machine capability study

WorkshopMachineCapabilityLightingShanghaiJanuary2000by:CFTEindhovenandCFTAPACs2machine=s2product-(s2material+s2processsetting+s2rest)PhilipsCFTIndustrialOperationsThebooklet:EquipmentCapabilityEquipmentPerformanceIndicators.“Thisreportdescribesamethodtoestimatethecapabilityofequipmentinthedesignstage.Boththecapabilityandtheefficiencyaretreatedintheory,wherebytheemphasisisontheeffectthattheequipmenttobebuiltwillhaveonthequality(CpandCpk)oftheproductthatmustbemade.Withthephasedapproachgiveninchapter5,thedesignerisofferedatooltomakeacapabilityestimatefortheequipmenttobebuilt,withoutspecialknowledgeofprocessControl.Alsoamethodisgivenofhowtherealisedcapabilityofthedeliveredequipmentcanbeverified.”W.J.J.vandeVenJ.J.M.KipsDevelopmentRealisationBKMRampupProductionGoalBetterQualityofdesign(moreexpensive,longerthroughputtime??)Costofnon-qualityCostReductionofDesignMachine-capability:GOALStatementConfusionFrom:To:Clearly,structuredconsiderationPhilipsCFTIndustrialOperationsMachine-Capability:GOALFrom:To:Motorola:6sigmaCp=2,Cpk=1.5Thinkingintolerances(+/-…mm)Ford:Cpk1.33Thinkinginboth:StdDevandTolerances(Cp=..,Cpk=…)PhilipsCFTIndustrialOperationsMachine-capability:GOALProjectleader,Designer,Peopleinpilotlab:-FromProcessCapabilitytoMachine-Capability-DeterminationofrequiredMachine-tolerancesPeopleindepartmentofEquipmentstart-upandrelease:-Coherencefordiscussionwith:Projectleaders,DesignerandCustomers-MeasuringValues(ExecutingExperiments)PhilipsCFTIndustrialOperationsMachine-Capability•1:Learningandtraininginthisworkshop•2:Usethetheoryinpractice•3:Localfacilitator:Mr…..•4:Assurance(ISO…BEST)PhilipsCFTIndustrialOperationsWorkshopAgenda9.00Introduction9.15Step0:TheoryCp,Cpk,Histogram,Standarddeviation10.306-Stepapproach,FillouttheCapabilityworksheet10.45Step1:Parametersurvey(Examples)Exercise:DeterminationofimportantparametersStep2:DeterminationofStandarddeviationExerciseinmeasuringandputdatainMS-ExcelspreadsheetProcessingmeasuredatawithCQM_EfPExceladd-in;DemonstrationdataanalysiswithhistogramExercisewithmeasuredataingroupsof3persons12.00Lunch13:00Step3:SimpleimprovementofcapabilityStep4:AnalysisofmachineandprocessdeviationExercisewithCapabilityToolinExcelStep5enstep6Discussionandexamples15:00MeasuringSystemEvaluation15.45ClosureandevaluationofworkshopPhilipsCFTIndustrialOperationsWorkshopMachineCapabilityObjectivesfortheworkshop:•Tobeabletochangethemindsettingfromtolerancesonlytotolerancesandstandarddeviations(Cp..Cpk)•UnderstandingthesixphasedapproachforcalculatingMachineCapabilityandhavingtheabilitytoworkoutanapplicationinateam•Havetheabilitytomakeanestimateoftheinfluenceofmaterial,processsettingandequipmentonthestandarddeviationofproductparameters.PhilipsCFTIndustrialOperationsTrendinprocesscontrolProcesscontrolDesigncontrol-AQL-Cp2.00-6s-FordTQE-FordQ1-Cp1.33-PQA%ppmppblevelofscrapTimeProductcontrolAQL:AcceptablequalitylevelPQA:PhilipsQualityAwardTQE:TotalQualityExcellencePhilipsCFTIndustrialOperationsThinkingintolerancesTraditional:Measuringmanyproductsandsubsequentlyjudgetheabsolutevalue(whichoneiswithintoleranceandwhichoneliesoutoftolerance)ThinkinginvariationandtolerancesNowadayswithCpk1.33:Measuringsmallsamplesofprocessparametersandjudgevariation(PredictHOWGOODtheproductsarewithintolerance)PhilipsCFTIndustrialOperationsPhasedapproachPhase0.TheoryofcapabilitiesandworkshopPhase1.OverviewofcriticalparametersPhase2.DeterminingthespreadPhase3.ImprovingthecriticalparametersPhase4.GettingthecapabilitiesuptolevelPhase5.VerifyingequipmentcapabilityPhase6.Product,Material,ProcessesandEquipmentPhilipsCFTIndustrialOperationsStep0-UnderstandingCapability•Calculations:–average,standarddeviation,ranges•Histogram,Gaußiancurve•Specification:–nominalvalue,upperlimitandlowerlimit•CpenCpkPhilipsCFTIndustrialOperationsAverageandStdDev1.Average:Addthevaluesofthemeasurementsanddividethesumbythenumberofvalues2.Squareofdifference:Subtractthecalculatedaveragefromeachindividualmeasurement;raiseeachdifferencetothesquare3.Averagesquare:AddallthesquaresofthedifferenceDividesumofsquaresbynumberofvaluesminusone(n-1)4.StandardDeviation:Takethesquarerootfromtheaveragesquare;ThisistheStandardDeviationofthesample.PhilipsCFTIndustrialOperationsExample:AverageandStdDevofsamplevalueaveragedifferencefromaveragesquareofdifference1215.5-3.512.251815.52.56.251515.5-0.50.251715.51.52.25samplesize:numberofvaluesn4averageofvalueswithinsamplex15.5spread(range):maximun-minimum6sumofsquarsofdifferences:21averagesquare:dividesumbyn-17standarddeviation(StdDev):squarerootofaveragesquares2.65PhilipsCFTIndustrialOperationsExercise#1:AverageandStdDevvalueaveragedifferencefromaveragesquareofdifference8257samplesize:numberofvaluesnaverageofvalueswithinsample:xspread(range):maximun-minimumsumofsquarsofdifferences:averagesquare:dividesumbyn-1standarddeviation(StdDev):squarerootaveragesquaresPhilipsCFTIndustrialOperationsExercise#2:AverageandStdDevvalueaveragedifferencefromaveragesquareofdifference31557samplesize:numberofvaluesnaverageofvalueswithinsample:xspread(rang