6-sigma案例

PJTNo:Plant：Dept：QualityControlBBName：AUTOW/M噪音不良改善D噪音不良为止到2004年3月CAR的故障类中占WORST-1，非故障类的WORST-2。但噪音测试中频繁发生不良，CPK只有0.46；SigmaLevel2.5Sigma。（1M~3M噪音测试DB数；SPEC:55DB)ProblemstatementsTARGET记述SigmaLevel达成4Sigma(含异音不良)。D454749515355575961LSLUSLProcessCapabilityAnalysisforNoisedBUSLTargetLSLMeanSampleNStDev(Within)StDev(Overall)CpCPUCPLCpkCpmPpPPUPPLPpkPPMLSLPPMUSLPPMTotalPPMLSLPPMUSLPPMTotalPPMLSLPPMUSLPPMTotal55.0000*45.000052.66341111.676872.366160.990.461.520.46*0.700.331.080.330.00108108.11108108.112.4481746.8181749.25600.26161699.55162299.80ProcessDataPotential(Within)CapabilityOverallCapabilityObservedPerformanceExp.WithinPerformanceExp.OverallPerformanceWithinOverall◆Project选定背景noise&蛏?晚姻?砺PCB荇辙锶?荇辙?壅荇辙?讵涮?荇辙颚?夼槟Others0.0610.0310.0260.0230.0140.0110.0110.0100.00531.816.113.512.07.35.75.75.22.631.847.961.573.480.786.592.297.4100.00.00.10.2020406080100DefectCountPercentCum%PercentCountParetoChartforASDATA噪音振动占故障类和非故障类的数据的31.8%SIPOC业体NSNW部品SPECFLOW操作员设备&工具合格产品不良产品物流营业代理商消费者ProjectScopeD部品入库部品检查部分资材预装部品投入TUB底部组立返品&邀请对策完成包装工程检查部品进厂入库FRAME等组立YNN修理Y◆SIPOCSPECCODE:JWC-002*BlackBeltCHAMPIONMBB总经理AW/MOQCBW/MTECHCW/MIQC□ProcessMapping□NoiseTest□SPCSystem□整机噪音研讨及验证□ProcessMapping□单品噪音研讨及验证□SPCSystem□业体访问及指导EW/MOQC□改善方案研讨及验证□SPCSystemDW/MR&D□单品噪音研讨及验证□业体访问及指导支援者KDefineMAPhaseImproveControl’04.0404.1604050607D◆TEAM◆SCHEDULEDPJT番号PJT名ChampionPJTTeamBB/MBB指标项目σ水准计财务成果PJT计划开始日DefineMeasureAnalyzeImproveControlFinish选题背景问题记述AUTOW/M噪音不良改善GM。PULSATORW/MNOISE现水准指标目标水准σ水准指标σ水准2.54.0004.04.1004.04.1604.04.3004.05.1504.06.1504.07.1504.07.30-噪音不良2004年3月CAR的故障类的Worst-1，非故障类的Worst-2。是需要长期改善的顽固不良。-与TEAM员每周2次推进现况会议，每次会议时间不超过30分钟。-业体+厂内预装+厂内组立。-噪音测试CPK0.46，SigmaLevel2.5Sigma（1M~3M噪音测试分贝数)。SigmaLevel达成4Sigma(含异音不良)。123运营计划目标记述PJT范围◆Project实行计划MM◆BASELINE&COPQTarget4SigmaLevelCOPQ财务效果返工费用96KCNY计算方法返工费用=12个月*每月平均次数*每回返工平均费用非财务效果降低市场故障类和非故障类,提高CompanyBRANDIMAGE.4547495153555759LSLUSLProcessCapabilityAnalysisforautonoiseUSLTargetLSLMeanSampleNStDev(Within)StDev(Overall)CpCPUCPLCpkCpmPpPPUPPLPpkPPMLSLPPMUSLPPMTotalPPMLSLPPMUSLPPMTotalPPMLSLPPMUSLPPMTotal55.0000*45.000051.6362341.965632.334640.850.571.130.57*0.710.480.950.480.0058823.5358823.53367.6043511.0443878.642238.1574815.8677054.01ProcessDataPotential(Within)CapabilityOverallCapabilityObservedPerformanceExp.WithinPerformanceExp.OverallPerformanceWithinOverall2.9252SIGMAMSA：由于设备是每年国家机关进行校验所以不进行MSA。M◆DETAILPROCESSMAPINPUTSOUTPUTS•CHECKSHEET,作业指导书•箱体•ASSYDAMPER•DAMPER涂胶机•LABEL,SCREW,BOLT,SADDLE等附件•外桶及相关附件•内桶及相关附件•C/P,TOPCOVER,LIDT.C等•I/W测试仪,功率仪,接地测试仪,偏心GAGE等•BOX,LABEL,BAG,PPBEND等包装物•良品洗衣机•体感异常噪音•振动数据•噪音测试数据START部品运输到厂DAMPERGREASE涂布TUBASSY作业ASSYFRAME投入输入检查NGOK工程检查OKNGC/P&T/C&LIDT.C组立AARETURN包装入库修理FRAMEPRESS&BENDING&RIVETINGDAMPERASSY出厂抽检测dBOKOKNG返机M◆洗衣机构造顶部结构箱体结构外桶结构内桶结构M◆CE-DIAGRAM内桶BUSH高度BEARING噪音NOISE箱体外桶顶部COVERT.CCONTROLPANELLIDT.CTOPCOVER线束整理异物橡胶变形内桶PULSATORFLANGE导水板桶圈尺寸平整度圆度GAP尺寸平整度ASSY后同心度内径尺寸整体高度厚度平面度安装孔尺寸紧固力线束整理SHAFTMOTORBELT底板OUTTUB张力异物固定孔平面度外桶孔尺寸BEARINGBEND噪音PULLY变形线束夹位置线捆扎处理异物尺寸SHAFT组装孔PULLY变形SCREW禁固ENDPLAY气隙电磁音矽钢片层叠ROTOR尺寸单品压入底座平整度尺寸CORNER材料SCREW紧固力FRAME上部折弯高度材料LEG相对BASE松紧度橡胶硬度GREASE材料均匀度DAMPERSPRINGK异物DAMPER力长度作业SPECGREASE涂布作业BELTGAGE使用CASE内壁磨擦内壁直径S/A硬度直径方法GAGE点检M◆FDMFDM结果：重要因子为—DAMPERGREASE，DAMPING力，DAMPER长度，FRAME左右高度，电机，LEG橡胶硬度，BELT张力。M◆FMEA输出变量Y输入变量X区分备注AUTOW/MNOISEDAMPERGREASESOPDAMPER力XNEXTGBPJT推进DAMPER力关联的分析和改善DAMPER长度XFRAME左右高度X电机(A阶段再细部分析)X作为GBPJT推进中，现水准为42dB–目标为39dB。所以不作为APHASE分析因子LEG橡胶硬度XBELT张力SOPM◆MPHASE重要X’SA◆APHASE要分析X’SLIST输入变量X区分规格备注DAMPERGREASESOP无GREASE流挂，遗漏，误适用。DAMPER力X1050~2000gDAMPER长度X520+0/-1.2mmFRAME左右高度X无分析后设定SPEC电机X45dB作为GBPJT推进中，现水准为42dB–目标为39dB。所以不作为APHASE分析因子LEG橡胶硬度X70+5/-5°BELT张力SOP60~62mmMODEL别BELT张力不一样A◆DATA收集PLANRef假设检定内容归属/对立假设ToolsToBeUsedDATA收集H0H1DataTypeSampleSizeWhoWillCollectDataHowWillDataBeReCorded1DAMPERGREASE没有影响有影响2SampleT计量型10EA许桦纪录表2DAMPER力没有影响有影响2SampleT计量型10EA宣云祥纪录表3DAMPER长度没有影响有影响2SampleT计量型10EA宣云祥纪录表4FRAME左右高度没有影响有影响2SampleT计量型10EA许桦纪录表5LEG橡胶硬度没有影响有影响2SampleT计量型10EA宣云祥纪录表6BELT张力没有影响有影响2SampleT计量型10EA许桦纪录表A◆ANALYSE1Average:56.06StDev:1.20388N:10Anderson-DarlingNormalityTestA-Squared:0.233P-Value:0.7245455565758.001.01.05.20.50.80.95.99.999Probabilitya1NormalProbabilityPlotP-Value:0.411A-Squared:0.343Anderson-DarlingNormalityTestN:10StDev:1.30792Average:51.4253525150.999.99.95.80.50.20.05.01.001Probabilitya2NormalProbabilityPlotTwo-SampleT-TestandCI:a1,a2Two-sampleTfora1vsa2NMeanStDevSEMeana11056.061.200.38a21051.421.310.41Difference=mua1-mua2Estimatefordifference:4.64095%CIfordifference:(3.454,5.826)T-Testofdifference=0(vsnot=):T-Value=8.25P-Value=0.000DF=17P-VALUE=0.000＜0.05，因此抛弃H0,所以不能说DAMPERGREASE对噪音没有影响。A◆ANALYSE2P-Value:0.875A-Squared:0.186Anderson-DarlingNormalityTestN:10StDev:0.980703Average:51.7853.252.251.250.2.999.99.95.80.50.20.05.01.001Probabilityb1NormalProbabilityPlotP-Value:0.790A-Squared:0.215Anderson-DarlingNormalityTestN:10StDev:0.583476Average:56.3457.056.556.055.5.999.99.95.80.50.20.05.01.001Probabilityb2NormalProbabilityPlotTwo-sampleTforb1vsb2NMeanStDevSEMeanb11051.7800.9810.31b21056.3400.5830.