SPC培训--夜雨西窗

CPK,SPC,GR&R&Correlation regressionHoward LinMay,11,2005目目 錄錄1.封面封面.(Page1)2.目錄目錄.(Page2)3.SPC基本概念基本概念.(Page3)4.SPC統計制程管制統計制程管制 4.1 Cpk.(Page445)4.2 QC舊七大手法.(Page4681)4.3 管制圖.(Page8294)5.相關回歸相關回歸.(Page9598)6.GR&R.(Page99 115)3.SPC-Statistical Process Control-統計制程管制統計制程管制1.SPC的焦點:制制 程程2.制程變異:(變異並非全是壞事)2.1機遇原因(共同原因)2.2非機遇原因(特殊原因)3.數據:制程取得的有用信息.4.統計:數據通過計算產生有意義的情報.5.SPC所使用的主要工具:5.1 Cpk 5.2七大手法 .管制圖6.計算:對數據進行處理的過程4.1Cpk制程能力分析常態分配.718.2)(.21)(222edxxxfekk通常寫為XN(:2):常態分配的中心值(MeanMean)2：常態分配的變異（VarianceVariance）:常態分配的標準差(Standard Deviation)常態分配特性(1)曲線與橫軸所圍的面積為1;(2)以為中心呈對稱性分布;(3)變異2代表分配函數的離散程度 如圖1所示,具有相同的二個常態分 配(a)與(b),(a)的離散程度比(b)小,即 2 a2b,所以常態分配(a)大多數 的點傾向於集中的附近.圖1(a)2 a(b)2 b-3-2-1-41234PERCENTAGES OF THE NORMAL DISTRIBUTION管制圖與常態分配管制圖與常態分配+k X值在+k與-k之間之或然率(Probability)或稱機率如右圖.以圖中斜線部分表示,其公式為:群 體平均值=標準差=x-k群體(制程)與樣本間之關系x)(xEnX分配之期望值分配之標準差x設 為樣本平均,為群體平均S=S為樣本標準差為群體標準差在統計學上x101Nn101NnnNnNX.11NnN注:如 可視為無限群體用式(3)為有限群體之修正系數設系有限數群體而 則 分配之標準差xniinsXXnn1211)(1*nXXinis12)(2143樣本平均值之分配x群體平均值之分配nX(無限群體)Cpk Vs Defective YieldCpk Vs Defective Yield 我們常用產品品質特性的常態分配與規格相比較,以決定產品的不良率.如右圖所示產品品質特性的常態分配.規格上限:USL (Upper Specification Limit)規格下限:LSL (Lower Specification Limit)落在規格上,下限外的斜線面積即為產品的不良率.LSLUSL-3-2-1+3+2+168.27%95.45%99.73%0.135%0.135%Standard Deviation from meanC C p pk k V V a al lu ue eD D e ef fe ec ct ti iv ve eY Y i ie el ld dD D i is st tr ri ib bu ut ti io on n12700ppm99.73%+/-3 Sigm a1.3363ppm99.9937%+/-4 Sigm a1.670.57ppm99.999943%+/-5 Sigm a2.000.002ppm99.9999998%+/-6 Sigm a目前在品管里常注重制程的分散寬度,故有定義制程能力為下式者:群體標準差每不易直接求得一般以樣本資料推定之,其推定方法有下列三式:(1)直接由樣本特性值計算時(2)由次數分配表計算時(3)管制圖計算時一般均采用公式(3)制程能力的數量表示法制程能力的數量表示法1.分散寬度以 表示之.VdR6,6,62制程能力=(或 )66RX 1)(22nnXXi1)(22fffufu2dRd2Cpk 計算時用公式(1)管制界限損失第二種錯誤第一種錯誤兩種錯誤總和134562兩種錯誤之經濟平衡點Break even point,BEP 通常,在管制圖使中會有兩種錯(ERROR).第一種即是當制程仍屬管制狀態,但卻因隨機性原因點落於管制界限外時,為了尋找不存在之問題而導致成本增加.第二種即是當制程已失去管制,但數據點由於隨機問題仍落於管制界限內,因而誤判制程處於管制狀態,因而造成更大之損失.YESNOYESNOACCURACY(準確度)PRECISION(精密度)The Accuracy of an instrument can be improved by recalibrating to reduce its error,but recalibrating generally does not improve the instruments Precision.(Repeatability also sometimes known as“Precision”)T/2Ca(制程準確度)Tux Ca:(Capability of accuracy)從生產過程中所獲得的資料其實際平均值()與規格中心值()之間偏差的程度X%規格容許差規格中心實績中心 Ca%2/)(TX 12.50%25%50%100%A級B級C級D級X(實績)規格中心值規格上限或下限X(實績)X(實績)等級A 12.5%B12.5%25%C 25%50%D 50%Ca 值CaCaCaCaCa之處置原則A級:維持原則B級:改進為A級C級:立即檢討改善D級:采取緊急措施,全面檢討,必要時停止生產.Cp(制程精密度)TCp:(Capability of precison)以規格公差(T)與生產中所獲得的6個估計實績標準差()其間相差的程度63規格公差規格容許差Cp雙邊 X-SL 3 只有規格下限:Cp=3Su-X 只有規格上限:Cp=單邊6 6B級6 A級Cp=1.331.006C級0.836 D級規格下限SL規格中心規格上限SU等級A1.33 CpBCDCp值1.00 Cp1.330.83 Cp1.00Cp0.83工程能力指數工程能力指數(Cp)之處理之處理T3T3355Cp=1.67Cp=1.33 1.33Cp1.67顯示有足夠之工程力.對規格而言,為正常狀態,應繼續保持.2Cp處理 1.67 Cp,顯示非常有工程能力 雖然有若干製品之標準差很大,但不會出現不良品.1344工程能力指數工程能力指數(Cp)之處理之處理TT3 1.00Cp1.33,顯示工程能力並不充足,但尚且可以.要注意有發生不良品之雇慮,必要時應提升工程之能力.Cp1.00顯示工程能力不足.在這種狀況下會出現不良品.必需藉著作業方法之改善,規格之再檢討,機械設備之改善,來提升工程能力.333Z1=3Cp(1+Ca)由Z1查常態分配表得p1%Z2=3Cp(1-Ca)由Z2查常態分配表得p2%p%=p1%+p2%.即為推定群體超出規格上下之不良率.XSZU1XSZL2 等級 總評P%A P0.44%B 0.44%P1.22%C 1.22%P6.68%D 6.68%P投影片 30或e.g:(例題)今庫存有某圓軸6000支,其品質特性為圓軸之長度,已知其長度母平均=15.7cm,母標準差=0.3cm,試問此6000支,中長度超過16.1cm的約有幾支?Key解題步驟:由已知得:=15.7cm;=0.3cm33.13.04.03.07.151.161XSZU方法一:查標準常態分配表(拉普拉斯表)得Z=-1.33時,對應值為0.0918長度超過16.1cm的支數:6000*0.0918=550.8四舍五入得551支方法二:33.13.07.151.163*3)1(31SuCpCaZ下述步驟與上同,故略制程能力指數CpK綜合Ca與Cp兩值之指數(1)CpK值之計算式有兩種CpCaCpK)1(B.單邊規格時:(2)等級判定 CpK值愈大,品質愈佳.依CpK值 大小分為五級3)(,3)(LUSXXSMinCpK等級A1.33 CpK1.67BCDCpK值1.00 CpK1.330.67 CpK1.00CpK0.67A+1.67 CpKA.雙邊規格時:CpK之處置原則A+:考慮管理的簡單化或成本的降低方法A:維持原狀B:改進為A級C:需全數選別並管理,改善制程D:進行品質改善,探求原因,需要采取緊急對策,並且 重新檢討規格.制程能力與規格之關系制程能力與規格之關系6ABCD ESuSL 或或66代表制程在正常狀態下變化之範圍代表制程在正常狀態下變化之範圍,稱為自然公差稱為自然公差(Natural tolerance)(Natural tolerance)規格上下限之差為規格上下限之差為S Su u-S-SL,L,則則 或或66與與S Su u-S-SL L有下列三種關系有下列三種關系(情況情況)如圖示如圖示:661.6 Su-SL1.6Evaluation formCpkCpk為什麼要大於或等於為什麼要大於或等於1.33?1.33?1.Cp=0.67時,穩態控制下不合格品率為4.6%;2.Cp=1.00時,穩態控制下不合格品率為0.27%;3.Cp=1.33時,穩態控制下不合格品率為0.0063%=63PPM在圖例上表示為中心沒有偏移(實際中心值與規格中心重合)DRLDRRLCLUCL6T=8XYDPPMDR=DRL+DRRDR(Defect Rate):總不良 DRL(Defect Rate Left):左不良 DRR(Defect Rate Right):右不良XLCLUCLDRLDR=DRL+DRRDRRXTable 1 Quality levels and Corresponding Number of DefectsSigmaSigmaCpkCpkDPPMDPPM拼拼拼拼錯錯錯錯字字字字620.002大型圖書館所有書籍中僅一錯字51.670.5742小型圖書館所有書籍中僅一錯字41.3363.37大英百科全書中僅一錯字312,700一本書中每 30 頁僅一錯字20.6745,500一本書中每 1.5 頁僅一錯字10.33317,310一本書中每頁錯 5 個字Table2.The Number of Defective(Parts per Million)for SpecifiedOff-Centering of the Process and Quality Levels中心偏离時dppm的計算off-center()面積面積z常態曲線下之面積常態曲線下之面積dzzzZPzFez2221)()(e=2.718.0Z=(x-)/投影片 161.對設計單位提供基本資料;2.分派工作到機器上;3.用來驗收全新或翻新調整過的設備;4.選用合格的作業員;5.設定生產線的機器;6.根據規格公差設定設備的管制界限;7.當制程能力超越公差時,決定最經濟的作業水準;8.找出最好的作業方法.Version:1.1A.Trial Run Data Collection Sample Size110112021303140415051606170718042.78742.82442.77242.70642.83242.87442.80642.70242.77542.71742.83642.84542.82542.83342.80542.70842.79242.78042.82342.77442.83642.89842.80742.69542.77842.80342.80142.69242.80742.78542.80742.72842.79142.75842.83642.86342.82942.84242.84042.84042.81042.82542.83642.86142.83242.84542.83642.86342.72942.75942.81742.83642.82442.82342.79642.67042.85042.69642.83042.86542.83042.84242.82242.80342.79142.77942.82742.78042.83342.89142.80542.69542.85042.69642.83042.86542.83042.84242.82242.803Calculation=42.804Sigma=0.051Max=42.898Min=42.670(at Design Phase)How to Define Specification&Verify the Process Capability Input Areafor DataItemNo.Quality LevelSpecification FormatLSLUSLDRL(Dppm)DRR(Dppm)DR(Dppm)11 Sigma1 Sigma42.804 42.753 42.855 158655.26 158655.26 317310.5221.5 Sigma1.5 Sigma42.804 42.727 42.88066807.2366807.23 133614.4632 Sigma2 Sigma42.804 42.702 42.90622750.0622750.0645500.1242.5 Sigma2.5 Sigma42.804 42.676 42.9316209.686209.6812419.3653 Sigma3 Sigma42.804 42.650 42.9571349.971349.972699.9363.5 Sigma3.5 Sigma42.804 42.625 42.982232.67232.67465.3574 Sigma4 Sigma42.804 42.599 43.00831.6931.6963.3784.5 Sigma4.5Sigma42.804 42.574 43.0333.403.406.8095 Sigma5 Sigma42.804 42.548 43.0590.2871050.2871050.57105.5 Sigma5.5 Sigma42.804 42.523 43.0840.0190360.0190360.04116 Sigma6 Sigma42.804 42.497 43.1100.000990.000990.00Prepared by:VQM/Xu Gang Approved by:Howard Lin B.Quality Level(For your reference and choosing)TimesQuality LevelNominal T/2()SpecLSLSpecUSLToleranceOff-Center (Sigma)1442.8040.204 42.599 43.0080.4080.002442.7800.204 42.576 42.9840.4080.4634.4642.7800.228 42.552 43.0080.4550.46Ca CpCpKGradeDRL(Dppm)DRR(Dppm)DR(Dppm)0.001.331.33A31.6931.6963.370.121.331.18B4.05202.05206.100.101.491.33A0.4332.0332.46Prepared by:VQM/Xu Gang Approved by:Howard Lin VerificationItemRemark:Green means it can be changed or modified,Yellow means it can not be changed or modified.C.Choose Quality Level and Define SpecificationD.Process Capability Verification231個別值管制圖最大值與最小值管制圖X圖管制界限 管制界限界限系數AA1A2C21/C2B1B2B3B4d21/d2d3D1D2D3D4A3D5D6E2A0m3A2C322.121 3.760 1.8800.56421.77250.000 1.8430.000 3.267 1.1280.88650.853 0.000 3.685 0.000 3.2672.224 0.000 3.8652.6602.6951.880 0.60331.732 2.394 1.0230.72361.38200.000 1.8580.000 2.568 1.6930.59070.888 0.000 4.358 0.000 2.5751.265 0.000 2.7451.7721.8261.187 0.46341.500 1.880 0.7290.79791.25330.000 1.8080.000 2.266 2.0590.48570.880 0.000 4.698 0.000 2.2820.829 0.000 2.3751.4571.5220.796 0.38951.342 1.596 0.5770.84071.18940.000 1.7560.000 2.039 2.3260.42890.864 0.000 4.918 0.000 2.1150.712 0.000 2.1791.2901.3630.691 0.34161.225 1.410 0.4830.85851.15120.026 1.7110.030 1.970 2.5340.39460.348 0.000 5.078 0.000 2.0040.562 0.000 2.0551.1841.2630.549 0.30871.134 1.277 0.4190.88821.12590.105 1.5720.118 1.882 2.7040.36980.333 0.205 5.205 0.076 1.9240.520 0.078 1.9671.1091.1910.509 0.28281.061 1.175 0.3730.90271.10780.167 1.6380.185 1.815 2.8470.35120.820 0.387 5.307 0.136 1.8640.441 0.139 1.9011.0541.1430.432 0.26291.000 1.094 0.3370.91391.09420.219 1.6090.239 1.761 2.9700.33670.808 0.546 5.394 0.184 1.8160.419 0.187 1.8501.0101.1040.412 0.246100.949 1.028 0.3080.92271.08370.262 1.5840.284 1.716 3.0780.32490.797 0.687 5.469 0.223 1.7770.369 0.227 1.8090.9751.0720.363 0.232110.905 0.973 0.2850.93001.07530.299 1.5610.321 1.679 3.1730.31520.787 0.812 5.534 0.256 1.744120.866 0.925 0.2660.93591.06840.331 1.5410.354 1.645 3.2580.30690.778 0.924 5.592 0.284 1.716130.832 0.834 0.2490.94101.06270.359 1.5230.382 1.618 3.3360.29980.770 1.026 5.646 0.308 1.692140.802 0.848 0.2350.94531.05790.384 1.5070.406 1.594 3.4070.29350.762 1.121 5.693 0.329 1.671150.775 0.816 0.2230.94901.05370.406 1.4920.428 1.572 3.4720.28800.755 1.207 5.737 0.348 1.652160.750 0.788 0.2120.95231.05010.427 1.4780.448 1.552 3.5320.28310.749 1.285 5.779 0.364 1.636170.728 0.762 0.2030.95511.04700.445 1.4650.466 1.534 3.5880.27870.743 1.359 5.817 0.379 1.621180.707 0.738 0.1940.95761.04420.461 1.4540.482 1.518 3.6400.27470.738 1.426 5.854 0.392 1.608190.688 0.717 0.1870.95991.04180.477 1.4430.497 1.503 3.6890.27110.733 1.490 5.888 0.404 1.596200.671 0.697 0.1800.96151.03960.491 1.4330.510 1.490 3.7350.26770.729 1.548 5.922 0.414 1.586210.655 0.679 0.1730.96381.03760.504 1.4240.523 1.477 3.7780.26470.724 1.606 5.950 0.425 1.575220.640 0.662 0.1670.96551.03580.516 1.4150.534 1.466 3.8190.26180.720 1.659 5.979 0.434 1.566230.626 0.647 0.1620.96701.03420.527 1.4070.515 1.455 3.8580.25920.716 1.710 6.006 0.443 1.567240.612 0.632 0.1570.96841.03270.538 1.3990.555 1.455 3.8950.25670.712 1.759 6.031 0.452 1.548250.600 0.619 0.1530.96961.03130.548 1.3920.565 1.435 3.9310.25440.709 1.804 6.058 0.459 1.541平均數管制圖中位數管制圖管 制 圖 常 用 系 數 表管 制 圖 常 用 系 數 表管制界限全距管制圖管制界限中線管制界限標準差管制圖中線取樣數n管制界限Return d2X Bar RA2D4Model:Parts Name:Data Source:Measured By:Measure Date:Measured By:ISLVENDORDifferenceUSLLSLMAX0.00000.00000.0000MIN0.00000.00000.0000AVG0.00000.00000.0000STD0.00000.00000.0000Ca-#VALUE!Cp#DIV/0!#DIV/0!#DIV/0!Cpk#DIV/0!#DIV/0!#DIV/0!Grade0.00000.0000DRL%0.00000.00000.0000DRR%0.00000.00000.0000DR%0.00000.00000.000010.000020.000030.000040.000050.000060.000070.000080.000090.0000100.0000110.0000120.0000130.0000140.0000150.0000160.0000RangeFrequency Normal Dist.RangeFrequencyNormal Dist.170.00000.00000#NUM!0.00000#NUM!180.00000.00000#NUM!0.00000#NUM!190.00000.00000#NUM!0.00000#NUM!200.00000.00000#NUM!0.00000#NUM!210.00000.00000#NUM!0.00000#NUM!220.00000.00000#NUM!0.00000#NUM!230.00000.00000#NUM!0.00000#NUM!240.00000.00000#NUM!0.00000#NUM!250.00000.00000#NUM!0.00000#NUM!260.00000.00000#NUM!0.00000#NUM!270.00000.00000#NUM!0.00000#NUM!280.00000.00000#NUM!0.00000#NUM!290.00000.00000#NUM!0.00000#NUM!300.00000.00000#NUM!0.00000#NUM!310.00000.00000#NUM!0.00000#NUM!320.00000.00000#NUM!0.00000#NUM!Measure Method轉換公式轉換公式:(y=bx+a)r a b x=#DIV/0!#DIV/0!#DIV/0!#DIV/0!y=#DIV/0!comments:(P.S.:CP:Caliper;MM:Micrometer;CM:CMM;PJ:Projetor;HG:Height Gauge;PG:Pin Gauge M:螺 紋 規螺 紋 規)Prepared by:曾 如 華曾 如 華Approved by:Howard Lin Ver.2.1a:截距截距 0.8=|R|=0.3 弱相關弱相關b:斜率斜率 0.3=|R|=0 錯相關錯相關相關分析相關分析 Process Capability&Correlation Analysis Worksheet Part Number:Vendor name:Drawing ver:r :相關系數相關系數|R|=0.8 強相關強相關制程能力比較分析表制程能力比較分析表A DataB DataLocationCustomer name:ISL Normal Distribution0001110.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.0000.20.40.60.81Vendor Normal Distribution0001110.000.000.000.000.000.000.000.000.000.000.000.000.000.000.000.0000.20.40.60.81Correlation Illustration0.00000.50001.00001.50000.00000.20000.40000.60000.80001.0000CPK Guidance CPK formula for 90%confidence intervalUse this calculator to calculate CPK confidence interval:Cpk)1(219165.112nnCpkCpk)1(219165.112nnCpkCpk4.2.QC4.2.QC七大手法七大手法項目項目不良數（特性值）不良數（特性值）不良率不良率影 影响 响度 度累 累计 计影 影响 响度 度冷气不冷气不凉 凉喷 喷漆 漆脱 脱落 落喷 喷漆不均漆不均其它其它合合计 计不良率A累计影响度不良项目8月11日8月12日8月13日8月14日8月15日合计容器破损11容器瑕疵污点51冲压瑕疵污点57接着剂20其它14内包装瑕疵16内包装破损39外包装破损6合计493643444321511101110129131178121712719310108121211121316911761012611178119913111410415118101410108121010131413111114157871210111181110951613111210129NO温度产量NO温度产量NO温度产量144.620.62651.623.85143.421.5250.3242746.322.15243.420.4346.221.12846.321.35347.821.8446.922.52948.322.55445.721.5548.921.33047.721.15544.121.1643.721.33150.923.75646.322.4748.823.2324922.25749.521.6846.621.63348.522.75844.821.3947.321.93450.521.8594923.11051.722.13546.820.86044211145.622.13644.221.9614321.41244.621.83745.522.36250.723.51345.421.43849.321.56346221446.4223945.820.86448.121.71547.920.94048.122654722.91649.222.24145.922.66644.221.91749.223.84243.1116747.922.91847.522.64345.521.56847.822.11943.521.14451.123.66947.122.3205022.64549.723.6701721.1N=70产量(千个)反应炉温度反应炉温度及产量的散布图1.1.定義定義:是一種以實際產品品質特與根據過去經驗所判斷的制程能力的管制界限比較,而以時間順序用圖形表示者.其分為計數值管制圖及計量值管製圖2.2.功能與用途功能與用途:縱軸為制品的品質特性,以制程變化的數據為分度橫軸為制品的群體號碼或制造年,月,日等.3.3.管制圖管制什么管制圖管制什么?管制圖管制制程的穩定性,而不是產品的規格.如果以規格為管制上下限而繪制成的圖形,可稱為推移圖.4.4.計算管制圖管制界限時注意事項計算管制圖管制界限時注意事項 剔除上次超出管制界限的异常點.管制圖之選定資料性質?資料是不良數還是缺點數?單位大小是否一定?N是否一定?樣本數N2?中心線CL之性質?N是否較大?X-圖X-R圖X-R圖X-Rm圖pn圖p圖C圖u圖計量值計量值缺點數不一定一定不一定一定N=1N 2XN=25N 10不良數3.管制圖之選定原則搜集數據繪製解析用管制圖安定狀態?繪製直方圖滿足規格?追求,去除異常原因以達安定狀態.檢討機械,設備等提升制程能力管制用管制圖4.管制圖之繪制流程5.5.作法作法:(1).P 管制圖的作法:(即計數值管制圖)A.收集數據,至少 20 組以上.B.計算每組的不良率 p.C.計算平均不良率 p=總不良個數/點檢查數.D.計算管制界限.中心線:CL=p,UCL=,LCL=E.繪管制界限,並將點點入圖中.F.記入數據履歷及特殊原因,以備查考,分析,判斷.(2).X-R 管制圖的作法:(即計量值管制圖)A.搜集 100 個以上數據依測定時間順序或群體順序排列.B.把 2-5 個(4-5)數據分為一組.C.把數據記入數據表.nppp/)1(3nppp/)1(3D.計算各組平均值X.E.計算種組的全距R.F.計算總平均.G.計算全距平均R.H.計算管制界限.X管制圖:中心線CL=X 上限UCL=X+A2R 下限:LCL=X-A2RR管制圖:中心線CL=R 上限UCL=D4R 下限:LCL=D3RI.繪管制界限,並將點點入圖中.J.記入數據履歷及特殊原因,以備查考,分析,判斷.6.求管制界限的系數表nA2D4D3E2m3A221.8803.267-2.6601.88031.0232.575-1.7721.18740.7292.282-1.4570.79650.5772.115-1.2900.69160.4832.004-1.1840.54970.4191.9240.0761.1090.50980.3731.8640.1361.0540.43290.3371.8160.1841.0100.412100.3081.7770.2230.9750.363Part Name:Part No.:Measure Unit:Quality Characteristic:Workstation:Specification:Date12345678910111213141593866997666611710696958777761061212A2=0.5578677698868119849D4=2.115769875117612991098Last Month:288512611688812968X=Max99991291188121112111212R=Min236555766666648This Month:X6.46.47.677.27.49.276.68.289.28.87.69.4X=7.83R763474422656584R=4.71429X-Chart10.510.510.510.510.510.510.510.510.510.510.510.510.510.510.5UCL=X+A2*R7.737.737.737.737.737.737.737.737.737.737.737.737.737.737.73CL=7.734.934.934.934.934.934.934.934.934.934.934.934.934.934.934.93LCL=X-A2*RR-Chart10.310.310.310.310.310.310.310.310.310.310.310.310.310.310.3UCL=D4*R4.874.874.874.874.874.874.874.874.874.874.874.874.874.874.87CL=4.87Remarks:每天取 5 個數據作為Sampling Data,第一個月X-R Chart控制線以本月前15 天數據平均值(X,R)計算.第二個月控制線以上月數據平均值(X,R)計算.綠色部 分為 I n p u t部分.Sampling DataX-R Control Chart Remarks X-Chart4681012123456789101112131415DataUCLCLLCLR-Chart024681012123456789101112131415DataUCLCLProduct Name:Part No.:Measure Unit:Quality Characteristic:Workstation:Specification:Date 123456789101112131415Insp Qty200100100100100200100100100100150100100100100Last Month:Rej Qty312123231231532P=Rej Rate1.5%1.0%2.0%1.0%2.0%1.5%2.0%3.0%1.0%2.0%2.0%1.0%5.0%3.0%2.0%P=2.0%UCL4.2%4.2%4.2%4.2%4.2%4.2%4.2%4.2%4.2%4.2%4.2%4.2%4.2%4.2%4.2%0.14CL2.0%2.0%2.0%2.0%2.0%2.0%2.0%2.0%2.0%2.0%2.0%2.0%2.0%2.0%2.0%CL=P2.0%Defect 1Defect 2Defect 3Defect 4Defect 5Defect 6Defect 7OthersStatusPlanRoot Cause ActionPICRemarksP-Chart Corrective ActionsDescriptionP-Chart0.0%1.0%2.0%3.0%4.0%5.0%6.0%123456789101112131415Date Rej RateCL管制圖不正常型態之判讀法1.檢定規則一:有單獨一個點子,出現在三個標準差區域之外者(有一點落在管制界限之外者).+1+2+3UCLCLA區B區C區.2.檢定規則二:連續三點之中有兩點落在A區或甚至於A區以外者(在中心線之同側三個連續點中有兩點出現在兩個標準差之外者).+1+2+3UCLCLA區B區C區.3.檢定規則三:連續五點之中有四點落在B區或甚至於B區以外者(在中心線之同側五個連續點中有四點出現在一個標準差之外者).+1+2+3UCLCLA區B區C區.4.檢定規則四:連續有八點落在C區或甚至於C區以外者(八個連續點子出現在中心線之同一側者).+1+2+3UCLCLA區B區C區.6.點在中心線之單側連續出現有七點以上時.7.點出現在中心線單側較多時,如:(1)連續11點中有10點以上.(4)連續20點中有16點以上.(3)連續17點中有14點以上.(2)連續14點中有12點以上.5.檢定規則五:連續有七點上升(或下降).+1+2+3UCLCL.LCL-1-2-3.(3)連續10點中有4點以上.(2)連續7點中有3點以上.(1)連續3點中有2點以上.8.點出現在管制界限之近旁時,一般是以超出2區域之 點為調查基準,如:(一)y y y x xx正相關負相關無(零)相關 y y x x弱相關強相關(二)yb=斜率y=a+bxa:截距 ab:斜率(三)r:相關系數(Coefficient Correlation)強相關弱相關錯相關 x相關回歸(Correlation Regression)8.0r8.03.0 r3.00 r5.Ver:AModel:Parts Name:Part Number(Version):Data Source:Set/Cav.No:Measure Date:Trail Shot(Production)Date:Measured By:LocationSilitekVendorDifferenceNSPr0.837a1.517b0.818USL9.0009.0008.508.50LSL8.0008.000MAX8.7008.6800.020MIN8.2808.300-0.020AVG8.4778.4490.028STD0.0920.0900.002Ca-0.05-0.10 0.056Cp1.811.86-0.043Cpk1.731.670.062GradeAADRL%0.00%0.00%0.000DRR%0.00%0.00%0.000DR%0.00%0.00%0.00018.5508.5000.050B.Correlation28.5008.4800.020 y b=斜率r:相關系數288.5208.4600.060y=a+bx r =0.8 強相關298.5108.4700.040a:截距0.3 r =0.8 弱相關308.7008.6800.020ab:斜率 r y=(9)+(10)xb=(F)+(E)-(A)+(C)(F)+(B)-(A)+(A)=92440-880444456+4544a=(B)+(C)-(A)+(E)(F)+(B)-(A)+(A)AverageStandard Deviationt=(F+B)-(A+A)+(G+D)-(C+C)ObservationsAverageStandard DeviationObservations2.直線性(Linearity):量具取不同規格精度時的偏移之差;1.偏移(Bias):觀察平均值與實際平均值之差量,需以較精密量具改進;實際值觀測平均值偏移(A)(B)直線性大偏移小偏移一.量測系統誤差的分類GR&R觀測者平均值3.穩定性(Stability):因環境改變,動力波動,量具磨損等,不同時間所造成之差量;重複性(D)同一操作員同一量具同一物體4.重复性(Repeatability):一人使用同一量具多次量 測同一物性之差量;(C)穩定性Time 1Time 2GR&R操作員b(E)再現性同一量具同一物體 不同操作員操作員a操作員c5.再現性(Reproducibility):不同人所量測同一物性多次平均之間的差量.備注:由于Bias,Linearity及Stability對量測系統造成的誤差很小,故給予忽略不計.GR&R二.為什麼要做量測系統分析4.評估量具間的差異.8.幫助挑選量測設備.1.防止良品被判退.2.防止不良品被接收.3.增強客戶的信心.5.提升量測技術.6.確認量測人員的資格.7.評鑑量具的量測能力.三.應用範圍4.GO&NG量具,限度樣品.1.量測設備.2.測試設備.3.檢測設備.GR&R四.何時需做GR&R1.新設備.3.客戶要求.5.訓練雇員.7.新量具.五.基本規則1.選擇正確的量測系統.3.零件必須從制程中獲取.5.操作員正常操作設備.2.重點呎寸.4.加嚴公差.6.推定制程條件.8.機械能力研究.2.選擇零件的重點呎寸.4.零件必須被編號且具備隨 機性.GR&R六.變化的來源1.操作員間的差異.3.物料的差異.七.執行量測系統分析的原因1.評定量具的量測能力.3.評監量測方式.2.設備的差異.4.客戶和廠商間的差異.2.比較不同的量具.4.評估校驗前後的差異.GR&R(一).不考慮PV 1.重複性(Repeatability)-Equipment Variation(EV)EV=R*K1 TrialsK124.5633.05式中:R=(Ra+Rb+Rc)/3(Trials為3組時)或 R=(Ra+Rb)/2(Trials為2組時)八.計算公式GR&R3.R&R=22AVEV 6.%R&R=100(R&R/T)%4.%EV=100(EV/T)%5.%AV=100(AV/T)%2.再現性(Reproducibility)-Appraiser Variation(AV)AV=Xdiff*K2 AppraisersK223.6532.70式中:Xdiff=Max(Xa,Xb,Xc)-Min(Xa,Xb,Xc)或 Xdiff=Max(Xa,Xb)-Min(Xa,Xb)(Trials為3組時)(Trials為2組時)GR&R(二).考慮PV(供參考)1.重複性(Repeatability)-Equipment Variation(EV)EV=R*K1 TrialsK124.5633.05式中:R=(Ra+Rb+Rc)/3(Trials為3組時)或 R=(Ra+Rb)/2(Trials為2組時)GR&R 2.再現性(Reproducibility)-Appraiser Variation(AV)AppraisersK223.6532.70式中:Xdiff=Max(Xa,Xb,Xc)-Min(Xa,Xb,Xc)或 Xdiff=Max(Xa,Xb)-Min(Xa,Xb)(Trials為3組時)(Trials為2組時)/()2*(22nrEVKXdiffAV=n=number of partsr=number of trialsGR&R3.R&R=22AVEV 4.Part Variation(PV)PV=Rp*K3PartsK323.6532.7042.3052.0861.9371.8281.7491.67101.62GR&R 8.%R&R=100(R&R/TV)%6.%EV=100(EV/TV)%7.%AV=100(AV/TV)%5.TV=22)&(PVRR9.%PV=100(PV/TV)%GR&R實例(1)GR&RCalculation Worksheet Version:2.0Part/Asm.Name Gauge Name CharacteristicGauge No.Specification Gauge Type OperatorSample No.12345678910TotalsRA=RB=RC=接受條件:a.0R&R%1 0%可接受b.10%R&R%3 0%條件接受c.30%R&R%不可接受,待修理,再教育,或用其他量測EV=EV%=EV/T=AV=AV%=AV/T=R&R=(AV2+EV2)1/2R&R%=R&R/T=Conclusion:核準核準:審核審核:經辦經辦:0.0200.00024.2300.0200.0100.0102.4200.02024.27024.28024.30024.3100.0702.4302.44029.68%0.1202.42800.0224UCLR=XB26.43%13.50%0.029680.008672.42730.01350.026430.0050024.270R=Xdiff=XA24.3200.07024.320XC2.432324.3300.0100.0102.4302.4302.4200.00700.01200.00700.0102.4302.4402.4402.4302.4302.4400.0000.0100.0100.0100.0100.0000.0000.0102.4302.4302.4300.0002.4202.4302.4300.0102.4302.4302.4302.4402.4302.4402.4302.4202.4300.0102.4302.4302.4202.4302.4402.4202.4302.4302.4400.0102.4202.4302.4402.4402.4402.4302.4202.4202.4300.0102.4302.4302.4302.4302.4302.4202.4302.4302.4300.0002.4402.4302.4302.4302.4302.4302.4302.4302.4300.0002.4302.4202.4102.4202.4202.4302.4300.0102.4302.4302.4200.0102.4302.4302.4202.4302.4200.0102.4402.4302.4300.0102.4301st Trial3rd Trial1st Trial2.4302.4202.4200.010Range2.4302nd TrialRangeRange2nd Trial3rd Trial1st Trial3rd Trial2nd TrialToleranceMeasurement Unit 曹志敏2.4302.4302.4200.0102.440胡梅英0.1CALIPERI04-050150mmPaper GuideDiameter 2.5+0/-0.1Part No.林娜G R&RPJHRB0024ZA0.01mm(Measurement System/Gauge Capability)實例(2)GR&RCalculation Worksheet Version:1.0OperatorSample No.12345678910TotalsRA=RB=接受條件:a.0R&R%1 0%可接受b.10%R&R%3 0%條件接受c.30%R&R%不可接受,待修理,再教育,或用其他量測EV=EV%=EV/T=AV=AV%=AV/T=R&R=(AV2+EV2)1/2 R&R%=R&R/T=Conclusion:核準核準:審核審核:經辦經辦:(Measurement System/Gauge Capability)G R&RMeasurement Unit 0.01mmGauge No.I04-05Part No.PJHRB0024ZAGauge Name CALIPERTolerance0.1Gauge Type 0150mmRange胡梅英曹志敏1st Trial2nd Trial3rd TrialRange1st Trial2nd Trial3rd Trial2.4302.4302.4200.0102.4302.4202.4200.0100.0102.4202.4302.4200.0102.4402.4302.4302.4202.4302.4200.0102.4302.4302.4200.0100.0202.4302.4302.4300.0002.4302.4202.4102.4302.4302.4200.0102.4302.4302.