统计质量控制

按一下以編輯母片標題樣式,按一下以編輯母片,第二層,第三層,第四層,第五層,*,*,*,Q.C.,的重要性：,Ch1 Quality Control,的基本概念,國際市場競爭激烈,自銷售中獲取利潤以維持企業命脈,產品品質工作品質服務品質,1,Quality,的意義：,滿足顧客的,要求,或,適用性,（,fitness of use）,。,（i）,Quality,Design Quality：,（,設計品質,）,設計的品質是否符合顧客的要求？,Conformance Quality：,（,製造品質,）,生產方法是否達到規格？,Quality means Excellence,or,both,e.g,.,顧客與裁縫師,2,（,ii）,品質的特性,（,quality characteristic）,（,a）physical,硬度、長度、電感等。,（,b）sensory,味覺、美感、姿態等。,（,c）time orientation,可靠度、維護度等。,3,3.,Control,的意義：,（,a）Plan,（,依循計劃）：,決定目標,決定達成目標的方法,（,b）Do,（,執行）,教育訓練,生產作業,Deming Cycle：,P-D-C-A,管理循環。,A,P,C,D,確立標準與保持品質;,顧客滿意且經濟的品質。,4,（,c）Check,（,檢核）：,測定,分析：應用統計方法整理分析測定結果,判定：判斷分析結果是否有異常原因,（,d）Action,（,措施）對執行上的偏差採取矯正行動,研擬改善對策,執行對策,對策覆查,再標準化,A,P,C,D,5,4,.,Q.C.,的意義：,（,i,）,Statistical Quality Control（S.Q.C.）,（A collection of production methods,management concepts and,praticts,）,在,製造的各階段，以製造工程為對象，從材料購,進至產品的出廠，皆使用統計方法，使能最經濟,的生產出用途最廣，銷路最好的產品,（,ii,）,Total Quality Control（T.Q.C.）,組織內各部門的品質發展，品質維持及品質改進,的各項努力，綜合成一個有效的體系，使生產的,服務皆能在最經濟的水準上，使顧客滿意,Managers Supervisors Workers,溝 通 與 合 作,6,5.,Q.C.,的演進：,（1）,操作員的,Q.C.,6.,Q.C,.,的主要工具,（,The magnificent seven,）,（1）Histogram,（2）,領班的,Q.C.,（3）,檢驗的,Q.C.,（4）,統計的,Q.C.,（5）,全面的,Q.C.,（2）Check Sheet,（3）Pareto Chart,（4）Cause and Effect diagram,（5）Defect concentration diagram,（6）Scatter diagram,（7）Control Chart,7,7.,何謂,A process is in statistical control,If it is operating with only,chance causes,of variation present（,Natural variability,）.,何謂,A process is out of control,If it is operating in the presence of,assignable causes.,e.g.improperly adjusted,operator errors,defective raw materials,8,2.,了解,life cycle,的,cost,。,i.e.maintenance labor,spare parts field failures,3.使,quality engineers,及,manager,能有效的,以,money,的方式來溝通,quality cost,。,1.科技發展，使製造過程更複雜，亦提高了,quality cost,。,傳統上企業的,financial control,包括,Actual cost,與,Budgeted cost,。,自,1950,年開始,由於下面三個因素，使得,quality,cost,亦成為,financial control tool,的一員：,9,與,producing，identifying，avoiding,，,repairing,不良品有關的,cost,均稱為,Quality costs.,Prevention costs,Appraisal costs,Internal failure costs,External failure costs,何謂,Quality costs,？,Quality costs,可分為四大類：,10,Quality planning and engineering,New products review,Product/process design,Process control,e.g.Control charts,Burn-in,Prevent early life failure,Training,Quality data acquisition and analysis,上一頁,Prevention costs,11,Inspection and test of incoming material,Product inspection and test,Materials and services consumed,Maintaining accuracy of test equipment,上一頁,2.,Appraisal costs,12,Scrap,Rework,Retest,Failure analysis,Downtime,Yield losses（off,-specing,）,Down grading,上一頁,3.,Internal failure costs,13,Complaint adjustment,Returned product/material,Warranty charges,Liability costs,義務,Indirect costs,上一頁,4.,External failure costs,14,假設在此生產過程中的,first-pass yield,為75%,（,i.e.,只有75%符合規格，25%不合規格）,且不合規格的產品僅有,60%,可再修理成為良品，,則若生產單假價為20，修理的單價為4，則,Cost/good part,20100415,90,22.89,其中 分母,1000.750.250.610090,Process,Inspection,Repair or rework,Shipment,Scrap or waste,加入,SPC,來減少,production cost,的例子,25 60,25 40,75,沒有,SPC,的模型,15,Cost/good part ,2010043,98,20.53,若,加入,SPC（e.g,.,使用,X,及,R chart）,first-pass yield,增為95%，而仍假設,不良品中僅有60%可修好，則,20.5322.89,22.89,10010.3,（1）,Reduction in,manufacturing,cost.,9890,90,1009,（2）,提高,productivity,而,加入,SPC,的費用卻是,negligible！,加入,SPC,的模型,16,Quality Improvement means Elimination of Waste！,Process,Shipment,Analysis,Output,Improve,Inspect with SPC,改進品質即可提高生產力！,17,Example：,Monthly quality-costs information for assembly for,Printed circuit boards,Insufficient solder 42$37,500.00 （52%）,Misaligned components,21 12,000.00,Defective components 15,8,000.00,Missing components,10 5,100.00,Cold solder joints,7,5,000.00,All other causes,5,4,600.00,Totals 100$72,200.00,Type of Defect,Percent of Scrap and,Total Defects Rework Costs,可,利用如上之,Pareto analysis,來分析,quality cost,的項目及所佔比例。,18,Example：,Production process inputs and outputs,Which inputs affect the output parameter,y,？,What is the relationship between the important inputs and,the output parameter,y,？,3.,How can,y,be improved？,Process,Uncontrollable inputs,Z,1,Z,2,Z,q,Input,Raw materials,Components,And,subassemblies,Controllable inputs,X,1,X,2,X,p,y,Quality,characteristic,Measurement,Evaluation,Control,Output product,（,e.g.,溫度、壓力）,（,e.g.,環境因素、原料品質）,19,本書,主要的三個主題,Statistical Process Control,Experimental Design,Acceptance sampling,其中,Designed Experiment,為發現影響品質主要變數的重,要且有效的方法，但其為一個,offline,的品管工具，通常,使用於,developed activities,：,製造過程的早期。,Statistical Process control,則為一個,online,（,或稱,in-process,）,的品管工具。,20,當確認影響生產的主要變數,（,x,）,之後，可利用,e.g.,regression analysis、time series,等方法來建立,y,（,output,品質特徵）與,x,之關係。,再以,SPC（e.g.control chart）,來,monitor,生產過程，,並決定何時應調整,input,以保證產品的品質，其調,整的量則可由上述建立之,regression,或,time series,模,型決定。,21,Phase diagram of the use of quality-engineering,methods（in manufacturing organization）.,隨著,時間增加,（亦即工廠的,運作越上軌道）,使用,SPC,及,Design of Exp.,的比例增加，而,Acceptance,Sampling,卻減少。,22,Application of quality-Engineering techniques and,the systematic reduction of process variability.,品,管,工程師的主要任務：,有系統的減少變異性（,systematic reduction of variability）,23,Work force m