10/1/2013

7 Cng c qun l cht lng trong sn xut

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10/1/2013

Quyt nh mc ch

Thu thp cc kin v s tht cn thit

Phn tch, tng hp li

Thc hin

Kim tra bng kt qu

Lp li t

CCH TIP CN NI CHUNG GII QUYT VN

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10/1/2013

Story

Chn ch

Nm bt hin trng

nh ra mc tiu

K hoch hot ng

Phn tch nguyn nhn

Xem xt i sch

Thc hin i sch

Xc nhn hiu qu

nh hnhTiu chun ho

Rt kinh nghim, phng hng sau ny

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10/1/2013

Chn ch

Xc nh cc vn ni tri

nh gi, nh dng vn (Quan im Q,D,C

Quyt nh ch

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10/1/2013

Nm bt hin trng

Thu thp d liu

Chnh l v tm ra ca gii quyt vn

Phn tch nguyn nhn

Xc nh nguyn nhn Gii thch nguyn nhn

Tm ra nguyn nhn chnh

Xem xt i sch

Lp phng n i sch, nh gi v nh dng

i sch

Lp k hoch thc hinXc minh =

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10/1/2013

Xc nhn hiu qu

Thu thp d liu, xc nhn mc t c so vi mc tiu

Xc nhn hiu qu phi vt th

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10/1/2013

7 CNG C L GI? L cng c phn tich d liu trn biu da trn t duy mang tnh thng k v thc hin phng php s dng ph hp vi

mc ch

Biu Pareto

Biu nguyn nhn

chnh

th

Check sheet

Histogram

Biu phn b

Biu qun l

Tn ti s khng ng u v

cht lng. Nguyn nhn dn

n khng ng u:

trong sn xut Con ngiMan Nguyn liuMaterial Thit bMachine Phng phpMethod o lngMeasurement

Cng on

ch to

Data

Sampling

Phn tch

7 cng c

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10/1/2013

2. Cc cng c c bn qun l cht lng sn phm

2.1. Phiu kim tra (CHECK SHEET)

Phiu kim tra l biu mu thu thp v ghi chp d liu mt cch trc quan, nht qun v to iu kin thun li cho vic phn tch.

Phiu kim tra s 71

Sn phm: B16 Ngy:

S n v c kim tra: 12.213 Ngi iu hnh:

Sn si 23

Rn nt 18

Lng lo 34

L do khc 15

Hnh 2 - Phiu kim tra ch ra nhng khuyt tt

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10/1/2013

2.2. Gin Pareto

Gin Pareto l mt cng c sp xp nhng vn qun l theo th t quan trng ca chng.

nh lut 20-80:

80% thit hi v khng c cht lng l do 20% nguyn nhn gy ln.

20% nguyn nhn gy ln 80% ln xy ra tnh trng khng c cht lng.

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10/1/2013

2.2. Gin Pareto

Th tc v mt gin Pareto.

Chn nhng nguyn nhn ca tnh trng khng c cht lng.

Quyt nh mt khong thi gian quan st

Tnh thit hi (hay m s ln pht hin) nhng tnh trng khng c cht lng do mi nguyn nhn gy nn trong mt khong thi gian no .

Xp nhng nguyn nhn theo th t thit hi (hay th t s ln pht hin)

V th vi:

+ Honh l nhng nguyn nhn khng c cht lng

+ Tung l thit hi (hay s ln pht hin) mi nguyn nhn gy nn v tch lu thit hi (hay s ln pht hin)

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10/1/2013

2.3. Gin quan h nhn qu

H qu

Nguyn nhn chnh 1

Nguyn nhn chnh 2

Nguyn nhn chnh 3

Nguyn nhn chnh 4

NN ph 1.1

NN ph 1.2

NN ph 3.2 NN ph 4.1

NN ph 2.2 NN ph 2.1

NN ph 4.3 NN ph 4.2 NN ph 3.1

NN ph 2.3

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10/1/2013

2.4. Kim sot qu trnh bng k thut thng k (STATISTICAL PROCESS CONTROL-SPC) v biu kim sot (CONTROL CHART)

Biu kim sot (BKS) bao gm:

+ ng trung tm CL (Central Line)

+ Hai ng gii hn kim sot: ng gii hn trn UCL (Upper Control Limit) v ng gii hn di LCL (Lower Control Limit

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10/1/2013

Th tc dng biu kim sot

Bc 1: La chn c tnh cn kim sot (v d: trng lng, th tch, ...). Tu thuc vo c tnh la chn mt loi BKS.

Bc 2: Quyt nh c mu v tn s ly mu

Bc 3: Thu thp v ghi chp s liu

Bc 4: Tnh cc gi tr thng k c trng ca mi mu

Bc 5: Tnh cc tr s trung tm CL v nhng ranh gii trn UCL v ranh gii di LCL.

Bc 6: c biu kim sot

Bc 7: Quyt nh v iu chnh qui trnh.

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10/1/2013

Cc loi biu kim sot v cng thc

c tnh gi tr: Gi tr lin tc (Nhng s o)

Biu x R: nh gi gi tr trung bnh v khong sai bit.

Biu x : nh gi gi tr trung bnh v lch chun.

Gi tr ri rc (Bin thuc tnh)

Biu np v biu p (t l phn trm khuyt tt): nh gi xu hng khuyt tt xy ra.

Biu c v biu u: nh g xu hng s khuyt tt xy ra trn mt n v sn phm

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10/1/2013

Biu kim sot nhng s o

n

x

x

n

i

ij

J

1 minjjmacj xxR

k

x

x

k

i

j 1

k

R

R

k

j

j

1

Biu kim sot :

ng tm CL:

UCL = +

LCL = -

x

x

x .2A R

x .2A R

Biu kim sot R:

ng tm CL:

UCL =

LCL =

R

4D

3D

R

R

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10/1/2013

Bn lm vic b phn bn thnh phm trong nh my ch to dy in. Sn xut bc v nha cho dy li c chuyn n t cng on Vut dy trc. Ti cng on ny c rt nhiu vn v cht lng i vi dy c ch to ra. Nhim v l phi thc hin lm sao cho gim c nhng vn ny

VN DIN TP TNG HP VI 7 CNG C QC

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10/1/2013

Tnh hnh cht lng ca v bc Loi hng

Thng Sn xut

S li

Sn xut S li

Sn xut S li Sn xut

S li

55 10 80 21 30 5 51 14

60 11 87 25 25 6 60 13

51 12 93 18 22 4 66 15

70 8 95 25 28 8 45 16

53 5 78 23 26 4 63 9

66 15 85 19 24 6 62 12

65 16 85 20 32 8 51 11

58 9 78 20 26 4 60 17

69 11 80 25 22 6 66 14

56 10 93 33 23 4 45 12

54 14 83 31 30 8 63 15

60 9 88 34 22 2 65 13

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10/1/2013

T bng d liu v th Loi hng

Thng Lng

sn xut S li T l li

55 10 18.2%

60 11 18.3%

51 12 23.5%

70 8 11.4%

53 5 9.4%

66 15 22.7%

65 16 24.6%

58 9 15.5%

69 11 15.9%

56 10 17.9%

54 14 25.9%

60 9 15.0%

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10/1/2013

0%

5%

10%

15%

20%

25%

30%

th bin thin t l li ca hng

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10/1/2013

So snh s bin thin t l li ca 4 loi hng

0%

5%

10%

15%

20%

25%

30%

35%

40%

45%

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10/1/2013

Chn ch

Hng c khuynh hng xu i trong thi gian gn y

Trong 4 thng gn nht th hng B c t l li cao nht

Quyt nh chn ch ci tin cht lng mt hng

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10/1/2013

Bo co cng vic

Loi hng

Ngy thng

Lc x

M sn xut

Ngi ph

trch Cch qun

My tm xc Xc

Vy

Loi li

Lc xYu cu lc x Cch qunnh gi bng mt Xc V tr pht hin bng my tm xcChiu di t u mt Vy V tr pht hin bng my tm xcChiu di t u mt

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10/1/2013

Chnh l d liu bng check sheet L cng c thu thp v chnh l d liu bng cch nh

du trn biu mu chun b trc

Li M ch to Ngy thng Ph trch Lc x X Cch qun Xc Vy

101 101.2 102 100.7 103 93.7 104 92.2 105 92.4 106 116.1 (52m) 107 87.1 108 106.2 (53m) 109 101.1 110 101.7 111 83.6 112 103.6 113 108.6 114 94.1 115 106.0

Ch to thng 1 nm 2008

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10/1/2013

Xc minh mc tiu qua biu Pareto Biu Pareto v s li

X

c

X

Vy

Cch

qun

Li xc chim

t l ln trong cc li

nguyn tnh trng ny

c c khng?

Ni dung li S tin tn tht

Li x

Li qun bng

Li xc

Li vy

YnCun

YnCun

YnCun

YnCun

Cn phi quy tn tht thnh tin

T

l lu

tin()

S

cu

n

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10/1/2013

NH GI BNG S TIN TN THT

L PHNG PHP C BN

Biu pareto v s tin tn tht

X

c

X

Vy

Qu

n

bn

g

T l lu

tin

(

)

Ch ring li x chim

ti trn 70% tng s tin tn

tht

C th hy vng s mang li

hiu qu ln v tin

S tin

tn

tht

Ngn

yn

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10/1/2013

NM R S BIN THIN QUA HISTGRAM

LP HISTGRAM T D LIU

CHNH L TRN CHECKSHEET

S hiu sp Lc x Li lc x S hiu sp Lc x Li lc x

112.3 98 100.5 121.4 94.6 91.4 89.5 111.3 97 93.7 95.9 93.1 104.3 97.5 96.1 99 93.8 98.8 95.8 98.3

89.7 105.5 115.1 100.4 84.8 102.6 105.6 87 95.7 99.8 101.4 85.6 112.1 93.8 94.7 88.4 109.1 80.3 110.8 105.2

S hiu sp Lc x Li lc x

101.2 100.7 93.7 92.2 92.4 116.1 87.1 106.2 101.1 101.7 83.6 103.8 108.6 94.1 106 109.7 98.8 105.4 103.7 98.2 107.7 116.1 103.4 107.5 102.6

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10/1/2013

TRNH T LP HISTGRAM

StepThu thp d liu trn 50 mu Stepc lng s khong cch: StepGi tr max,min; Max121.4;Min80.3 Stepc lng rng khong cch

865 taSoluongdat

3 . 80 4 . 121

8 5.1 14 . 5

S lng khong cch

MaxMin

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10/1/2013

TRNH T LP HISTGRAM

Stepquyt nh s lng khong cch thc, rng khong cch, gi tr gii hn khong cch

V th cho ngi khc

d hiu

S lng

khong cch 9

rng khong

cch 5.0

Khong cch

1 80-85

2 85-90

3 90-95

4 95-100

5 100-105

6 105-110

7 110-115

8 115-120

9 120-125

Gi tr yu cu gii hn di

Gi tr yu cu gii hn trn

Gi tr gii hn khong cch Gi tr yu cu - d hiu

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10/1/2013

StepLp biu s ln lp

Khong cch Gi tr tm Du s ln lp S ln

1 80-85 82.5 3

2 85-90 87.5 6

3 90-95 92.5 11

4 95-100 97.5 13

5 100-105 102.5 13

6 105-110 107.5 11

7 110-115 112.5 4

8 115-120 117.5 3

9 120-125 122.5 1

///

//// /

//// //// /

////

////

////

////

////

////

////

///

/

///

///

/

TRNH T LP HISTGRAM

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10/1/2013

Gii hn di

SL85

Gii hn trn

SU115 N=65 2008/3

0

2

4

6

8

10

12

14

75-80

80-85

85-90

90-95

95-100

100-105

105-110

110-115

115-120

120-125

125-130

S

ln

Vn l ch lch

gii hn trn v di

Gi tr trung bnh theo

nh gi tr mc tiu

Vn chnh l gim

s khng ng u

Gi tr trung

bnh 99.87 lch

chun

8.62

StepLp Histgram

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10/1/2013

Gi tr trung bnh v lch chun Gi tr trung bnh

Bnh phng lch

iu chnh

lch chun

1n

SV

V

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10/1/2013

Nng lc cng on l g?

L gi tr cho bit rng s thc hin c cht lng mc no? khi thc hin cc cng vic theo ng nh tiu chun

Ch s nng lc cng on l g?

L i lng th hin nng lc cng on bng con s

V6

SSCp LU

rng yu cu

S bin ng (khng ng u)

Xc nh nng lc cng on

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10/1/2013

Cc bc c bn nm r nng lc cng on

Xc minh r gi tr c tnh v phm vi iu tra, tp hp d liu Lp s qun l, xc nhn cng on c nm trong trng thi n nh khng? Tnh ton ch s nng lc cng on Nu nng lc cng on khng th cn tm i sch

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10/1/2013

0

2

4

6

8

10

12

14 75-80

80-85

85-90

90-95

95-100

100-105

105-110

110-115

115-120

120-125

125-130

S l

n

Gii hn di SL85

Gii hn trn SU115

N=65

2008/3

Gi tr trung bnh 99.87 lch chun 8.62

CH S NNG LC CNG ON

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10/1/2013

XC NH NGUYN NHN CHNH THEO S NHN QU

Phn tch theo l thao tc c bn

S k

hng

ng

u

v l

c x

Vt liu Thit b

Con ngi Phng php o lng

Tc quay

ca trc vt

Lot dung

dch xc tc

Nhit

nc lm mt

Li thit lp

iu kin Li trnh t

thao tc

L nguyn liu

Thi gian t ngy sn xut

Phng php trn

vt liu

Gc x

K nng

p lc u ra

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10/1/2013

NM R QUAN H NHN QU QUA

S PHN B

Khng tng

quan

80

90

100

110

120

0.8 1 1.2 1.4 1.6 1.8 2 2.2

S PHN B GIA P LC U RA V LC X S TNG QUAN

p lc u ra (/2)

Lc x

(

)

rng

yu cu

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10/1/2013

Tng quan t l nghch Nhit nc tng th lc x gim

80

90

100

110

120

10 15 20 25 30

Nhit nc ()

L

c x (

)

rng

yu cu C tng quan t l nghch

NM R QUAN H NHN QU QUA

S PHN B

S PHN B LIN QUAN GIANHIT NCV LC XS TNG QUAN

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10/1/2013

180

30

13 14 15 169 10 11 125 17 181 2 3 4 6 7 8

0

20

170

160

150

20

10

19

S qun l Rx

n=5

UCL=172.0

LCL=158.0

CL=165.0

UCL=25.7

CL=12.1

S mu

Gii hn

qun l trn

Gii hn

qun l di

Dy trung tm

Phm viR

(Gi tr maxGi tr min)

Gi tr

trung bnh

Khng qun

l c

Gii hn

qun l trn

Dy trung tm

x

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10/1/2013

Xc nh gii hn qun l trong s qun l Rx

StepTnh bnh qun cc tp v phm vi R

Step Tnh tng bnh phng v trung bnh ca phm vi R

x

x R

S nhm

S nhm

Tng cc R R

Tng ca x x

Gi tr MaxGi tr Min

S lng Data

Tng cc Data

R

x

Tng s c 20 nhm

20

3R

20

15.8x

C mt tp gm cc Data l 15,17,16,14,17

3 14 - 17 R

15.8 5

79

5

17 14 16 17 15 x

Gi tr MaxGi tr Min

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10/1/2013

CCH TM GII HN QUN L TRONG S QUN L

Step Tnh CL, UCL, LCL trong s qun l

RAxUCL 2

RAxLCL 2

xCL

A2 L mt s khng i quyt nh bi s mu Khi s mu n5 A20.577

S lng mu A 2

2 1.880 3 1.023 4 0.729 5 0.577 6 0.483 7 0.419 8 0.373 9 0.337 10 0.308

x

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10/1/2013

CCH TM GII HN QUN L TRN S QUN L

Step Tnh CL, UCL, LCL trn s qun l R

RDUCL 4

RDLCL 3

RCL

D4D3 l nh s quyt nh bi s lng mu

Khi n5 th D42.115 (Khng tn ti D3)

(Nu s mu n6 th khng cn LCL)

S lng mu D 3 D 4

2 3.267 3 2.575 4 2.282 5 2.115 6 2.004 7 0.076 1.924

8 0.136 1.864

9 0.184 1.816

10 0.223 1.777

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10/1/2013

KIM TRA N NH CNG ON QUA S QUN L

Lot

85

9 0

9 5

1 0 0

1 0 5

1 1 0

0

5

1 0

1 5

2 0

UCL=106.3 CL=99.8 LCL=93.3

UCL=16.3 CL=6.3

Cng on sau

ci tin c trng

thi n nh

BIU QLSX

BIU QUN L R

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10/1/2013

Qun l cht lng theo phng php 6 Sigma

a- 6 Sigma l g?

6 Sigma mt phng php lun gip ci thin cht lng bng cch a ra mt thc o ring nh gi kh nng (tnh trng cht lng) ca mt qui trnh, v hng dn vic ci thin cht lng theo cch thc ring. Thc o l h s Sigma, v cch thc trin khai 6 Sigma (chnh l s kt hp cc cng c) l vng trn DMAIC.

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10/1/2013

Six Sigma v hiu sut ca qu trnh

-6 6 -4 -2 2 4

99,9997%

99,4%

69,2%

50%

H s Sigma s c xc nh da trn s khuyt tt xy ra trn mt triu n v kh nng gy li, gi tt l DPMO (Defect Per Million Opportunity).

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10/1/2013

DPMO = S khuyt tt pht hin x 1.000.000

Tng s c hi xy ra sai li

DPMO =

S khuyt tt pht hin x 1.000.000

S sn phm kim tra x S kh nng xy ra sai li

trn 1 v sp

DPMO (Defect Per Million Opportunity).

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10/1/2013

Quan h Sigma v DPMO

Nu hiu sut ca qu

trnh l...

DPMO tng ng

l...

th s l...

Sigma

30,9% 690.000 1

69,2% 308.000 2

93,3% 66.800 3

99,4% 6.210 4

99,98% 230 5

99,9997% 3,4 6

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10/1/2013

Six

Sigma

Measure

o lng

Phng php lun DMAIC

Analyse Phn tch

Improve Ci tin Control

Kim tra

Define Xc nh

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10/1/2013

Giai on 1: Xc nh c hi

Mc tiu

Nhn bit v xc

nh cc c hi ci

tin, pht trin cc

qu trnh kinh

doanh, xc nh cc

yu cu ch yu ca

khch hng v

chun b nhm d

n (cho mt mc

tiu xc nh) cho

tt.

Cc hot ng chnh

+ Xc nh v thm

nh cc c hi kinh

doanh

+ Xc nh h s qui

trnh hot ng.

+ Xc nh s x l.

+ Chuyn ti cc yu

cu ca khch hng,

thnh cc c tnh ca

sn phm.

Cc cng

c v k

thut

+ S qu

trnh .

+ Phn tch

+ Pareto

Kt qu t c

+ S , biu

qu trnh hot

ng

+ Cc yu cu ch

yu ca khch

hng (cc yu cu

v cht lng sn

phm)

+ K hoch hnh

ng ca d n

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10/1/2013

Giai on 2: o lng hot ng

Mc tiu

+ Xc nh cc php o c

bn cn thit cho vic nh

lng chnh xc mc tiu

ca qun l cht lng

+ Hiu cch thc tnh ton

ca 6 Sigma v thit lp

gii hn 6 Sigma cho cc

qu trnh m nhm phn

tch

Cc hot ng

chnh

+ Nhn bit u

vo qu trnh v

cc ch s u ra.

+ Xy dng, o

lng.

+ Pht tho vo

phn tch d liu

+ Xc nh cc

nguyn nhn c

bit nu c

+ Xc nh cc

mc hot ng

Sigma.

Cc cng c

v k thut

+ Phiu kim

tra

+ Biu

kim sot

+ Biu

phn b.

Kt qu t

c

+ Cc ch s

qua u vo,

qu trnh u ra.

+ Cc chun

mc hot ng.

+ nh dng cc

d liu thu thp

+ Cc chun

mc Sigma hot

ng

+ Tinh thn tp

th

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10/1/2013

Giai on 3: Phn tch qui trnh

Mc tiu

+ Sng lc, phn

tch cc c hi

xc nh c th

tng vn v nh

ngha s c mt

cch d hiu.

+ Xc nh nhng

nguyn nhn c

bn nht t

tm ra vn

nhm tp trung gii

quyt

Cc hot ng chnh

+ Phn loi qu trnh

+ Phn loi d liu v xc

nh vn c th

+ nh ngha v m t vn

.

+ Nhn bit cc nguyn nhn

c bn

+ Thit k phng php phn

tch nguyn nhn c bn

+ Xc nh cc nguyn nhn

c bn

+ Tng cng hot ng

nhm

Cc cng

c v k

thut

+ Biu

Pareto

+ Biu

nhn qu

Kt qu t

c

+ D liu qu

trnh

+ Cc s

qu trnh

+ Cc nguyn

nhn gc d

ca cc vn

( c thm

nh)

+ M t vn

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10/1/2013

Giai on 4: Ci tin qui trnh

Mc tiu

+ Nhn bit, nh

gi v la chn

gii php ci tin

hp l

+ Thay i trong

cch tip cn qun

l h tr t

chc trong vic

thch ng vi thay

i trong qu

trnh trin khai

gii php.

Cc hot ng chnh

+ To ra cc tng v

gii php

+ Xc nh cc nh hng

v li ch ca ci tin

+ nh gi v la chn cc

gii php

+ Xy dng s qu trnh

+ Pht trin v trnh by

kch bn trin khai cc gii

php

+ Gii thiu gii php ti

nhng ngi lin quan

Cc cng

c v k

thut

+ Phn tch

+ Parato

+ Biu

Gantt

Kt qu t

c

+ Cc gii

php

+ S qu

trnh v h

thng vn bn

+ L trnh qu

trnh trin

khai

+ Li ch v

cc tc ng

ci tin

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10/1/2013

Giai on 5: Kim sot qui trnh

Mc tiu

m bo

tnh hiu

qu ca cc

gii php

khi a vo

trin khai,

tiu chun

ho cc gii

php thnh

cc cng

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