管制图-赵章非

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,*,SPC,*,管制图,（,CHART,）,制程品质衡量方式的演进,常态分布,1850,高斯,管制图,(%),1924,W.A,Shewhart,美国,1960,日本,Ca,Cp,Cpk,(,ppm,),6,1980,Motorola,1992,TI,1994,Allied Signal,95,GE,98,Sony,1,概述,统计方法的定义：资料的收集、整理与解释，并导出 结论或加以推广。,资料种类：计数值（间断资料，,Discrete Data,）,计量值（连续资料，,Continuous Data,）,资料来源：原材料,制程（制程参考）,检验（产品特性）,2,数字数据处理的步骤,1.,原始资料审核：保存资料的真实性。,2.,分类的决定：分成几类，避免重复及遗漏。,3.,分类后整理：进行归类。,4.,列表：根据结果编成适用的表式。,5.,绘图：绘成统计图。,4,统计技术之应用,1.,市场分析,2.,产品设计,3.,相依性规格、寿命及耐用性预测,4.,制程管制及制程能力研究,5.,制程改善,6.,安全评估风险分析,7.,验收抽样,8.,数据分析，绩效评估及不良分析,5,统计工具,1.,柏拉图,2.,统计检定,3.,管制图,4.,抽样计划,5.,变异数分析回归分析,6,常态分配,K,界限内的概率,界限外的概率,0.67,50.00%,50.00%,1,68.26%,31.74%,1.96,95.00%,5.00%,2,95.45%,4.55%,2.58,99.00%,1.00%,3,4,99.73%,99.9937%,0.27%,0.0063%,9,常态分配,10,管制界限的构成,11,共同原因与特殊原因之变异,共同原因：,制程中变异因素是在统计的管制状态下，其产品之特性有固定的分配,。,特殊原因：,制程中变异因素不在统计的管制状态下，其产品之特性没有固定的分配。,12,制程中只有共同原因的变异,13,制程中有特殊原因的变异,14,管制图原理,1.,当过程能够保持稳定受控状态时，质量数据都是取自典型分布，因此管制,图中的点子会有,99.73%,在控制界限内，在中心线两侧随机分布。,2.,如果过程受到异常因素的作用，典型分布就会遭到破坏，典型分布的破坏,可以表现为分布中心由,或标准偏差,的,显著变化。现在只看一种简单的变化,状况，由于受异常因素的作用，质量数据的实际分布的分布中心由,逐渐变,化为,。此时，管制图中点子的分布状况就会出现：趋势，链状，甚至出,界。,管制图中点子分布状况所出现的趋势，链状，超界等，就表明过程中已出现,异常或异常先兆，给生产者和管理者发出过程异常的警报。,管制图的应用,决定管制项目,决定管制标准,决定抽样方法,选用管制图的格式,记入管制界限,绘点、实施,重新检讨管制图,管制图判读,处置措施,OK,OK,NG,19,管制图的选择,计数值,计量值,n=1,管制图的选择,数据性质？,样本大小,n=,？,数据系不良数,或缺点数,CL,性质,?,n,是否相等？,单位大小是,否相关,n=？,n,2,n=25,n=3,或,5,n,10,不是,是,不是,是,缺点数,不良数,管,制,图,管,制,图,管,制,图,管,制,图,P,管,制,图,PN,管,制,图,U,管,制,图,C,管,制,图,20,质量,特性,样本数,管制图,B/L,外框,长度,3,pcs,IC,短路,不良率,2000,pcs,静电压,1pc,OQC,抽检,不良数,50,pcs,每一平方米的,异物个数,1平方米,以下质量特性，应该选用何种管制图呢？,Xbar,-R chart,P chart,X-,Rm,chart,NP chart,C chart,计量值计数值管制图公式汇总,管制图,CL,UCL,LCL,附注,计,量,值,-R,，,未知,n=2,5,最适当,n10,以下,R,-,，,未知,10,n,25,S,-R,N=3 or 5,较佳,R,与之,R,图相同,X-,Rm,X,k,：,组数,n,：,样本大小,Rm,计,数,值,P,P,使用小数,P,使用,%,Pn,n=,C,样本大小相同时使用,，,n=20 25,U,样本大小不同时使用,(,为阶梯界限,)n=2025,21,管制图（平均值与全距）,1.,公式：,(1),管制图,CL=,UCL=,A,2,LCL=,A,2,(2),R,管制图,CL=,UCL=D,4,LCL=D,3,2.,实例：,某工厂制造一批紫铜管，应用,-R,管制图来控制其内径，尺寸单位为,m/m,，,利用下页数据表之资料，求得其管制界限并绘图。（,n=5,）,22,R,管制图用数据表,制品名称：紫铜管,机械号码：,XXX,品质特性：内径,操 作 者：,XXX,测定单位：,m/m,测 定 者：,XXX,制造场所：,XXX,抽样期限：自年月日至年月日,样,组,测 定 值,R,样,组,测 定 值,R,X1,X2,X3,X4,X5,X1,X2,X3,X4,X5,1,50,50,49,52,51,50.4,3,14,53,48,47,52,51,50.2,6,2,47,53,53,45,50,49.6,8,15,53,48,49,51,52,50.6,5,3,46,45,49,48,49,47.4,4,16,46,50,53,51,53,50.6,7,4,50,48,49,49,52,49.6,4,17,50,52,49,49,49,49.8,3,5,46,48,50,54,50,49.6,8,18,50,49,50,49,51,49.8,2,6,50,49,52,51,54,51.2,5,19,52,49,52,53,50,51.2,4,7,47,49,50,48,52,49.2,5,20,50,47,50,53,52,50.4,6,8,48,50,46,49,51,48.8,5,21,52,49,51,53,50,51.0,4,9,50,50,49,51,53,49.0,4,22,55,54,51,51,50,52.2,5,10,49,51,51,46,48,49.2,5,23,50,54,52,50,49,51.0,5,11,51,50,49,46,50,49.2,5,24,47,51,51,52,52,50.6,5,12,50,50,49,52,51,50.4,3,25,53,51,51,50,51,51.2,3,13,49,49,49,50,55,50.4,6,1254,120,23,R,绘图步骤,1.,将每样组之 与算出记入数据表内。,2.,求 与,50.16,4.8,3.,查系数,A,2,，,D,4,，,D,3,A,2,0.58,，,D,4,2.11,，,D,3,负值（以,0,代表）,p35,24,R,绘图步骤,4.,求管制界限,。,(1),管制图,CL,50.16,UCL,A,2,50.16,(0.58)(4.8),52.93,LCL,A,2,50.16,(0.58)(4.8),47.39,(2)R,管制图：,CL,4.8,UCL,D,4,(0.11)(4.8),10.13,LCL,D,3,(0)(4.8),0,25,R,绘图步骤,5.,将管制界限绘入管制图,6.,点图,7.,检讨管制界限,26,R,管制图,27,Work shop,R,范例,某产品制成后，经常发现不良品，今利用,R,管制图控制其品质特性，每天取样,2,次，每次样本大小,n=5,，,下表是,10,天内所收集之数据（由同一作业员操作同一部机器所得之数据），试计算,R,管制图之管制界限，并绘成管制图。,组别,R,组别,R,1,177.6,23,11,179.8,9,2,176.6,8,12,176.4,8,3,178.4,22,13,178.4,7,4,176.6,12,14,178.2,4,5,177.0,7,15,180.6,6,6,179.4,8,16,179.6,6,7,178.6,15,17,177.8,10,8,179.6,6,18,178.4,9,9,178.8,7,19,181.6,7,10,178.2,12,20,177.6,10,28,P,管制图,(,不良率,),1.,公式,(1),公组样本大小,n,相等时：,CL,UCL,3,LCL,3,(2)n,不等，且相差小于,20%,时：,CL,UCL,3,LCL,3,29,P,管制图,(,不良率,),(3)n,不等，且相差大于,20%,时：,CL,UCL,3,LCL,3,30,P,管制图,(,不良率,),2.,实例,某工厂制造外销产品，每,2,小时抽取,100,件来检查，将检查所得之不良品数,据，列于下表，利用此项数据，绘制不良率,(p),管制图，控制其品质,组,别,n,d,p,组,别,n,d,p,组,别,n,D,P,1,100,3,0.03,11,100,3,0.03,21,100,5,0.05,2,100,4,0.04,12,100,6,0.06,22,100,8,0.08,3,100,3,0.03,13,100,8,0.08,23,100,4,0.04,4,100,8,0.08,14,100,5,0.05,24,100,5,0.05,5,100,5,0.05,15,100,2,0.02,25,100,4,0.04,6,100,5,0.05,16,100,3,0.03,合计,2500,125,7,100,7,0.07,17,100,6,0.06,平均,100,0.05,8,100,5,0.05,18,100,2,0.02,9,100,5,0.05,19,100,7,0.07,10,100,6,0.06,20,100,5,0.05,31,P,管制图绘图步骤,1.,求管制界限,CL,0.05,5%,UCL,3 =11.54%,LCL,3,（,为负值，视为,0,）,32,P,管制图绘图步骤,2.,点绘管制图,33,Work shop,P,范例,某工厂之生产线，每分钟制造产品,200,个，今为控制其焊锡不良，采用不良率管制图加以管制，每,2,小时抽查,200,个，试根据下列资料计算不良率管制图之中心线及管制界限，并绘制其管制图。,月 日,不良罐数,月 日,不良罐数,10,月,6,日,2,10,月,9,日,5,0,7,4,2,2,4,7日,3,11,日,2,2,6,2,12,6,12,日,4,8日,3,3,3,4,4,2,2,13,日,2,34,计量值管制图常用之系数表,35,n,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17,18,19,20,A2,1.880,1.023,0.729,0.577,0.483,0.419,0.373,0.337,0.308,0.285,0.266,0.249,0.235,0.223,0.212,0.203,0.194,0.187,0.180,A3,2.659,1.954,1.628,1.427,1.287,1.182,1.099,1.032,0.975,0.927,0.886,0.850,0.817,0.789,0.763,0.739,0.718,0.698,0.680,B3,-,-,-,-,0.303,0.118,0.185,0.239,0.284,0.321,0.354,0.382,0.406,0.428,0.448,0.466,0.482,0.497,0.510,B4,3.267,2.568,2.266,2.089,1.970,1.882,1.815,1.761,1.716,1.679,1.646,1.618,1.594,1.572,1.552,1.534,1.518,1.503,1.490,D3,-,-,-,-,-,0.076,0.136,0.184,0.223,0.256,0.283,0.307,0.328,0.347,0.363,0.378,0.391,0.403,0.415,D4,3.267,2.574,2.282,2.114,2.00