SigmaKaizenAnalyzeImproveControl

1Preparedby:VitJiangDate:Jul27,2011西格玛改善分析/改善/控制SigmaKaizenAnalyze/Improve/Control2目标Objectives利用各种图形工具,分析显示数据结果Usedifferentgraphicaltoolstodisplayandanalyzedataandinterprettheresults进行假设性试验,排除解释的可能Implementhypothesistestingasameanstoruleoutchanceasanexplanation确定原因“X”是否为必然的Determineifacause“X”issignificant量化“X”与“Y”之关系Quantifytherelationshipbetweenthe“X”andthe“Y”根据数据类型,决定测试方法Determinewhichteststoapplydependantonthedataworld如果存在关系,找出线性模型,对“Y”作出预测Obtainalinearmodeltopredictthe“Y”ifacorrelationexists3找出不良品DeterminetheDefectY制定流程表现EstablishProcessPerformanceY评审测量系统EvaluateMeasurementSystemY评审标准化操作EvaluateStandardOperationsY识别根本原因IdentifyRootCausesX’s提出解决方案DevelopSolutionsX’s排列及实施解决方案Prioritize&ImplementSolutions关键的少数XVitalFewX’s测试解决方案,验证结果TestSolutions&VerifyResults关键的少数XVitalFewX’s完善标准化操作RefineStandardOperations关键的少数XVitalFewX’s验证测量系统ValidateMeasurementSystem关键的少数XVitalFewX’s实施控制系统及评审计划ImplementControlSystem&AuditPlan关键的少数XVitalFewX’s确定制程能力DetermineProcessCapabilityY测量Measure分析Analyze改善Improve控制Control精益西格玛项目阶段LeanSigmaProjectPhases4•精益西格玛回顾LeanSigmaOverview•改善突破法KaizenBreakthroughMethodology•精益西格玛测量工具LeanSigmaMeasureTools•识别缺陷、“Y”及项目范围Identifydefect,“Y”,&projectscope•观察流程,收集现场及历史资料ObserveProcess&CollectLive&HistoricalData•详细的现场行走示意图EnhancedSpaghettiMap•质量图QualityMap•验证标准化操作VerifyStandardOperations培训&范围Training&Scope•确定制程能力DetermineProcessCapability•测量系统分析MeasurementSystemAnalysis•必要时,改善测量系统Improvemeasurementsystem,ifnecessary•快速解决Quickkills•比较分析ComparativeAnalysis•基本质量工具BasicQualityTools•因果图Cause&EffectChart•必要时,收集资料GatherAdditionalDataifRequired•测量阶段的演示PresentationofMeasurePhase项目实施ProjectImplementation测量阶段–为期5天的改善活动MeasurePhase–5dayKaizen第5天Day5第4天Day4第3天Day3第2天Day2第1天Day1传授&行动Teach&Do传授&行动Teach&Do传授&行动Teach&Do5项目实施ProjectImplementation分析/改善阶段–为期5天的改善活动Analyze/Improve–5dayKaizen第5天Day5第4天Day4第3天Day3第2天Day2第1天Day1培训&范围Training&Scope传授&行动Teach&Do传授&行动Teach&Do传授&行动Teach&Do•分析/改善阶段的演示PresentationofAnalyze/ImprovePhase•精益西格玛测量回顾LeanSigmaMeasureReview•用另外收集的数据更新资料UpdateInformationw/AdditionalDataCollection•精益西格玛分析/改善工具LeanSigmaAnalyze/ImproveTools•基本分析工具BasicAnalyticalTools•假设性试验HypothesisTesting•确定根本原因IdentifyRootCause•现场观察ShopFloorObservations•实施改善ImplementImprovements•防错MistakeProofing•数据收集CollectData•通过假设性试验,验证改善VerifyImprovementsthroughHypothesisTesting•完善标准化操作RefineStandardOperations6项目实施ProjectImplementation控制(30天跟进)Control(30dayfollowup)–改善公报Kaizennewspaper–鉴察使用统计制程控制Monitorusingstatisticalprocesscontrol–鉴察坚持标准化操作Monitoradherencetostandardoperations–借力其它地区Leveragetootherareas–精益西格玛辩论LeanSigmareportout–庆祝项目结束Celebrate7根本原因RootCause(s)质量工具/假设性试验QualityToolsHypothesisTesting比较分析ComparativeAnalysis(在鱼骨图上圈出最可能原因)(circlethemostlikelyonthefishbone)因果法Cause&Effect质量系统分析MSA现场行走示意图SpaghettiMap业务流程图BusinessProcessFlowMap根本原因流程RootCauseProcess用数据来证实这些可以解决的少数根本原因Validatesthemanageablefew“root”causeswithdata过滤所有可能原因,找出可以解决的少数原因Filtersallpossiblecausestoamanageablefew识别各种事件及可能原因Identifiesnumerousissuesandpossiblecauses在鱼骨图上写出所有可能原因Allpossiblecausesputonfishbone8象形图Pictogram•在图形上显示缺陷位置Graphicallydisplaysthelocationofthedefects•工人收集资料的最简单工具EasytoolforoperatorstousetocollectdataXXXXXXXXXXXXXXXXX9数据收集表DataCollectionSheets资料收集表是记录及分析资料的一种结构性表格Adatasheetisastructuredformusedtorecordandthenanalyzedata资料收集表DataSheets:•适合进行比较分析,什么缺陷为“是”,什么缺陷为“非”Supportthecomparativeanalysis,whatthedefect“is”and“isnot”•标出与缺陷有关的其它重要资料,例如工人、班次、机器、工夹具及产品型号Tagotherimportantinformationassociatedwiththedefect,i.e.operator,shift,machine,fixture,model•数据标记有助于对数据进行分组并确定必然的“X”Datatagshelpdeterminesignificant“x’s”throughthesubgroupingofdata10日期Date班次Shift时间Time载车号码CarrierNumber工作单号WorkOrder#流程温度RoutingTemp实际温度ActualTemp流程时间RoutingTime实际时间ActualTime零件形式PartType零件代号PartNumber2001-2-2019:05186375940044011401000SW108644-01-0022001-2-2019:05186375940044011401000SW108644-01-0022001-2-2019:05186375940044011401000SW108644-01-0022001-2-2019:4516375940043111401000SW108644-01-0022001-2-2019:4516375940043111401000SW108644-01-0022001-2-2019:4516375940043111401000SW108644-01-0022001-2-20110:2036375940043011401000SW108644-01-0022001-2-20110:2036375940043011401000SW108644-01-0022001-2-20110:2036375940043011401000SW108644-01-0022001-2-20110:2646375546543211401000SW108522-00-0022001-2-20110:3156375546544411401000SW108522-00-0022001-2-20110:3766375546546511401000SW108522-00-0022001-2-20110:4376375546546511401000SW108522-00-0022001-2-20110:49863755465M11401000SW108522-00-0022001-2-20110:55963755465M11401140SW108522-00-0022001-2-20111:01106375546543311401140SW108522-00-0022001-2-20111:0711637554654221140MSW108522-00-0022001-2-20111:2012637554654231140MSW108522-00-0022001-2-20111:4013637554654261140MSW108522-00-0022001-2-20112:051463759MMMMSW108644-01-0022001-2-20112:201764605440420600TOTS108569-00-0442001-2-20112:201764605440420600TOTS108569-00-0442001-2-20112:201764605440420600TOTS108569-00-0442001-2-20112:201764605440420600TOTS108569-00-0442001-2-20112:201764605440420600TOTS108569-00-044数据收集表DataCollectionSheets11推移图RunChart按时间次序显示数据Displaysdataintimeordersequence图上画有数据集平均值M