunitiesateachprocessstep)-Administrativeareas:NumberofopportunitiesforerrorforeachactivityperformedTheOpportunities...6-SigmaTraining15SomeExamplesofOpportunityCustomerPerspective:1opportunityperproductdeliveredex.1regulator=1opportunity1controller=1opportunityProductionlines:Regulator=160opportunitiesController=1200opportunitiesForm(Payment,PurchaseOrder,..):NumberoffieldsExpedite/Delivery:1opportunity/packagingunit6-SigmaTraining16Aqualitylevelof6correspondstolessthan3.4defectspermillionOpportunities(i.e.,correct99.99966%ofthetime)SigmaandOpportunities6-SigmaTraining17AUniversalMeasurementScale...345676681062102333.4SigmaDPMOpOnonecondition:Calculatethedefectsandestimatetheopportunitiesinthesameway...6-SigmaTraining18MeasurementWithSIGMAIsSimple!!!EstimatetheOpportunitiesCounttheDefectsFollowtheIndicator:DefectspermillionOpportunitiesConversionintoSigmacanbeaccomplishedwiththehelpofastatisticaltable.6=3.4dpmo6-SigmaTraining19ConvertingDefectLevelsto.....Sigma!175defectsareidentifiedwhileproducing5000controllersThemanufactureofonecontrollerallowsfor1367defectopportunities.D.P.Op=0.035/1367=0.0000256AnExample:D.P.U=175/5000=0.035D.P.M.Op=25.6Sigmalevel:5.556-SigmaTraining20SixSigma:AnAmbitiousObjective?•Accurateto99.99966%(lessthan3.4defectsforeachmillionopportunities)couldappearexcessive....!99.9%isalreadyVERYGOOD!Butwhatc