六西格玛绿带报告.pptx
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六西格玛绿带报告.pptx
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p1六西格玛绿带报告六西格玛绿带报告-Reduceshieldscrapp2Reduceshieldscrapfrom10%to5%by50%.p3SixSigma项目摘要说明项目摘要说明p4项目说明DMAICp5项目选择矩阵931939399Reduce70%FCCdistortion389393999999Reduce50%Shieldscrap(Thebiggestsaving)483931339399减少10%JT4platformshieldQPA347311133399减少5%JT5PST坏品265311339399减少5%JK0654219NL断线返工32193393939975耐压优化70%39934576771010weightitemsTotal是否可以改善70%?
项目范围可管理(4-6个月?
)头一年的节省是否可达到至少NT$200万样本可被使此项目?
是否有适当的团队组合与人选历史与现有资料易收集取得?
可以被测量吗?
主管,顾客,供应商赞同对顾客满意的影响是否与公司的目标或面临的挑战相关项目选择优先度改善程度项目范围项目目标移植范例资源与支持资料易取性关系人赞同顾客影响企业策略绿色表格内输入关系强度(9,3,1)p6项目选择Shield20.2%costItemShieldHeaderFCCPCBLeadframeHousingCoilLEDSiliconeSolderwireTotalMaterialcost3.27$2.83$1.81$1.81$1.69$1.51$1.24$0.37$0.29$0.14$16.16$Materialcost/Totalmaterialcost20.2%37.7%48.9%60.1%70.5%79.8%87.5%89.8%91.6%92.5%$-$0.50$1.00$1.50$2.00$2.50$3.00$3.50ShieldHeaderFCCPCBLeadframeHousingCoilLEDSiliconeSolderwire0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%CostRatep7客户需求分析DMAICp8客户需求分析DMAICp9Problemstatement(问题陈述)10%FG铁壳检查不合格导致返工及铁壳报废.(10%shieldofFGvisualinspectionfailedleadtoreworkandshieldscrap)DMAIC铁壳A级面刮花铁壳B级面刮花铁壳C级面污染p10Projectscope(项目范围)DDMMAAIICCPROCESSPROCESS主要活动工程主要活动工程(mainengineeringactivities)(mainengineeringactivities)NextNextCCCC铁壳铁壳供应商供应商铁壳及待铁壳及待装铁壳的成品装铁壳的成品铁壳装配铁壳装配装铁壳装铁壳的成品的成品成品成品QAQA检验检验CTQCTQSSupplierSupplierIInputInputPProcessProcessOOutputOutputCCustomerCustomerStopStopStopStopStartStartStartStart铁壳铁壳印字印字,浸锡浸锡铁壳铁壳装配装配,焊接焊接返工返工成品测试成品测试外观检查外观检查成品成品包装包装PASSPASSFAILFAILp11Measurementindexandgoal(测量指针和目标)测量指标(Measurestandard):
QA-125数据收集点(Datacollectionpoint):
铁壳来料铁壳来料(Incomingmaterial);铁壳印字铁壳印字(Shieldmarking);铁壳浸锡铁壳浸锡(Dippingshield);铁壳装配铁壳装配(Shieldassembly);铁壳焊接铁壳焊接(Handsolderingshield);成品测试成品测试(FGtest);成品外观检查成品外观检查(FGvisualinspection).目标(Target):
Reduceshieldscrapfrom10%to5%by50%.DMAICp12Projectplan(项目计划)DMAICwk01wk02wk03wk04wk05wk06wk07wk08wk09wk10wk11wk12wk13wk14wk15wk16wk17wk18wk19wk20wk21wk22选定项目选定项目全体成员全体成员项目章程明确项目章程明确全体成员全体成员测量指标及目标制定测量指标及目标制定全体成员全体成员项目计划及分工项目计划及分工全体成员全体成员流程图绘制及分析流程图绘制及分析全体成员全体成员FMEA制作分析制作分析MSA分析分析控制图分析控制图分析统计检定分析统计检定分析要因确认要因确认改善改善改善确认改善确认FMEA更新更新人员训练人员训练报告整理报告整理3月4月5月1月项目项目责任人责任人2月预计实际p13M阶段(MeasureStage)DMAICp14输出部份的测量系统能力说明不合格产品不合格外观不合格电性DMAICp15MSA的分析结果DMAICp16MSA结果分析一电性电性测试设备选择:
测试数据相差2%判断为不稳定DMAIC4284testerpreferredFirstSecondThirdFirstSecondThirdFirstSecondThird1Passokokokokokokokokok2Passokokokokokokokokok3Passokokokokokokokokok4Passokokokokokokokokok5PassokokokNookNoNoNoNo6Passokokokokokokokokok7Passokokokokokokokokok8Passokokokokokokokokok9Passokokokokokokokokok10Passokokokokokokokokok11Passokokokokokokokokok12PassNoNoNoNoNoNoNoNoNo13Passokokokokokokokokok14Passokokokokokokokokok15Passokokokokokokokokok16Passokokokokokokokokok17Passokokokokokokokokok18Passokokokokokokokokok19PassokokokokNoNookNoNo20Passokokokokokokokokok21Passokokokokokokokokok22PassokokokokokokNoNook23Passokokokokokokokokok24Passokokokokokokokokok25Passokokokokokokokokok96.00%96.00%96.00%92.00%92.00%88.00%88.00%84.00%88.00%TotalTester100%passsample428428184263BSamplep17MSA结果分析一电性DMAIC利用minitab做出相应的各项结果.(Usingminitabanalysiseachresult)评估一致性#检#相95%置信区验数符数百分比间252184.00(63.92,95.46)测量系统不可接受(Measuresystemofpresentisunacceptable),所有检验员与标准仅84.00%一致,90%.32110095908580757065测测试试仪仪百百分分比比95.0%置信区间百分比32110095908580757065测测试试仪仪百百分分比比95.0%置信区间百分比研究日期:
报表人:
产品名称:
其他:
评评估估一一致致性性测测试试仪仪自自身身测测试试仪仪与与标标准准p18MSA结果分析一电性电性(计数型)的R&R分析:
DMAIC2.4%electricityfailureRework?
CanbereworkFailuremodeCWWOpenHipotDCROCLFailure%1.0%0.5%0.5%0.2%0.2%2.4%Failurerate/Totalfailurerate41.67%62.50%83.33%91.67%100.00%Dontrework0.0%0.2%0.4%0.6%0.8%1.0%1.2%CWWOpenHipotDCROCL0.00%20.00%40.00%60.00%80.00%100.00%120.00%Series2Series1p19MSA结果分析二外观从生产线抽取三个外观检查人员(Choosingthreevisualinspectionoperatorfromproduct-line),对随机编号的30个外观样品(15个pass,15个fail)进行第一次检查;然后重新编号后进行第二次检查(eachoperatorinspecttwotimesfor30samples).获得180个数据如下:
DMIC第一次第一次第二次第二次第一次第一次第二次第二次第一次第一次第二次第二次1#1#passpasspasspasspasspasspasspasspasspasspasspasspasspass2#2#passpasspasspasspasspasspasspasspasspasspasspasspasspass3#3#passpasspasspasspasspasspasspasspasspasspasspasspasspass4#4#passpasspasspasspasspasspasspasspasspasspasspasspasspass5#5#passpassfailfailfailfailpasspasspasspassfailfailpasspass6#6#failfailfailfailfailfailfailfailfailfailfailfailfailfail7#7#failfailfailfailfailfailfailfailfailfailfailfailfailfail8#8#passpasspasspasspasspasspasspasspasspasspasspasspasspass9#9#passpasspasspasspasspasspasspasspasspasspasspasspasspass10#10#failfailfailfailfailfailfailfailfailfailfailfailfailfail11#11#failfailfailfailfailfailfailfailfailfailfailfailfailfail12#12#passpassfailfailfailfailpasspasspasspasspasspasspasspass13#13#passpasspasspasspasspasspasspasspasspasspasspasspasspass14#14#passpasspasspasspasspasspasspasspasspasspasspasspasspass15#15#failfailfailfailfailfailfailfailfailfailfailfailfailfail16#16#failfailfailfailfailfailfailfailfailfailfailfailfailfail17#17#failfailfailfailfailfailfailfailfailfailfailfailfailfail18#18#failfailfailfailfailfailfailfailfailfailfailfailfailfail19#19#passpasspasspasspasspasspasspasspasspasspasspasspasspass20#20#passpasspasspasspasspasspasspasspasspasspasspasspasspass21#21#failfailpasspasspasspassfailfailfailfailpasspassfailfail22#22#failfailpasspasspasspassfailfailfailfailfailfailfailfail23#23#failfailfailfailfailfailfailfailfailfailfailfailfailfail24#24#failfailfailfailfailfailfailfailfailfailfailfailfailfail25#25#passpasspasspasspasspasspasspasspasspasspasspasspasspass26#26#passpasspasspasspasspasspasspasspasspasspasspasspasspass27#27#failfailfailfailfailfailfailfailfailfailfailfailfailfail28#28#failfailfailfailfailfailfailfailfailfailfailfailfailfail29#29#failfailfailfailfailfailfailfailfailfailfailfailfailfail30#30#passpasspasspasspasspasspasspasspasspasspasspasspasspass检查员3检查员3样品样品标准标准检查员1检查员1检查员2检查员2p20MSA结果分析二外观DMIC利用minitab做出相应的各项结果.所有检验员与标准所有检验员与标准评估一致性#检#相95%置信区验数符数百分比间302686.67(69.28,96.24)测量系统不可接受(Measuresystemofpresentisunacceptable),所有检验员与标准仅86.67%一致,90%.321100959085检检验验员员百百分分比比95.0%置信区间百分比321100959085检检验验员员百百分分比比95.0%置信区间百分比研究日期:
报表人:
产品名称:
其他:
评评估估一一致致性性检检验验员员自自身身检检验验员员与与标标准准p23CTQ现状从生产线每批抽100个产品(Extracting100samplesfromproduct-lineperbatch),不合格数如下(failedquantityasbelow):
DMAIC批次(Batch)不合格品(Failed)批次(Batch)不合格品(Failed)批次(Batch)不合格品(Failed)131132102112122330132232431432435315325369165261731732738618328893190293101203300p24CTQ现状DMAIC制程是不稳定的,目前的DPU=0.028(Theprocessisnotstable)282522191613107410.0750.0500.0250.000样样本本每每单单位位样样本本计计数数_U=0.028UCL=0.0782LCL=0302520151050.0350.0300.0250.0200.015样样本本DDPPUU均值缺陷:
2.8000置信区间下限:
2.2334置信区间上限:
3.4666DPU均值:
0.0280置信区间下限:
0.0223置信区间上限:
0.0347最小DPU:
0.0000最大DPU:
0.0900目标DPU:
0.0000(95.0%置信)摘要统计10507.55.02.50.0观观测测缺缺陷陷期期望望缺缺陷陷0.080.060.040.020.001612840DDPPUU频频率率Tar11不不合合格格品品的的PPooiissssoonn能能力力分分析析UU控控制制图图累累积积DDPPUUPPooiissssoonn图图直直方方图图p25CTQ流程图(CTQflow-chart)InputTypeProcessOutput锡炉温度锡炉温度浸锡时间浸锡时间助焊剂助焊剂浸锡质浸锡质量量员工操员工操作作装铁壳装铁壳铁壳浸锡铁壳浸锡InputTypeProcessOutputCCCCCCCCCCCCCCCCCC外观检查外观检查烙铁温度烙铁温度焊接时间焊接时间加锡方法加锡方法助焊剂助焊剂焊锡夹具焊锡夹具包装物料包装物料包装方法包装方法CCCC产品包装产品包装电性测试电性测试焊铁壳后窗焊铁壳后窗口口焊锡质量焊锡质量员工取放产员工取放产品的动作品的动作测试架测试架员工操作员工操作试脚位试脚位脚位板脚位板员工操作员工操作产品脚位产品脚位质量质量CCCCCCNNNN铁壳印字铁壳印字(Markingshield)铁壳外铁壳外观观电性质量电性质量产品表产品表面质量面质量包装质量包装质量铁壳来料不良铁壳来料不良(Poor(Poorincomingmaterial)incomingmaterial)铁壳印字铁壳印字方法方法(The(Themethodofmarking)methodofmarking)CCCC印字质量印字质量(The(Thequalityofqualityofmarking)marking)DMAICp26A-分析阶段(Analysisstage)p27鱼骨图(Fishbone)DMAICp28柏拉图DMAICC21125623158百分比52.326.210.77.03.7累积%52.378.589.396.3100.0C1其他脚仔露铜焊锡不良测试返工铁壳刮花200150100500100806040200CC22百百分分比比铁铁壳壳报报废废的的PPaarreettoo图图p29C&E矩阵DMAIC从15个输入因子中进行降序排列,按2/8法则从中筛选出了9个影响顾客不良的输入因子,下一步将对该9个重要的输入因子再进行FMEA,进一步找出最关键的输入因子.(Choosing9factorsfrominputfactors)结论结论(Con(Conclusclusion)ion)9999333311223344铁壳表面划伤铁壳表面划伤测试不良测试不良焊锡不良焊锡不良脚仔露铜脚仔露铜1212电性测试电性测试测试方式测试方式3399003311711777焊后窗口焊后窗口烙铁温度烙铁温度0099990010810888焊后窗口焊后窗口焊接时间焊接时间009999001081081111电性测试电性测试员工操作员工操作99110033999911铁壳印字铁壳印字铁壳品牌铁壳品牌99003300909066装铁壳装铁壳员工操作员工操作9900000081811010焊后窗口焊后窗口焊锡夹具焊锡夹具9900000081811313外观检查外观检查员工操作员工操作9900000081811414试脚位试脚位员工操作员工操作33000099545499焊后窗口焊后窗口加锡方法加锡方法0033330036361515试脚位试脚位脚位板脚位板11000099363622铁壳印字铁壳印字印字方法印字方法33000000272733铁壳浸锡铁壳浸锡锡炉温度锡炉温度000033009955铁壳浸锡铁壳浸锡助焊剂助焊剂000033009944铁壳浸锡铁壳浸锡浸锡时间浸锡时间0000330099No.No.总分总分工序(Procedure)工序(Procedure)输入(Input)输入(Input)p30FMEA分析利用FMEA分析9个重要的输入因子,进一步找出最关键的输入因子DMAIC通过该9个重要的输入因子进行FMEA,进一步找出最关键的输入因子2个:
铁壳品牌和测试方式.(ThroughFMEAanalysis9keyinputfactors,furtherfindoutthemostcriticalfactors:
Supplierofshieldandtestmethod.)结结论论MicrosoftExcelWorksheetp31可能的X因子的分析和确认DMAICp32因子一的验证DMAIC双比率检验和置信区间双比率检验和置信区间样本XN样本p182000.0400002222000.110000差值=p
(1)-p
(2)差值估计:
-0.07差值的95%置信区间:
(-0.121166,-0.0188341)差值=0(与0)的检验:
Z=-2.68P值=0.007Fisher精确检验:
P值=0.012P值=0.012,小于=0.05,结果与铁壳品牌有关系.p33因子二的验证DMAIC双比率检验和置信区间双比率检验和置信区间样本XN样本p1303000.1000002153000.050000差值=p
(1)-p
(2)差值估计:
0.05差值的95%置信区间:
(0.00803968,0.0919603)差值=0(与0)的检验:
Z=2.34P值=0.020Fisher精确检验:
P值=0.029P值=0.029,小于=0.05,结果与测试方式有关系.p34分析阶段的结论DMAICp35I阶段(Improvementstage)p36DOE实验DMAIC标准序标准序运行序运行序中心点中心点区组区组TesterTesterShieldShieldTrayTrayResultResult2111CHECKSUMWINGCHEONGBluetray68.00%7211PTTCOM-TECHBlacktray98.00%3311PTTCOM-TECHBluetray87.00%4411CHECKSUMCOM-TECHBluetray80.00%8511CHECKSUMCOM-TECHBlacktray95.00%6611CHECKSUMWINGCHEONGBlacktray92.00%5711PTTWINGCHEONGBlacktray97.00%1811PTTWINGCHEONGBluetray82.00%因子类型水平数值Tester固定2-1/CHECKSUM,1/PTTShield固定2-1/WINGCHEONG,1/COMTECHTray固定2-1/Bluetray,1/Blacktrayp37DOE效应正态图DMAIC0.200.150.100.050.00-0.05-0.10999590807060504030201051效效应应百百分分比比ATesterBShieldCTray因子名称不显著显著效应类型效效应应的的正正态态图图(响应为Result,Alpha=.05)Lenth
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