01 Process Map (CN)

六西格玛方法论Connect ReworkSetupDisconnectTestDispose流程图Rev. G Printed 12/20/2010 © 2004 by Sigma Breakthrough Technologies, Inc.®1流程图提供流程图的概述 示范如何分步骤制作流程图 展示流程图在Six Sigma方法论中位于何处 提供流程图例子 流程图练习2六西格玛总方法论3流程图的作用4流程图在项目中的用途主要目的 1>找出所有因子 找出所有因子 2>为因果矩阵提供输入 为因果矩阵提供输入 3>为FMEA提供输入 为 提供输入 4>为流程能力分析提供输入 为流程能力分析提供输入 5>为多变量分析提供输入 为多变量分析提供输入 6>为实验设计提供输入 为实验设计提供输入 7>为控制计划提供输入 为控制计划提供输入5流程改善指引定义阶段 测量阶段计划项目并识别关键流程输入/输出 计划项目并识别关键流程输入 输出 变量 确定最优运行窗口 对基本的测量系统进行量具研究 更新控制计划 进行短期流程能力分析并建立控制 计划改善阶段用 DOE验证关键输入 验证关键输入控制阶段 分析阶段确定流程控制计划 完成初步的 FMEA 并评估控制计划 对流程能力及稳定性进行持续验证 完成多变量分析以识别潜在关键输入审核数据并区分关键输入变量的优先 顺序6流程过程中的逻辑心法7漏斗效应• 流程图30+ 输入 10 - 15 8 - 10 4-8 3-6所有 X’s “许多微不足道的” 许多微不足道的” 许多微不足道的测量• C&E 矩阵 • 失败模式及效应分析 • 多变量分析 初步筛选分析筛选列表改善• 实验设计 (DOE)找到关键 X’s控制• 控制计划控制关键 X’s “少数关键的” 少数关键的” 少数关键的关键输入变量8宏观流程图1>宏观流程图：有助于团队项目达成共识，界定项目范围。

1>宏观流程图：有助于团队项目达成共识，界定项目范围。

宏观流程图Supplier Input Process Output Customer9区域流程图2>区域流程图：有助于发现过程的瓶颈，查找问题的原因，发现“隐蔽的工厂”。

区域流程图：有助于发现过程的瓶颈，查找问题的原因，发现“隐蔽的工厂” 区域流程图10详细流程图更方便快捷的查找和分析原因。

对流程动作的分解，，更方便快捷的查找和分析原因3>详细流程图详细流程图：：对流程动作的分解8.流程图与鱼骨图1>1>流程图分析过程中应用了鱼骨图技术流程图分析过程中应用了鱼骨图技术流程图分析过程中应用了鱼骨图技术。

2>2>流程图分析要求我们到现场更深入地了解过程流程图分析要求我们到现场更深入地了解过程流程图分析要求我们到现场更深入地了解过程，，分析问题分析问题。

3>3>流程图更全面的查找原因流程图更全面的查找原因流程图更全面的查找原因。

团队合作:−制造工程师−生产线操作员−生产线主管−维修技术人员−供应商绘图输入:−头脑风暴法−操作手册−工程标准−工作安全分析−操作员经验−5M1E人机器方法测量材料环境流程图绘制步骤确定流程、外部输入、客户输出，这就是SIPOC。

图示流程中的所有步骤(微观法)。

列出各步骤的关键输出变量(包括报废& 返工)。

列出关键输入变量并将它们按可控(C)，不可控(U) 或标准操作流程(S)加以分类。

为输入变量加入流程规格。

12345步骤1: 识别流程及输入/输出SUPPLIERSOUTPUTSCUSTOMERSFURNACE ASM. LINE* TESTED FURNACE TRENTON PLANT ( O.F.)R&D MACHINE CONTROL * REJECTED PARTS SHIPPINGTEST TECHNICIAN * TEST RECORDSDEALER / DISTRIBUTOR IT PROGRAMMER * REGULATORY AGENCY HOMEOWNERSYMBOL TECHREQUIREMENTS MET WALLACE PRINTING INC.* TRANE / AM.STANDARD PSEG ( GAS & ELECTRICITY)REQUIREMENTS METSTARTFINISHTRENTON GAS FURNACE FINAL TEST SIPOCCONNECT FURNACE TO TESTER SETUP TEST (SCAN)START TESTREPAIR FURNACE (IF REQUIRED)DISPOSE OF FURNACE TO NEXT STATIONFURNACE TEST PROCESSINPUTSASSEMBLED & WIRED FURNACE TEST EQUIPMENT & PROGRAM TEST CONNECTIONS TEST OPERATOR SOESCAN EQUIPMENT PRINTERTRAVEL TICKET / RUNBAR AIR GUN & GROUND SCREWS E.T.Q.C. COMPUTER SYSTEM JOB SAFETY ANALYSES步骤2: 从SIPOC中移出流程步骤包括所有增值与非增值步骤−流程步骤，检查/测试，返工，报废点Answer PhoneGreet customer Determine parts needed Identify need date Identify ship to addressIdentify price Identify shipment methodInternal InformationGet internal P/NDetermine termsIdentify lead timeComplete order worksheetOrder EntryInput informationPrint order confirmationDetermine ship dateReview orderOrder ConfirmationFAX confirmation tocustomerVerify manufacturingreceipt of order 非制造业DisconnectPassed TestUpdate ETQCOperator InputTest SOPInspection制造业Connect Test Connect Furnace toTesterSetup TestScan Unit tosetup TestParameters &Verify ETQCis OKStart TestOperator StartsTest andfollows SOPRepairRepair any testfailures orvisible defectsDisposeApply “Tested by”and NP Labels.Disconnect &Move步骤3: 列出关键输出变量包括流程和产品输出变量•FurnaceReady to test •Bad TestEquipment •TestParametersselected •ETQC Check •Passed TestUnits •Failed testunits •Rework •Scrap parts •Scrap units •Repaired units ready for retest •ETQC Records updated for S/N •Unit ready fordoor installation输出输出ConnectConnect furnace totesterSetup Scan Unit tosetup test parameters & verify ETQC isokRepairRepair any testfailures orvisible defects制造业例子Start Test Operator Starts Test and followsSOPDispose Apply “Tested by” and NPLabels. Disconnect &Move使用积聚图确定流程步骤Return to previous slide标示以前记录的事故盘管部制作部控制部步骤4:列出输入变量并分类列出输入变量并分类−可控输入、不可控输入、标准操作流程可控输入: 可被改变并观察到其对输出的影响有时叫“Knob”变量”): 影响输出的输入变量噪音”影响输出的输入变量，，但很难或不可能“噪音不可控输入(也叫也叫“，不过不在当前控制之中)或许可控，控制(或许可控−例子: 环境变量如湿度调整指示、、调整指示、工作安全分析等标准操作流程: 详细指示详细指示、、方法表方法表、步骤4: 列出输入变量包括流程和产品输出变量制造业例子•Furnace Ready to test •Bad Test Equipment•TestParameters selected•ETQC Check•Passed Test Units•Failed test units•Rework •Scrap parts •Scrap units •Repaired units ready for retest•ETQC Records updated for S/N •Unit ready for door installationOutputsOutputs Connect Connect furnace to testerSetup Scan Unit to setup test parameters & verify ETQC is okRepair Repair any test failures or visible defectsStart Test Operator Starts Test and followsSOPDispose Apply “Tested by” and NP Labels. Disconnect &Move•Furnace (U)•115 v cable (S)•24 v cable (S)•Door clip (S)•Ampclamp (S)•Test Parameters (C)•ETQC (S)•Scanner (S)•Runbar (S)•Operator (C)•Test Procedure (S)•Furnace Fail (U)•Repair Procedure (S)•Operator Training (C)•Test Label (C)•ETQC (S)•Product Literature (C)•Rating Nameplate (S)•Label Application (C)Input Type Input Type步骤5:为输入添加规格对于可控的关键的输入变量，我们可为其添加操作规格和目标这些信息是控制计划的开端!Controlled InputVariableTargetLowerSpecUpperSpec Lo Spd Motor Amps 4.7 4.0 5.2Gas Flow Rate9588.0103.0Ignition Time202020Ignitor Amps10.8 1.2后续步骤P rocess StepInpu t O utp utP rocess S pecification(Targ et, LS L, U S L)Cpk M ean - S igm a M easurem en t Tech nique %R&R P/T S am ple S izeS am p le Frequency Con trolM ethodR eaction P lanC oatingDosage22.5, 22, 23 1.22U IL-170025%1/hr A uto-tim er Cross checkCoatingHeight 24,23,251.54M icrom eter 31%/0.4735 pts per panel1/hr C oating & pum p speedA djust previousCoating width 14,12,16 1.78Laser M easuringD evice1/hr None in place Coating length36,34,38 1.43Laser M easuring D evice1/hr None in placeV acuum35" H gV acuum G auge1/hrM onitorCom pare guages, look for blockage流程图1234567891011Process Step Process Inputs H e a v i e s i n P r o d u c tL i g h t s i n P r o d u c tM o i s t u r e i n P r o d u c tA c i d i t y i n P r o d u c tL o w C a p a c i t y F r o m U n i tE x c e s s i v e D o w n t i m eM a t e r i a l L o s s e sC o r r o s i o n o f E q u i p m e n tP o o r R e a c t o r P e r f o r m a n c e Total 139Day Tanks Analysis1010993359Reactor Cat./HF Ratio 5871577Reactor Rxr Temperature 654714973Lights Rem oval Condenser Leak 4824114874Lights Rem oval Reboiler Leak 48241148131Purification Low Stages 88144144Final Storage Containers 3266140100Neutralization pH Value 66313816C atalyst StripperPluggage3653137111Drying Decomposition 2632213439Drier W ater Carryover 465113234DrierMolecular Sieve33272125因果矩阵图P r o c e s s S te p /P a r t N u m b e rP o te n tia l F a ilu r e M o d e P o te n tia l F a ilu r e E ffe c ts SE VP o te n t ia l C a u s e sOC CC u r r e n t C o n tr o lsDE TR P N A c tio n s R e c o m m e n d e dR e s p .C O A T IN G & IM A G IN GD IR T Y P H O T O M A S KM IC R O C R A C K IN G ,D E L A M IN A T IO N , S T R E A K S8L O W F R E Q U E N C Y O F C L E A N IN G 8S O P , V IS U A L IN S P E C T IO N7448IN C R E A S E F R E Q U E N C Y T O O N C E E V E R Y 20 P A N E L SM GIM P R O V E C L E A N IN G M E T H O D P FP U R C H A S E O F F -L IN E C L E A N IN G S Y S T E M M GT E S T O N -L IN E M A S K R E P L A C E M E N TP FFMEA输出输入I n p u tT y p e O u t p u t A g i t s p e e d C o n t r S t a b t i m eT e m p e r a t u r e C o n t r S t a b i l i z eA c id n u m b e r P r e s s u r e C o n t r C o l o rA ir f lo wC o n t r P u t in s e t p o in t s V is c o s it y% O 2 in a ir N o is e S l o w ly r e d u c e p r e s sR e a c t o r t e m p A ir t e m pC o n t rM o n it o r t e m pT e m p p r o f i le O f f g a s f l o w O f f g a s c o m p H T c o e f fB e l t s p e e dC o n t r F in i s h t im e B e l t t e m p C o n t r F i n i s hA c id n u m b e r F lo w r a t e C o n t r C o l o rN o z z l e t y p e S O P C h e c k n o z z le t y p e V is c o s it y H o l e s i z e C o n t r P u t in s e t p o in t s D r o p P o in t R o o m t e m p N o is e M o n it o r a p p e a r a n c eH a r d n e s sA g i t s p e e d C o n t r P e l le t a p p e a rT a n k t e m p C o n t rI n p u tT y p e O u t p u t W a x g r a d e S O P P r e p t im eA m t w a xC o n t r P r e p a r e R e a c t o r A c id n u m b e r C h a r g e r a t e C o n t r V is c o s it yA g i t s p e e d C o n t r C h a r g e m e lt e d w a x R e a c t o r t e m p R x n t e m p C o n t rB r i n g t o r e a c t io n t e m pT e m p p r o f il e P r e s s u r e C o n t r H T c o e f fA ir f lo wC o n t r % O 2 in a i r N o i s e V is c o s it y N o i s e W a x t e m pN o i s eA N t a r g e t S O P O x id t im eA g i t s p e e d *C o n t r O x i d i z eA c id n u m b e r T e m p e r a t u r e *C o n t r C o lo rP r e s s u r e *C o n t r P u t i n s e t p o in t s V is c o s it yA ir f lo w *C o n t r S a m p le h o u r lyR e a c t o r t e m p % O 2 in a i r N o i s e M o n i t o r a c id n u m b e rT e m p p r o f il e A ir t e m pC o n t r O f f g a s f l o w A ir h u m id it y N o i s eO f f g a s c o m p H T c o e f f R e s p t im e有时:(有较少输入时)能力分析和控制计划的初步评估C u s to m e r R e q u ir e m e n t (O u tp u t V a r ia b le )M e a s u r e m e n t T e c h n iq u e%R &R o r P /TR a tioU p p e r S p e c L im it T a r g e t L o w e r S p e c L im itC p C p k S a m p le S iz eD a te A c tio n s G e l T im e V is c o s ityC le a n lin e s s C o lo r H o m o g e n e ity C o n s is te n c yD ig e ts T im e T e m p e r a tu r e S o lid sK e y P ro c e s s O u tp u t V a ria b le C a p a b ility S ta tu s S h e e t控制计划的初步评估完成流程图后开始控制计划的初步评估为可控和关键的输入及输出增加测量方法，操作规格及目标Excel 模板: Control Plan.XLSProcess Step Input OutputProcess Spec(LSL, USL,Target)Cpk / Date(SampleSize)MeasurementSystem%R&Ror P/TCurrentControlMethod(from FMEA)Who Where WhenReactionPlanCurrent Control Plan流程图例子DetermineSettings Fix LocationSet Parameters Draw back firing armRelease / Fire 测量系统输入测量系统输出Formula (S) Target distance (U)Required direction(U) Catapult base secure (C) Ball type (C)Stop angle (C) attachment point (C) hinge point (C)Draw back angle (C)Hinge wobble (U) Hinge friction (U) Rubber band wear (U)Release SOP (S)Tape Measure /visualVisualVisualSettingsOrientationSet-upRubber band tensionDistanceDirectionVisualVisualVisual (angle)Tape measure / visualRuler / visual流程图例子污染例子另一形式Process StepSBSuncontrollableCoal Tar uncontrollable Prepare Production BatchS Clean transfer lines/filters Tank temp.Add SBSInput Variables I nputtypeMajor StepSub-process Evaluate Incoming Materialsgranular size uncontrollable Oil uncontrollable Filleruncontrollable Fire Retardants uncontrollable Standard formulaS Material characteristicsSFormula PreparationHistoric data Sprocedure SZero the tankS Set tank temperature Formula S Add Coal tar FormulaSAdd oil 275-300 RPMControllable AgitateMotor horsepower Controllable FormulaS1 1/2 hours mix Controllable Add stabilizers 1 hour mix Controllable Add fillersholding timeControllableTransfer to holding tank团队跟踪例子PROCESS INPUT VARIABLES:-TENSION-STATIC BARS PROCESS INPUTVARIABLES:MIX-MIX TIME-MIX TEMPERATURE-MIX SPEEDPUMP CART-CONCENTRATION**-COMPOSITION-VISCOSITY-Material GRADE-VOLUMECOATING-ROLL DOWN PRESSURE-MASK CLEANLINESS**-PUMP SPEED-COAT SPEED-VACUUM LEVEL**PROCESS INPUTVARIABLES:-TENSION-STATIC BARS-ROLLER GAPPROCESS INPUTVARIABLES:-TENSION-ROLLER GAPON-LINECOATINGTHICKNESSINSPECTIONSTATION注意: 粗体字–已做DOE** -主要变量/潜在失效模式WEB UNWIND COATINGSTATION TOP WEBLAYDOWNTOPREWINDATIKEY PROCESS OUTPUTVARIABLES:-COATING THICKNESS-COATING STRUCTURE-BASE INTEGRITY污染例子冲压2000个洁净的物料决定让你的团队去解决一个长期困扰新产品研发团队的材料污染问题。