精益六西格瑪案例學(xué)習(xí)-GP

1、1SBTI/AMC PartnershipSix Sigma Case Study2SBTI/AMC PartnershipDMAIC3SBTI/AMC PartnershipDMAIC項(xiàng)目選擇的理由（背景） 為什么要做這個(gè)項(xiàng)目？確定CTQ/Y（關(guān)鍵質(zhì)量特性）顧客是誰(shuí)？顧客的要求是什么？什么是關(guān)鍵質(zhì)量特性？D階段4SBTI/AMC PartnershipYEASTFLOUR 公司公司面粉酵母DMAIC5SBTI/AMC Partnershipl市場(chǎng)上品牌越來(lái)越多，競(jìng)爭(zhēng)越來(lái)越激烈l消費(fèi)者的消費(fèi)檔次在不斷提升l近3個(gè)月來(lái)日銷量持續(xù)下降（-14%）l經(jīng)市場(chǎng)調(diào)查顧客減少購(gòu)買的主要原因是面包的質(zhì)量l要提

2、升面包質(zhì)量，增加市場(chǎng)競(jìng)爭(zhēng)力DMAICC C 4 4I In nd di iv vi id du ua al l V Va al lu ue e17-Aug12-Aug7-Aug2-Aug14-Jul9-Jul4-Jul16-Jun11-Jun6-Jun1-Jun11001000900800700_X=849.1UCL=957.3LCL=740.9JunJulAug16336651I I C Ch ha ar rt t o of f S Sa al le es s b by y M Mo on nt th h6SBTI/AMC PartnershipDMAIC7SBTI/AMC Partners

3、hipD M AIC8SBTI/AMC PartnershipDMAIC9SBTI/AMC Partnership質(zhì) 地 結(jié) 構(gòu)膨 松 度新 鮮 度氣 味口 感 23 27 37 49117 9.110.714.619.446.2100.0 90.9 80.2 65.6 46.2250200150100500100806040200DefectCountPercentCum %PercentCountPareto Chart for YDMAIC10SBTI/AMC PartnershipCTQ的信息：測(cè)量基準(zhǔn)是什么？測(cè)量系統(tǒng)可靠性如何？初始流程能力是多少？目標(biāo)的設(shè)定確定潛在的原因影響CTQ的

4、可能原因都有哪些？確定潛在的關(guān)鍵原因哪些是潛在的關(guān)鍵原因？M階段DMAIC11SBTI/AMC PartnershipDMAIC12SBTI/AMC Partnership = 1 2 3 4 5 6 D M AIC13SBTI/AMC PartnershipD M AIC14SBTI/AMC PartnershipD M AIC15SBTI/AMC PartnershipMisc:Tolerance:Reported by:Date of study:Gage name:09.58.57.56.55.54.53.57654321Xbar Chart by PanelSample MeanMe

5、an=6.524UCL=7.151LCL=5.89701.00.50.07654321R Chart by PanelSample RangeR=0.3333UCL=1.089LCL=0321987654LoafPanelPanel*Loaf InteractionAverage1 2 3 4 5 6 7 7654321987654OperResponse By Panel321987654LoafResponse By Loaf%Contribution %Study Var Part-to-PartReprodRepeatGage R&R100500Components of Va

6、riationPercentGage R&R (ANOVA) for DataD M A I C16SBTI/AMC PartnershipMisc:Tolerance:Reported by:Date of study:Gage name:987654321DataLoaf1 2 3 4 5 6 7 Runchart of Data by Loaf, PanelD M AIC17SBTI/AMC PartnershipGage R&R %ContributionSource VarComp (of VarComp) Total Gage R&R 0.2113 5.08

7、 Repeatability 0.0952 2.29 Reproducibility 0.1161 2.79 Panel 0.0074 0.18 Panel*Loaf 0.1086 2.61 Part-To-Part 3.9449 94.92 Total Variation 4.1563 100.00 StdDev Study Var %Study VarSource (SD) (5.15*SD) (%SV) Total Gage R&R 0.45968 2.3674 22.55 Repeatability 0.30861 1.5893 15.14 Reproducibility 0.

8、34069 1.7546 16.71 Panel 0.08626 0.4442 4.23 Panel*Loaf 0.32959 1.6974 16.17 Part-To-Part 1.98619 10.2289 97.42 Total Variation 2.03869 10.4992 100.00 Number of Distinct Categories = 6DMAIC測(cè)量系統(tǒng)測(cè)量系統(tǒng)基本可以基本可以信賴，但信賴，但不是很好不是很好18SBTI/AMC PartnershipD M AI C19SBTI/AMC Partnership64321143D M AIC20SBTI/AMC P

9、artnership2520151050151050Individual and MR ChartObser.Individual ValueMean=7.375UCL=13.04LCL=1.7097.55.02.50.0Mov.RangeR=2.130UCL=6.961LCL=02520151050Last 24 Observations10864Observation NumberValuesT7Capability PlotProcess ToleranceIIIIIIIISpecificationsWithinOverall1272Normal Prob Plot1062Capabil

10、ity HistogramWithinStDev:Cp:Cpk:1.88868 *0.07OverallStDev:Pp:Ppk:Cpm:1.90444 *0.07 *Process Capability Sixpack for taste-beforeD M AIC21SBTI/AMC PartnershipDMAIC22SBTI/AMC Partnership WONDER DMAIC23SBTI/AMC PartnershipDMAIC24SBTI/AMC PartnershipYEAST FLOURDMAIC25SBTI/AMC PartnershiplABClBDBlCNNl面粉l輔

11、料l烤爐l水l膨松度 l質(zhì)地結(jié)構(gòu)l氣味l新鮮度l口感l(wèi)年輕女性l老年人l小孩DMAIC26SBTI/AMC Partnershipl面粉品牌l酵母品牌l酵母用量l水溫l鹽用量l面團(tuán)發(fā)酵溫度l面團(tuán)發(fā)酵時(shí)間l原料存放時(shí)間l原料存放溫度l原料存放濕度l面粉品牌l面粉新鮮度l酵母品牌l烘烤溫度l烘烤時(shí)間l存放時(shí)間l存放溫度l存放濕度D M A I C27SBTI/AMC PartnershipDMAIC28SBTI/AMC PartnershipDMAIC29SBTI/AMC PartnershipYEAST FLOURDMAIC30SBTI/AMC Partnership多變量分析（噪聲分析）是否存

12、在噪聲變量？關(guān)鍵變量的確定什么是影響CTQ的關(guān)鍵原因變量？A階段DMAIC31SBTI/AMC PartnershipOne-way ANOVA: Taste versus ChefAnalysis of Variance for Taste Source DF SS MS F PChef 2 63.517 31.758 32.57 0.000Error 27 26.325 0.975Total 29 89.842 Individual 95% CIs For Mean Based on Pooled StDevLevel N Mean StDev -+-+-+-Bush 10 8.7500

13、0.9204 (-*-) John 10 5.3000 1.0055 (-*-) Nick 10 7.8000 1.0328 (-*-) -+-+-+-Pooled StDev = 0.9874 6.0 7.5 9.NickJohnBush109876543ChefTasteBoxplots of Taste by Chef(means are indicated by solid circles)結(jié)論：廚師John的操作有問(wèn)題，需要進(jìn)行技能培訓(xùn)DMAIC32SBTI/AMC PartnershipOne-way ANOVA: Taste versus Flour-BrandAnalysis

14、of Variance for Taste Source DF SS MS F PFlour-Br 2 23.51 11.76 4.79 0.017Error 27 66.33 2.46Total 29 89.84 Individual 95% CIs For Mean Based on Pooled StDevLevel N Mean StDev -+-+-+-A 12 8.208 1.630 (-*-) B 10 7.200 1.418 (-*-) C 8 6.000 1.648 (-*-) -+-+-+-Pooled StDev = 1.567 6.0 7.2 8.4CBA1098765

15、43Flour-BrandTasteBoxplots of Taste by Flour-Br(means are indicated by solid circles)結(jié)論：不同品牌的面粉對(duì)口感有顯著的影響DMAIC33SBTI/AMC Partnership4504003509.58.57.5temptasteS = 0.192117 R-Sq = 77.5 % R-Sq(adj) = 76.5 % - 0.0002219 temp*2taste = -22.7844 + 0.167728 tempRegression Plot結(jié)論：溫度與口感之間有顯著的相關(guān)關(guān)系DMAIC34SBTI/A

16、MC PartnershipDMAIC35SBTI/AMC PartnershipDMAIC36SBTI/AMC PartnershipDMAIC37SBTI/AMC PartnershipLSLUSLTARGETDMAIC38SBTI/AMC Partnership6050403020100358354350346Individual and MR ChartObser.Individual ValueMean=351.9UCL=356.9LCL=347.06420Mov.RangeR=1.853UCL=6.053LCL=0605040Last 25 Observations35435235

17、0348Observation NumberValues355345Capability PlotProcess ToleranceIIIIIIIISpecificationsWithinOverall357352347Normal Prob Plot357352347Capability HistogramWithinStDev:Cp:Cpk:1.642321.010.62OverallStDev:Pp:Ppk:Cpm:1.657511.010.620.00Process Capability Sixpack for temp-beforeDMAIC39SBTI/AMC Partnershi

18、pDMAIC關(guān)鍵變量的改進(jìn)如何改進(jìn)關(guān)鍵原因變量？關(guān)鍵變量的優(yōu)化設(shè)置關(guān)鍵原因變量的最佳設(shè)置是什么？I階段40SBTI/AMC Partnership6050403020100356352348344Individual and MR ChartObser.Individual ValueMean=350.1UCL=355.0LCL=345.16420Mov.RangeR=1.869UCL=6.108LCL=0605040Last 25 Observations352350348346Observation NumberValues355345Capability PlotProcess Tole

19、ranceIIIIIIIISpecificationsWithinOverall355350345Normal Prob Plot355350345Capability HistogramWithinStDev:Cp:Cpk:1.657351.010.99OverallStDev:Pp:Ppk:Cpm:1.544661.081.070.00Process Capability Sixpack for temp-centerDMAIC41SBTI/AMC Partnership6050403020100353.5351.0348.5346.0Individual and MR ChartObse

20、r.Individual ValueMean=349.8UCL=352.8LCL=346.74.53.01.50.0Mov.Range11R=1.142UCL=3.732LCL=0605040Last 25 Observations351350349348Observation NumberValues355345Capability PlotProcess ToleranceIIIIIIIISpecificationsWithinOverall352350348Normal Prob Plot352350348Capability HistogramWithinStDev:Cp:Cpk:1.

21、012741.651.57OverallStDev:Pp:Ppk:Cpm:1.093441.521.450.00Process Capability Sixpack for temp-variDMAIC42SBTI/AMC PartnershipDMAIC43SBTI/AMC Partnership FLOUR FLOUR FLOURDMAIC44SBTI/AMC PartnershipGeneral Linear Model: Taste versus Brand, TempFactor Type Levels Values Brand fixed 3 1 2 3Temp fixed 3 1 2 3Analysis of Variance for Taste, using Adjusted SS for TestsSource DF Seq SS Adj SS Adj MS F PBrand 2 17.3333 17.3333 8.6667 26.00 0.000Temp 2 9.3333 9.3333 4.6667 14.00 0.002Brand*Temp 4 4.3333 4.3333 1.0833 3.25 0.066Error 9 3.0000 3.0000 0.3333Total 17 34.0000 DMA