Introduction to Statistical Quality Control, 5 th edition.ppt

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1、IntroductiontoStatisticalQualityControl,5theditionDouglasC.MontgomeryArizonaStateUniversity12Chapter13IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter14IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(

2、c)2005JohnWiley&Sons,Inc.LearningObjectivesChapter15IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.1-1DefinitionsandMeaningofQuality1-1.1 The Eight Dimensions of Quality1.Performance2.Reliability3.Durability4.Serviceability5.Aesthetics6.Fea

3、tures7.PerceivedQuality8.ConformancetoStandardsChapter16IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.ThisisatraditionaldefinitionQualityofdesignQualityofconformanceChapter17IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Mont

4、gomery.Copyright(c)2005JohnWiley&Sons,Inc.ThisisamoderndefinitionofqualityChapter18IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.TheTransmissionExampleChapter19IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyrig

5、ht(c)2005JohnWiley&Sons,Inc.ThetransmissionexampleillustratestheutilityofthisdefinitionAnequivalentdefinitionisthatqualityimprovementistheelimination of waste.Thisisusefulinserviceortransactionalbusinesses.Chapter110IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)

6、2005JohnWiley&Sons,Inc.1-1.2TerminologyChapter111IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.TerminologycontdSpecificationsLowerspecificationlimitUpperspecificationlimitTargetornominalvaluesDefectiveornonconformingproductDefectornonconfo

7、rmityNotallproductscontainingadefectarenecessarilydefectiveChapter112IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.1-2.HistoryofQualityImprovementChapter113IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c

8、)2005JohnWiley&Sons,Inc.Chapter114IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter115IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter116IntroductiontoStatisticalQuality

9、Control,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter117IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.ProductionprocessinputsandoutputsProcessx1x2xpz1z2zqOutput productChapter118IntroductiontoStatisticalQuality

10、Control,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.StatisticalMethodsStatisticalprocesscontrol(SPC)Controlcharts,plusotherproblem-solvingtoolsUsefulinmonitoringprocesses,reducingvariabilitythrougheliminationofassignablecausesOn-linetechniqueDesignedexperiments(DOX)Discovering

11、thekeyfactorsthatinfluenceprocessperformanceProcessoptimizationOff-linetechniqueAcceptanceSamplingChapter119IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.WalterA.Shewart(1891-1967)TrainedinengineeringandphysicsLongcareeratBellLabsDeveloped

12、thefirstcontrolchartabout1924Chapter120IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.AfactorialexperimentwiththreefactorsChapter121IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.C

13、hapter122IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Effectivemanagementofqualityrequirestheexecutionofthreeactivities:1.QualityPlanning2.QualityAssurance3.QualityControlandImprovementChapter123IntroductiontoStatisticalQualityControl,5th

14、EditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter124IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter125IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Ch

15、apter126IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.1-4.1QualityPhilosophiesandManagementStrategiesW.EdwardsDemingTaughtengineering,physicsinthe1920s,finishedPhDin1928MetWalterShewhartatWesternElectricLongcareeringovernmentstatistics,USD

16、A,BureauoftheCensusDuringWWII,heworkedwithUSdefensecontractors,deployingstatisticalmethodsSenttoJapanafterWWIItoworkonthecensusChapter127IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.DemingDemingwasaskedbyJUSEtolectureonstatisticalqualityc

17、ontroltomanagementJapaneseadoptedmanyaspectsofDemingsmanagementphilosophyDemingstressed“continualnever-endingimprovement”DeminglecturedwidelyinNorthAmericaduringthe1980s;hedied24December1993Chapter128IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&So

18、ns,Inc.Demings14Points1.Createconstancyofpurposetowardimprovement2.Adoptanewphilosophy,recognizethatweareinatimeofchange,aneweconomicage3.Ceaserelianceonmassinspectiontoimprovequality4.Endthepracticeofawardingbusinessonthebasisofpricealone5.Improveconstantlyandforeverthesystemofproductionandservice6

19、.Institutetraining7.Improveleadership,recognizethattheaimofsupervisionishelppeopleandequipmenttodoabetterjob8.Driveoutfear9.BreakdownbarriersbetweendepartmentsChapter129IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.14Pointscontd10.Eliminat

20、eslogansandtargetsfortheworkforcesuchaszerodefects11.Eliminateworkstandards12.Removebarriersthatrobworkersoftherighttoprideinthequalityoftheirwork13.Instituteavigorousprogramofeducationandself-improvement14.PuteveryonetoworktoaccomplishthetransformationNote that the 14 points are about changeChapter

21、130IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.DemingsDeadlyDiseases1.Lackofconstancyofpurpose2.Emphasisonshort-termprofits3.Performanceevaluation,meritrating,annualreviews4.Mobilityofmanagement5.Runningacompanyonvisiblefiguresalone6.Exc

22、essivemedicalcostsforemployeehealthcare7.ExcessivecostsofwarranteesChapter131IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.JosephM.JuranBorninRomania(1904),immigratedtotheUSWorkedatWesternElectric,influencedbyWalterShewhartEmphasizesamores

23、trategicandplanningorientedapproachtoqualitythandoesDemingJuranInstituteisstillanactiveorganizationpromotingtheJuranphilosophyandqualityimprovementpracticesChapter132IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.TheJuranTrilogy1.Planning2.

24、Control3.ImprovementThesethreeprocessesareinterrelatedControlversusbreakthroughProject-by-projectimprovementChapter133IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.SomeoftheOther“Gurus”KaoruIshikawaSonofthefounderofJUSE,promotedwidespreadu

25、seofbasictoolsArmandFeigenbaumAuthorofTotalQualityControl,promotedoverallorganizationalinvolvementinquality,Three-stepapproachemphasizedqualityleadership,qualitytechnology,andorganizationalcommitmentLessergods,falseprophetsChapter134IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgo

26、mery.Copyright(c)2005JohnWiley&Sons,Inc.TotalQualityManagement(TQM)Startedintheearly1980s,Deming/JuranphilosophyasthefocalpointEmphasisonwidespreadtraining,qualityawarenessTrainingoftenturnedovertoHRfunctionNotenoughemphasisonqualitycontrolandimprovementtools,poorfollow-through,noproject-by-projecti

27、mplementationstrategyTQMwaslargelyunsuccessfulChapter135IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.TotalQualityManagement(TQM)TQMis“justanotherprogram”ValueengineeringZerodefects“Qualityisfree”Recipe for Ineffectiveness and maybe Disast

28、erChapter136IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.QualitySystemsandStandardsChapter137IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.TheISOcertificationprocessfocusesheavi

29、lyonqualityassurance,withoutsufficientweightgiventoqualityplanningandqualitycontrolandimprovementChapter138IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter139IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copy

30、right(c)2005JohnWiley&Sons,Inc.TheMBNQAprocessisavaluableassessmenttoolSeeTable1-3forPerformanceExcellenceCriteriaandpointvaluesTheMalcolmBaldrigeNationalQualityAwardChapter140IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter141Introdu

31、ctiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter142IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.SixSigmaUseofstatistics&otheranalyticaltoolshasgrownsteadilyforover80yearsStatistic

32、alqualitycontrol(originsin1920,explosivegrowthduringWWII,1950s)Operationsresearch(1940s)FDA,EPAinthe1970sTQM(TotalQualityManagement)movementinthe1980sReengineeringofbusinessprocesses(late1980s)Six-Sigma(originsatMotorolain1987,expandedimpactduring1990stopresent)Chapter143IntroductiontoStatisticalQua

33、lityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.FocusofSixSigmaisonProcessImprovementwithanEmphasisonAchievingSignificantBusinessImpactAprocessisanorganizedsequenceofactivitiesthatproducesanoutputthataddsvaluetotheorganizationAllworkisperformedin(interconnected)process

34、esEasytoseeinsomesituations(manufacturing)HarderinothersAnyprocesscanbeimprovedAnorganizedapproachtoimprovementisnecessaryTheprocessfocusisessentialtoSixSigmaChapter144IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Chapter145IntroductiontoS

35、tatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Why“QualityImprovement”isImportant:ASimpleExampleAvisittoafast-foodstore:Hamburger(bun,meat,specialsauce,cheese,pickle,onion,lettuce,tomato),fries,anddrink.Thisproducthas10components-is99%goodokay?Chapter146I

36、ntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.SixSigmaFocusInitiallyinmanufacturingCommercialapplicationsBankingFinancePublicsectorServicesDFSSDesignforSixSigmaOnlysomuchimprovementcanbewrungoutofanexistingsystemNewprocessdesignNewproductde

37、sign(engineering)Chapter147IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.SomeCommercialApplicationsReducingaverageandvariationofdaysoutstandingonaccountsreceivableManagingcostsofconsultants(publicaccountants,lawyers)SkiptracingCreditscorin

38、gClosingthebooks(faster,lessvariation)Auditaccuracy,accountreconciliationForecastingInventorymanagementTaxfilingPayrollaccuracyChapter148IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.SixSigmaAdisciplinedandanalyticalapproachtoprocessandpro

39、ductimprovementSpecializedrolesforpeople;Champions,MasterBlackbelts,BlackBelts,GreenBeltsTop-downdriven(Championsfromeachbusiness)BBsandMBBshaveresponsibility(projectdefinition,leadership,training/mentoring,teamfacilitation)Involvesafive-stepprocess(DMAIC):DefineMeasureAnalyzeImproveControlChapter14

40、9IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.WhatMakesitWork?Successfulimplementationscharacterizedby:CommittedleadershipUseoftoptalentSupportinginfrastructureFormalprojectselectionprocessFormalprojectreviewprocessDedicatedresourcesFinan

41、cialsystemintegrationProject-by-projectimprovementstrategy(borrowedfromJuran)Chapter150IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.OVERALL PROGRAMSLEANVariation ReductionPredictabilityFeasibilityEfficiencyCapabilityAccuracyFlow Mapping W

42、aste EliminationCycle TimeWIP ReductionOperations and Design LeanLead-timeCapableDMAICELIMINATE WASTE,IMPROVE CYCLE TIMEDESIGN PREDICTIVE QUALITY INTO PRODUCTSELIMINATE DEFECTS,REDUCE VARIABILITYDFSSRobustRequirements allocationCapability assessmentRobust DesignPredictable Product QualityDesign for

43、Six SigmaThe“I”in DMAIC may become DFSSTheProcessImprovementTriad:DFSS,Lean,andDMAICChapter151IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.DFSSMatchesCustomerNeedswithCapabilityMeanandvariabilityaffectsproductperformanceandcostDesignersca

44、npredictcostsandyieldsinthedesignphaseConsidermeanandvariabilityinthedesignphaseEstablishtoplevelmean,variabilityandfailureratetargetsforadesignRationallyallocatemean,variability,andfailureratetargetstosubsystemandcomponentlevelsMatchrequirementsagainstprocesscapabilityandidentifygapsClosegapstoopti

45、mizeaproducibledesignIdentifyvariabilitydriversandoptimizedesignsormakedesignsrobusttovariabilityProcesscapabilityimpactdesigndecisionsDFSS enhances product design methods.Chapter152IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.LeanFocuses

46、onWasteEliminationDefinitionAsetofmethodsandtoolsusedtoeliminatewasteinaprocessLeanhelpsidentifyanythingnotabsolutelyrequiredtodeliveraqualityproductontime.BenefitsofusingLeanLeanmethodshelpreduceinventory,leadtime,andcostLeanmethodsincreaseproductivity,quality,ontimedelivery,capacity,andsalesChapte

47、r153IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.11DMAICSolvesProblemsbyUsingSixSigmaToolsDMAICisaproblemsolvingmethodologyUsethismethodtosolveproblems:DefineproblemsinprocessesMeasureperformanceAnalyzecausesofproblemsImproveprocessesremo

48、vevariationsandnonvalue-addedactivitiesControlprocessessoproblemsdonotrecurChapter154IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.SixSigmaDMAICiscloselyrelatedtotheShewhartcycle(variouslycalledtheDemingcycle,orthePDCAcycle)Chapter155Intro

49、ductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.QualityCostsChapter156IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.LegalAspectsofQualityProductliabilityexposureConceptofstrict liabilit

50、y1.Responsibilityofbothmanufacturerandseller/distributor2.AdvertisingmustbesupportedbyvaliddataChapter157IntroductiontoStatisticalQualityControl,5thEditionbyDouglasC.Montgomery.Copyright(c)2005JohnWiley&Sons,Inc.Astrategicmanagementprocess,focusedalongtheeightdimensionofqualitySuppliersandsupplychai