统计过程管制介绍

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,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,*,RMA&EQC,SPC,讲义-,),SPCStatistical Process Control,统计过程管制,Excellent Quality Consultant Co.,Ltd.,1,SPC统计过,程,程管制,SPC,由来,SPC,定义,SPC,发展历程,SPC,应用现状,SPC,基本统计观念,SPC,基本概念,SPC,展开步骤,确定管制项目,选择管制图,收集数据,绘制管制图,计算,CPK,判定,长期控制,异常处理,公式,常用数据,XBAR-R,范例,PN,范例,2,SPC的由来,生产力发展的,世,世纪,新的世纪-品质的世,纪,纪,品质的趋势-世界级,的,的品质,百分比千分,比,比,PPMPPBNEARZERO,QS9000,要求:,PPK=1.67,CPK=1.33,3,SPC的由来,指数与不良率,的,的关系,指数,不良率,说明,0.67,4.55%,2,1,0.27%,3,1.33,63.3,PPM,4,1.67,0.57,PPM,5,2,2,PPB,6,4,SPC的由来,我们的不良率,是,是多少?,我们的制程能,力,力是多少?,我们能做到吗?,赶快应用SPC,5,SPC的定义,SPC:Statistical ProcessControl,S-Statistical,统计,P-Process,过程,C-Control,控制,利用,统计,的方法,对,过程,中的各个阶段,进,进行,监控与诊断,从而达到,改进与保证,产品品质的目,的,的.,PQC+S=SPC,6,SPC的发展,历,历程,Bell Telephone LaboratoryShewhart,Control Chart(1924) &EconomicControl of Qualityof manufactured Products(1931),美军,SQC(1941-1942):,强制性战时规,格,格,Z1-1-1941 Guide for Quality Control,Z1-2-1941 ControlChartMethodfor anaalyzing Data,Z1-3-1942ControlChartMethodforControlQualityDuringProduction,7,SPC发,展,展历,程,程,1950,Dr.Deming,送“,经,经”,日,日本,日,本,本崛,起,起,ISO9000:1994,统计,方,方法,的,的引,入,入,QS9000:1998,SPC,的强,制,制应,用,用,未来:,SPCD:StatisticalProcessControl&Diagnosis,SPCDA:StatisticalProcessControl,Diagnosis&Adjustment,8,SPC的,应,应用,现,现状,日本,名,名古,屋,屋大,学,学调,查,查,115家,企,企业,平,平均,每,每家,使,使用137张,控,控制,图,图,美国,柯,柯达,公,公司5000,人,人,使,使用35000张,控,控制,图,图,平,平均,每,每人,应,应用7张,日本,DEMING,奖10大,项,项目,中,中,七,七大,项,项目,强,强调,统,统计,尤,其,其是,SPC,ISO9000,统计,的,的需,要,要,QS9000SPC,的需,要,要,我国80%的,ISO,认证,通,通过,企,企业,SPC,几乎,为,为零,9,SPC的,基,基本,统,统计,观,观点,无论,生,生产,过,过程,还,是,是产,品,品结,果,果,都,都是,具,具有,规,规律,的,的.,正常,情,情况,下,下,具,具有,一,一定,的,的数,据,据分,布,布:,计量,值,值数,据,据,服,服从,正,正态,分,分布,计件,值,值数,据,据,服,服从,二,二项,分,分布,计点,值,值数,据,据,服,服从,泊,泊松,分,分布,最为,常,常见,的,的是,正,正态,分,分布-,钟,钟形,分,分布,10,SPC的,基,基本,统,统计,概,概念,群体:一,组,组过,程,程的,输,输出,结,结果,的,的全,体,体.,样本:从,群,群体,中,中按,照,照一,定,定的,抽,抽样,方,方法,选,选择,出,出来,的,的研,究,究对,象,象.,群体,具,具有,一,一定,的,的分,布,布特,性,性,合理,的,的抽,样,样(,足,足够,的,的样,本,本容,量,量,随,随机,的,的抽,样,样方,法,法),可,以,以保,证,证样,本,本与,群,群体,具,具有,共,共同,的,的分,布,布特,性,性,也,也即,是,是说,可,可以,由,由样,本,本的,状,状况,推,推断,群,群体,的,的状,况,况.,群体,通,通常,是,是未,知,知的,研,研究,对,对象,从,经,经济,成,成本,的,的角,度,度,可,可以,研,研究,分,分析,样,样本,而,而知,群,群体.,11,SPC的,基,基本,概,概念,分布,的,的集,中,中性-,X,平均,值,值,为,为所,有,有数,值,值的,平,平均,值,值,读,读做,X-BAR,n,=X,i,/n,i=1,X,X,1,X,2,12,SPC的,基,基本,概,概念,分布,的,的分,散,散性-,各具,体,体数,值,值与,平,平均,值,值之,间,间的,偏,偏差,通,常,常以,标,标准,差,差,来表,示,示.,读,读做,SIGMA(,西格,码,码),n,=(,(Xi-),2,/(n-1),i=1,X,13,SPC的,基,基本,概,概念,分散,性,性的,图,图解,2,1,14,SPC的,基,基本,概,概念,管制,界,界限:是,指,指实,际,际作,业,业的,特,特性,的,的分,布,布所,遵,遵从,的,的上,下,下界,限,限.,用,用于,在,在实,际,际工,作,作中,进,行,行动,态,态控,制,制,以,以判,断,断作,业,业的,有,有效,性,性.,规格,界,界限:是,指,指根,据,据设,计,计(,产,产品,设,设计,和,和过,程,程设,计,计),的,的要,求,求,所,所确,定,定的,工,工程,界,界限.用,于,于在,进,进行,工,工程,分,分析,中,中,对,对特,性,性的,分,分布,状,状况,是,是否,满,满足,预,预定,要,要求,的,的判,断,断,从,从而,确,确信,满,满足,设,设计,要,要求,的,的能,力,力.,在实,际,际控,制,制过,程,程中,使,用,用的,应,应该,是,是管,制,制界,限,限.,管,管制,界,界限,来,来自,于,于对,作,作业,过,过程,的,的调,查,查.,15,SPC的,基,基本概念,过程能力:实际作,业,业的结果,满,满足预计,工,工程要求,的,的能力.,过程的影,响,响因素有,两,两个方面:一是普,通,通原因,二,二是特殊,原,原因.,普通原因:在既定,的,的4,M1E,下,属,于,于过程,本,本身先,天,天存在,的,的变动,因,因素,一,一般是,不,不可控,制,制的,如,如需改,善,善,需,从,从管理,和,和设备技术,的,的角度,予,予以全,面,面改进.,特殊原,因,因:在,过,过程运,行,行中,随,随机发,生,生的可,控,控因素.,普通原,因,因通常,影,影响分,布,布的分,散,散度和,均,均值.,直,直接决,定,定过程,能,能力.,16,SPC,的,的基本,概,概念,特殊原,因,因导致,超,超出界,限,限或规,律,律变动,的,的现象,可以,直,直接从,管,管制图,中,中看出.影响,分,分布的,波,波形.,管制图,的,的重要,作,作用便,在,在于动,态,态过程,中,中,看,出,出特殊,原,原因的,存,存在,发出需要处,理,理的警报.,过程能力只,有,有在不存在,特,特殊原因的,前,前提下,才,能,能予以计算,并以此推,断,断未来的输,出,出结果.,17,SPC展开,的,的步骤,确定管制项,目,目,选择管制图,收集数据,绘制管制图,并,并计算,Cpk,稳定否,绘制管制图,收集数据,稳定否,查明原因,消,消除异常,YES,YES,NO,NO,18,确定管制项,目,目,确定管制项,目,目,选择管制图,收集数据,绘制管制图,并,并计算,Cpk,稳定否,绘制管制图,收集数据,稳定否,查明原因,消,消除异常,YES,YES,NO,NO,19,确定管制项,目,目,管制项目的,对,对象为产品,的,的特性和过,程,程的特性,产品特性:,尺,尺寸电性,值,值亮度,焊,焊接效果,功,功能等,过程特性:,波,波峰电流电压流,水,水线速度,温,温度药液,浓,浓度等,确定的方法:,产品特性:,QFD,过程特性:,因,因果图,来源:,客户要求的,信,信息,设计规格,产品特性形,成,成的工序及,关,关键工序(,工,工序流程图),历史经验(,曾,曾经出现的,问,问题),APQP,的展开的结,果,果,20,选择管制图,确定管制项,目,目,选择管制图,收集数据,绘制管制图,并,并计算,Cpk,稳定否,绘制管制图,收集数据,稳定否,查明原因,消,消除异常,YES,YES,NO,NO,21,选择管制图,管制项目的,特,特性,计量值,计数值(计,件,件值还是计,点,点值),样本数据的,特,特点,n 9(,样本少),n9(,样,本,本,多,多),n=1(,单,值,值),每,组,组,数,数,据,据,n,是,否,否,相,相,等,等,使,用,用,的,的,对,对,象,象,可,采,采,用,用,计,计,算,算,器,器,或,或,计,计,算,算,机,机,进,进,行,行,分,分,析,析,的,的,工,工,程,程,人,人,员,员,现,场,场,作,作,业,业,人,人,员,员,22,选,择,择,管,管,制,制,图,图(,计,计,量,量,值,值),性,质,质,上,上,是,是,否,否,均,均,匀,匀,或,不,不,能,能,按,按,组,组,取,取,样,样,使,用,用,X-MR,各,组,组,均,均,值,值,计,计,算,算,是,否,否,方,方,便,便,使,用,用,-R,X,X,样,本,本,容,容,量,量,是,是,否,否,大,于,于,或,或,等,等,于,于9,各组标准差,S,是否容易计算,使用,-R,使用,-S,X,NO,NO,NO,NO,YES,YES,YES,YES,当由现场人员使,用,用时,尽量用?,图,图,23,选择管制图(计,数,数值),是否关心,不合格品率,使用,np,或,p,样本大小,是否一致,使用,u,图,使用,c,或,u,图,NO,NO,NO,YES,YES,YES,样品大小,是否一致,使用,p,图,当由现场人员使,用,用时,尽量用,c/np,图,24,收集数据,样本组数最好不,要,要少于25,p,图或,np,图每组数据的要,求,求,1/,Pn5/P(P,为预估的总体不,良,良率,目的为在,n,中尽量能抽到多,于,于一个的不合格,品,品),计量值数据的要,求,求,组内数据变异小,组间数据变异,大,大,采用中位数控制,图,图时,尽量用奇,数,数样本,现场使用的,XBAR-R,图,样本以不超,过,过5为宜,25,收集数据,计量值数据合理,的,的抽样间隔和样,本,本大小,抽样的随机性,以,以充分代表群体,每小时,生产量,抽样间隔,样本大小,不稳定,稳定,10以下,8小时,8小时,4,1019,4小时,8小时,4,2049,2小时,8小时,4,5099,1小时,4小时,4,100以上,1小时,2小时,4,26,绘制,管,管制,图,图,计算,各,各统,计,计量,计算,管,管制,界,界限(不,能,能使,用,用规,格,格界,限,限),CLUCLLCL,建立,管,管制,图,图形,纵坐,标,标为,各,各组,相,相应,数,数值,中,中最,大,大和,最,最小,值,值差,的,的两,倍,倍(,以,以便,超,超过,管,管制,界,界限,的,的点,可,可以,绘,绘入),极差,R,或标,准,准差,S,图的,单,单格,刻,刻度,代,代表,的,的数,值,值是,均,均值,单,单格,刻,刻度,代,代表,的,的数,值,值的,两,两倍(图,形,形宽,度,度基,本,本一,致,致),标,注,注,数,数,据,据,项,项,目,目,及,及,描,描,绘,绘,各,各,数,数,据,据,点,点,27,计,算,算CPK(,计,计,量,量,值,值),过,程,程,稳,稳,定,定,即,即,不,不,存,存,在,在,特,特,殊,殊,原,原,因,因,时,时,才,才,能,能,计,计,算,算,过,过,程,程,能,能,力,力.,计,量,量,值,值,CPK,的,计,计,算,算,分,布,布,中,中,心,心,与,与,规,规,格,格,中,中,心,心,重,重,叠,叠,时,时,极差图,CPK=MIN(USL- )/(3* /d,2,), ( - LSL)/(3* /d,2,),标准差图,CPK=MIN(USL- )/(3* /c,4,), ( - LSL)/(3* /c,4,),X,X,R,R,X,X,S,S,28,计,算,算CPK(,计,计,量,量,值,值),分,布,布,中,中,心,心,与,与,规,规,格,格,中,中,心,心,发,发,生,生,偏,偏,离,离,时,时:,计,算,算,Ca(,过,程,程,准,准,确,确,度,度),Ca=(-SL)/(USL-LSL)/2),以,中,中,心,心,重,重,叠,叠,时,时,的,的,Cpk,值,作,作,为,为,Cp(,过程精确,度,度),Cpk=(1-Ca)Cp,X,29,计算CPK(计数,值,值),计数值管,制,制的过程,能,能力为,图形,p,图,Np,图,C,图,U,图,过程能力,P,C,P,U,30,管制图的判断-稳定,原,原则,原则一:不可,超,超出管制界限,!,31,管制图的判断-稳定,原,原则,原则二:不可,呈,呈现规律变动,连续7点上升,或,或下降,呈现规律性波,动,动,具有显著,的,的波动周期,32,管制图的判断-稳定,原,原则,原则二:不可,呈,呈现规律变动,连续7点在管,制,制界限一侧,连续11点中,有10点在,管,管制界限一侧(间断),33,管制图的判断,稳定原则,原则三:不可,过,过于集中分布,显著多于2/3的点集中在,CL,附近:即90%的数据在1,线以内,显著少于40%的数据落在,1,线以内,数据集中分布,在,在2,到管制线之间(超过2/3),3点中,有两,点,点接近一侧之,管,管制界限,7点中,有3,点,点以上接近控,制,制界限,原则四:符合,过,过程能力要求,34,长期控制,符合以下条件,可将管制图用于长,期,期控制:,过程稳定,符合过程能力,的,的要求,再收集15组,数,数据,无异常,情,情形,利用已经算出,之,之管制界限进,行,行管制,按要求收集数,据,据,并进行管,制,制分析/控制,在下列情况下,重新计算管,制,制界限:,初次过程能力,研,研究,异常消,除,除时,对4,M1E,进行重大改进,时,时,产品修正时,经过长期运行,后,后,35,异常处理,可以采取的措,施,施,有效后,不要,忘,忘了标准化的,处,处理,现象,可能原因,处理,分布,不稳定,计算错误,数据未层别,查清原因,重新计算,存在特殊原因,查清原因,予以消除,过程能力不足,过于分散,平均值偏移,采用管理性/技术性措施,进行改进,36,管制图中应用,的,的公式,管制图,相关统计量,CL,UCL,LCL,-,R,图,n:,各组样本数,K:,组数,n,=,Xi/n,i=1,K,=, j/K,j=1,Rj=Max-Min,K,=,Rj/K,j=1,+,A,2,-,A,2,D,4,D,3,X,X,R,X,X,X,R,R,R,R,R,X,X,37,管制图中应用,的,的公式,管制图,相关统计量,CL,UCL,LCL,-,R,图,n:,各组样本数,K:,组数,k,=,j,/n,j=1,Rj=Max-Min,K,=,Rj/K,j=1,+,A,2,-,A,2,D,4,D,3,X,X,X,R,R,R,R,R,R,X,X,X,38,管制图中应用,的,的公式,管制图,相关统计量,CL,UCL,LCL,-,S,图,n:,各组样本数,K:,组数,n,=,Xi/n,i=1,K,=, j/K,j=1,S,j,= (,(Xi- ),2,/(n-1),K,=,S,j,/K,j=1,+,A,3,-,A,3,B,4,B,3,X,X,S,X,X,X,S,S,S,S,S,X,X,X,39,管制图中应用,的,的公式,管制图,相关统计量,CL,UCL,LCL,X-MR,图,n:,样本数,n,=,Xi/n,i=1,R,i,= X,i,-X,i+1,n-1,=,Ri/(n-1),i=1,+,2.66,-2.66,3.27,0,X,R,R,R,R,R,X,X,X,40,管制图中应,用,用的公式,图形,统计量,CL,UCLi,LCLi,p,=,di/,n,+,3( (100- )/,n),-,3( (100- )/,n),1/2,np,=,di/,k,+,3( (1- /,n),-,3( (1- /,n),1/2,p,p,p,p,p,p,p,p,d,d,d,d,d,d,d,d,41,管制图中应,用,用的公式,图形,统计量,CL,UCL,LCL,c,=,ci/,k,+ 3,-3,1/2,u,=,c/,n,+ 3( /,n),-3( /,n),1/2,C,C,c,c,c,c,u,u,u,u,u,u,42,管制图中常,用,用的数据,n,d2,A2,A2,A3,B3,B4,D3,D4,C4,2,1.128,1.880,1.880,2.659,3.267,3.267,0.798,3,1.693,1.023,1.19,1.954,2.568,2.574,0.886,4,2.059,0.729,0.800,1.628,2.266,2.282,0.921,5,2.326,0.577,0.690,1.427,2.089,2.114,0.940,6,2.534,0.483,0.550,1.287,0.303,1.970,2.004,0.952,7,2.704,0.419,0.510,1.182,0.118,1.882,0.076,1.924,0.959,8,2.847,0.373,0.430,1.099,0.185,1.815,0.136,1.864,0.965,9,2.970,0.337,0.410,1.032,0.239,1.761,0.184,1.816,0.969,10,3.078,0.308,0.360,0.975,0.284,1.716,0.223,1.777,0.973,11,3.173,0.285,0.350,0.927,0.321,1.679,0.256,1.744,0.975,43,-R图范例,X,所测量的活,塞,塞直径数据:,n=5,k=25,规格为74.0000.02,样本序号,X1,X2,X3,X4,X5,1,74.030,74.002,74.019,73.992,74.008,2,73.995,73.992,74.001,74.001,74.011,3,73.998,74.024,74.021,74.005,74.002,4,74.002,73.996,73.993,74.015,74.009,5,73.992,74.007,74.015,73.989,74.014,6,74.009,73.994,73.997,73.985,73.993,7,73.995,74.006,73.994,74.000,74.005,8,73.985,74.003,73.993,74.015,73.998,9,74.008,73.995,74.009,74.005,74.004,10,73.998,74.000,73.990,74.007,73.995,11,73.994,73.998,73.994,73.995,73.990,12,74.004,74.000,74.007,74.000,73.996,13,73.983,74.002,73.998,73.997,74.012,44,-R图范例,X,样本序号,X1,X2,X3,X4,X5,14,74.006,73.967,73.994,74.000,73.984,15,74.012,74.014,73.998,73.999,74.007,16,74.000,73.984,74.005,73.998,73.996,17,73.994,74.012,73.986,74.005,74.007,18,74.006,74.010,74.018,74.003,74.000,19,73.984,74.002,74.003,74.005,73.997,20,74.000,74.010,74.013,74.020,74.003,21,73.998,74.001,74.009,74.005,73.996,22,74.004,73.999,73.990,74.006,74.009,23,74.010,73.989,73.990,74.009,74.014,24,74.015,74.008,73.993,74.000,74.010,25,73.982,73.984,73.995,74.017,74.013,45,-R图范例-计算,统,统计量(一),管制图,相关统计量,-,R,图,n:,各组样本数,K:,组数,n,=,Xi/n,i=1,K,=, j/K,j=1,Rj=Max-Min,K,=,Rj/K,j=1,X,X,R,X,X,X,46,-R图范例,计算统计,量,量(一),样本序号,X1,X2,X3,X4,X5,XBAR,R,1,74.030,74.002,74.019,73.992,74.008,74.010,0.038,2,73.995,73.992,74.001,74.001,74.011,74.001,0.019,3,73.998,74.024,74.021,74.005,74.002,74.008,0.036,4,74.002,73.996,73.993,74.015,74.009,74.003,0.022,5,73.992,74.007,74.015,73.989,74.014,74.003,0.026,6,74.009,73.994,73.997,73.985,73.993,73.996,0.024,7,73.995,74.006,73.994,74.000,74.005,74.000,0.012,8,73.985,74.003,73.993,74.015,73.998,73.997,0.030,9,74.008,73.995,74.009,74.005,74.004,74.004,0.014,10,73.998,74.000,73.990,74.007,73.995,73.998,0.017,11,73.994,73.998,73.994,73.995,73.990,73.994,0.008,12,74.004,74.000,74.007,74.000,73.996,74.001,0.011,13,73.983,74.002,73.998,73.997,74.012,73.998,0.029,X,47,-R图范例-计算,统,统计量 (,一,一),样本序号,X1,X2,X3,X4,X5,XBAR,R,14,74.006,73.967,73.994,74.000,73.984,73.990,0.039,15,74.012,74.014,73.998,73.999,74.007,74.006,0.016,16,74.000,73.984,74.005,73.998,73.996,73.997,0.021,17,73.994,74.012,73.986,74.005,74.007,74.001,0.026,18,74.006,74.010,74.018,74.003,74.000,74.007,0.018,19,73.984,74.002,74.003,74.005,73.997,73.998,0.021,20,74.000,74.010,74.013,74.020,74.003,74.009,0.020,21,73.998,74.001,74.009,74.005,73.996,73.996,0.033,22,74.004,73.999,73.990,74.006,74.009,74.002,0.019,23,74.010,73.989,73.990,74.009,74.014,74.002,0.025,24,74.015,74.008,73.993,74.000,74.010,74.005,0.022,25,73.982,73.984,73.995,74.017,74.013,73.998,0.035,总平均值,74.001,0.023,X,48,-R图范例-计算,管,管制界限(,二,二),查系数,n=5,则有:,A2=0.577,D4=2.114,D3=0,图管制线,CL,X,=74.001,UCL,X,=+A2*,=74.001+0.577*0.023=74.014,LCL,X,=-A2*,= 74.001-0.577*0.023=73.988,X,X,X,R,R,X,X,49,-R图范例-计算,管,管制界限(,二,二),R,图管制线,CL,R,=0.023,UCL,R,= D4*=2.114*0.023=0.049,LCL,R,=D3*=0*0.023=0,R,R,R,X,50,-R图范例-绘制,图,图形(三),绘制R管制,图,图,UCL,CL,X,LCL,51,-R图范例-绘制,图,图形(三),绘制,图,图,UCL,CL,LCL,X,X,52,-R图范例-判定,图形状况判,定,定:,两图均未违,反,反判稳原则,属于稳态,管制界限在,规,规格界限内,过程能力评,定,定:,d2=2.326, =74.000,=74.001,中心不,重,重叠,Ca=(74.001-74.000)/0.02=0.05,Cp=T/(6*0.023/2.326)=0.674,Cpk=(1-Ca)Cp=0.95*0.674=0.64,结论:过程,是,是稳定的,但,但应加强过,程,程能力的提,升,升,X,X,53,pn图范例,SMT,加工后检查,数,数据如下:,n=100,k=25,组号,d,组号,d,组号,d,1,3,11,4,21,4,2,4,12,1,22,1,3,0,13,1,23,0,4,4,14,2,24,6,5,3,15,0,25,4,6,3,16,3,7,2,17,0,8,2,18,6,9,2,19,1,10,5,20,4,54,Pn图,计算统计量,和,和管制界限,CL=di/ k=65/25=2.6,UCL=,+3(1-/,n),=2.6+3(2.6(1-2.6/100) ,=7.4,LCL=,-3(1-/,n),=2.6-3(2.6(1-2.6/100),=-2.2,取0,d,d,d,d,d,d,d,55,