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7/25/2019 Production Management.pdf
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1.1) ( SEIRI )
1. 2.
( )
3.
7-1
2
2 /
( -/-)
1.2) (Seiton)
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(visual control)
7-2
1.3) (Seiso) ( ) 5
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1.3.1) (Cleaning is Inspection)
5 (Ownership)
1.3.2) 3
1. 1. 2.
1. (Daily cleanliness)
2. (Cleanliness Inspection)
: :
:
:
:
3. (Cleanliness Maintenance)
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1. 2.
3.
5 5
5
5 5 5 5
(Big Cleaning Day) 4. 5 5
5.
6. 5 (Big Cleaning)
commitment
1.3.3) 1.
2. 360
3.
4.
/
5.
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1.4) (SEIKETSU)5 3
3
3
5
1. 2. 3. 4. 5. 6. 7. 8. 9.
10.
3 3
3
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1.4.1) 1. 1 ,
1 2.
3
3. 5
1.5) (Shitsuke) 5
1.5.1)
1.
2.
3.
5 4. 5.
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7-1 5.
5
55
Big Cleaning Day
5
- Visual Control
- Suggestion Scheme
- Internal Communication
5
5
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(2) (Just In Time : JIT)Just In Time () Toyota Motor
Corporation
(Wastes) (Non Value-AddedActivity) (Kaizen)
2.1) 7 (7 Wastes) 1. (Overproduction)
2. (Unnecessary Stock)
3. / (Transportation)
4. (Non effective Process)
Work inprocessqueues(banks)
Changeorders
Engineering designredundancie
s
Vendordelinquencies
Scrap
Designbacklog
s
Machinedowntime
Decisio
nbacklog
s
Inspectionbacklog
s
Paperworkbacklog
identify defects from a supplier
early in the process saves the
downstream work
identify defective work from
upstream stations, saves the
downstream work
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5. (Motion)//
6.
/ (Waiting / Idle / Delay) 7. (Defects / Rework)
7 JIT
3 Mu Muda , Mura , MuriMuda Mura ( )Muri
7-3
JIT
- Pull System
- Leveled Production
- Continuous-Flow
- Takt Time
Autonomation
Quality Build in Process
- Visual Control
- Poka-Yoke
- ANDON
Standardize work
KAIZEN
JIT Pull System ()
Leveled Production (/Heijunka) (Production Volume) (Production Sequence)
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Continuous-Flow Processing () Stock
(Inventory)
Takt Time ()
(Takt Time) =
Autonomation (/Jidoka)
Visual Control ()
Poka Yoke ()
ANDON
(Standardize Work)
Kaizen
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3) ( Total Productive Maintenance : TPM ) ( Total Productive Maintenance : TPM )
( Zero Failure ) ( Zero Defect ) ( Zero Accident )
3.1)
3.1.1)(Breakdown Maintenance; BM)
3.1.2) (Preventive Maintenance, PM)
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2 (Time Based Maintenance; TBM)
(Condition Based Maintenance; CBM)
3.1.3)(Corrective Maintenance, CM)
(Reliability)
(Maintainability)
3.1.4)(Maintenance Prevention, MP)
3.1.5)(Productive Maintenance) (Breakdown Maintenance)
(Preventive Maintenance) (Corrective Maintenance) (Maintenance Prevention)
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3.1.6) ( Total Productive Maintenance : TPM )
TPM 5 1. 2. 3. 4. 5. TPM
TPM
( Zero Accident )
( Zero Defect )
( Zero Failure ) TPM
TPM
3.2)TPMTPM TPM
TPM ( Overlapping Small Group )
( Two Ways Communication )
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7-2
TPM
3.3) (
)
3.3.1)16 (16 Major Losses) TPM
16 3 1 2
(Shutdown Losses)
(Production Adjustment Losses)2 6
(Breakdown Losses)
(Set up and Adjustment Losses)
(Minor Stoppage and Speed Losses)
TPM
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(Speed Losses)
(Defect) (Reprocesing)
3
5
(Management Losses)
(Motion Losses)
(Arrangement Losses)
(Losses resulting off automated systems)
(Monitoring and Adjustment losses)
4 3
(Yield Losses)
(Energy Losses) (Jig and Figure Losses)
3.3.2 )6 (6 Big Losses) 6
2 16 TPM
(OEE)
6
1. (Breakdown Losses)2. (Setup and Adjustment Losses)
3.
(Minor Stoppages and Speed Losses)4. (Speed Losses)5. (Defects and Rework)6. (Startup Losses)
1 2 (Availability)3 4 (Performance Rate) 5 6 (Quality Rate)
6 OEE
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1. (Breakdown Losses) 6
(Availability)
2
5-10 / 5
2. / / (Set up and Adjustment Losses) 6 (Availability)
A B A B
A B
A B
B
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3. (Minor Stoppagess and IdlingLosses) 6 (Performance Rate)
/
4. (Speed Losses) 6 (Performance
Rate)
1 1
120 60 0.5 / (60/120 /) 120 90 () 0.75 / (90/120 /) 0.25 /
2 / (120/60 /) 1.33 (120/90 /)
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5. (Defect and Rework Losses) 2 6
( )
(Quality Rate)
6. (Start Up Losses) 6
6 (Reprocessing Losses Rework Losses)
Recycle
3.3.3) (Overall Equipment Effectiveness,OEE) TPM
(Individual Improvement) OEE 6
(OEE) 3 1. (Availability)2. (Performance Rate)
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3. (Quality Rate)3 OEE
= X X X 100
(Availability)
= (+ ) x 100
= X 100
40 40 5 10 = (40 - (5+10)) x 100 / 40 = 25 X 100 /40 = 0.625 x 100 = 62.5%(World Class) 90%
(Performance Rate)
= (++) x 100
= X 100
= X
= (Standard Cycle Time)
(Actual Cycle Time)
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= X 25 1500 1
1.2 25 1,240
= (Standard Cycle Time)(Actual Cycle Time)
= 1.0 / = 0.8331.2 /
= X
= 1240 X 1.2 / = 1,488
= X = 0.833 X 1488 = 1239.5
= X 100
= 1239.5 X 100 = 82.63 %1500
(World Class) 95%
(Quality Rate)= (+ ) x 100
= X 100
1,240 40 200 = (1240 - (40+200)) x 100 / 1240 = 1000 X 100 / 1240 = 0.8064x100 = 80.64%
(World Class)
99%
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3 OEE
= X
X X 100= 0.625 X 0.8263 X 0.8064 X 100OEE. = 41.64 %
( Overall Plant Effectiveness: OPE)
(World Class) 85%
3.3.4)(Equipment Operating Rate,EOR) TPM
1 16 2
(Shutdown Losses)
(Production Adjustment Losses)
= (+) X 100
= X 100
48 ( 6 8 ) 48 1 2
48
6 2
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= 48 (6+2) = 40 (EOR) = 40 X 100 /48 = 83.33%
100%
6
OEE EOR OEE EOR
3.3.5) 5 (The Five Breakdown Measure)
1. ()
Nut Bolt
2.
( , , ) ( , , ) ( , , )
3. 1 2 ( )
4. 1 3
5.
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3. TPM ( TPM Implementation ) TPM
2
3
TPM 8
7-4 8
1. ( Individual Improvement )
2.
( Self Maintenance )
3. ( Planned Maintenance )
4. ( Education and Training )
5.
( Initial Phase Management )
6. ( Quality Maintenance )
7. ( Indirect Section Activity )
8. ( Safety and Environment Management )
:
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TPM 12 3 ( Preparation Step ) ( Implementation Step ) ( Stabilization Step )
7-5 12 TPM
4.
TPM
TPM
2. TPM TPM 3.
TPM4.
TPM5. TPM
6. TPM TPM
5.
7.1 7.2 7.3 7.4
7 6
8.
9. 10 10.
11.
12. TPM
PM Prize
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1. TPMTPM TPM
2.
TPM
TPM TPM
3.
TPM ( Overlapping Small Group )
TPM TPM TPM
TPM TPM
TPM
4. TPM
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TPM
2 % 1 % 1/10 85 %
5. TPMTPM
TPM TPM( PM Prize JIPM : Japan Institute of Plant Maintenance TPM
WWW.Jipm.Com ) TPM TPM TPM TPM8 TPM
6. TPM TPM
TPM
TPM TPM
7. ( 1-6 )
4
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(Individual Improvement)Focus Improvement Kobutsu Kaizen
1
16 PDCA 4-6
( Self Maintenance : SM )
TPM
TPM
7 1. ( Initial Cleaning )2. ( Eliminate Source of Contamination and
Difficult to Access Area )
3. ( Draw up Provisional Standard )4. ( General Inspection )5. ( Autonomous Inspection )
6. ( Standardize Procedure and WorkplaceSuits )
7. ( Continuous Improvement )
(Planned Maintenance)
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1.
2.
1-3
3.
4.
5.
6.
(Education and Training)
TPM On the job training
Operator 4
Bolt Nut
(Bearing) ( )
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8. ( Initial Phase Management )
/
( Life Cycle Cost : LCC ) ( Maintenance Prevention Design : MP Design )
LCC
9. ( Quality Maintenance )
( Quality Assurance ) (Equipment Management )
/ ( Defect-free Equipment ) /
/
/
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10. TPM ( TPM Activities of Administration and Support Department)
TPM
TPM TPM
/
TPM 5
1. (Individual Improvement)2. (Self Maintenance)3. (Education and Training)4. (Flexible Staffing)5. (Performance Measurement)
11. (Safety and Environment Management)
TPM TPM TPM
5
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12. ( Sustaining TPM Implementation and Raising Levels )
TPM
PMAward
3.5) ( Measuring TPM Effectiveness )
TPM 4. TPM ( 12 ) TPM ( TPM Basic Policy ) -
TPM TPM
3 6 TPM
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7-6
( Labor Productivity ) / ( Overall Plant Effectiveness )
* *
( Overall Equipment Effectiveness )
* *
/ /
*
/ ( MTBF ) / ( MTTR ) / M/C
( Quality )
/ /
( Cost )
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( Delivery )
( Safety ) /
( Morale )
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4) (Quality Control Circle:QCC)
4.1) Quality Control Circle (QCC)
QCC QCC QCC
4.2) QCC1 2
3 4 5 6 7 8
4.3) QCC1
QCC QCC
2
3
4
5
6
7
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4.4) QCC QCC
7-3QCC
:
: 1. , , QCC
2.QCC QCC
4.5)QCC
4.5.1) QCC QCC QCC
4.5.2) QCC
QCC
QCC
QCC
QCC
1
2
QCC 1
QCC 2
QCC 3
QCC 4
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/4.5.3) QCC
QCC
QCC / QCC , QCC QCC , QCC ,
, QCC
4.5.4) QCC
QCC
/QCC4.5.5) QCC
QCC
4.6) QCC 4.6.1)QCC
4.6.2)
QCC QCC / ( )
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QC
/
QCC QCC
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4.7) QCC
: 1 QCC 3-7 2.QCC
2.1 /2.2 2.3
QCC
QCC
&
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4.8) QCC
4.8.1) (Creative Thinking)
1. 2. 3. 4. 5.
6. 7.
8. 9.
1.
2. 3. 4. 5. 6.
4.8.2) (Brain Storming)
1. 2. 3. 4.
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1.
2. ( )3.
4. 5. 6. 7.
4.8.3)
(Team Working)Trust Endurance Accountability Management Willingness Orientation Respect Knowledge Intelligence Nuturance Generousity
1. 2. 3. 4. 5.
6. 7.
8.
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9. 10.
1. 2. 3. 5.
4.8.4) 1. 2.
3. 4. 5. 6. 7. 8.
1. 2. 3. 4. 5.
6.
7. 8. 9.
1. 2. 3.
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4. 5.
6. 7.
8.
1. (Leader)
2. (Trainer)
3.
(Coach)
4. (Consultant)
1. 2. 3.
4. 5.
1. 2.
3.
4. 5. 6. 7. 8. 9.
10.
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4.8.5)
1. 2. 3. 4. 5. 6. 7. 8.
1. 2. 5 W I H
* WHAT - * WHO - * WHERE - * WHY - * WHEN - * HOW -
1.
2.
3. 4. 5.
1.
2.
3.
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4. 5.
1. 2. 3. 4. 5.
1.
2. 3. 4. 5. 6.
7.
8. 9. 10.
1.
2.
3. 4. 5.
6. 7. 8.
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1. 2.
3.
4. 5. 1 6. 7.
4.8.6)
-
15 -
* Overhead Projector* Operate * * *
* *
4.9. QCC4.9.1)
QCC QCC
4.9.2) QCC QCC , QCC
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QCC QCC QCC
4.9.3) QCC
QCC , QCC QCC QCC QCC
QCC 10 QCC QCC 3
, - QCC QCC QCC
4.9.4) QCC QCC /
4.9.5) QCC
/ QCC QCC
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5) 7 (7 QC Tools)
5 1. 2. 3. 4. 5.
5.1) (Cause & Effect Diagram) ( ) ( )
4-8
5.1.1)
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5.2)
5.2.1) (Monitoring)
5.2.2)
......:
: 1525
...........
.
........
Check Sheet
42
62
17
11
26
3
5
7-4
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5.3) . 1897
80% 20% .
7-5
5.3.1)
X Y
5.3.2)
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5.4) (Graph)
5.4.1)
5.4.2)
Shipments of hazardous waste
7-6
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7-7
7-8
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100%
7-9
100 %
7-10
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5.5) (Scatter Diagram)
XX
Y X
7-11
5.5.1) 2 ( ) ( )
2
5.5.2) - - (x , y) (n = ?)
5.5.3) ( r) X Y
r = xy-nXY
( (x2- nX2) (y2- nY2)
X = X/n
Y = Y/n
r -1 1 r = 1 + r = -1 -
x
y
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r 0 r
5.5.4)
7-12
(Positive Correlation) X Y (Negative Correlation) X Y
(Non-Correlation) X Y
r =
1
r =
0.6
r =
-1
r =
0
r = -
0.8
r =
0.8
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5.6) (Variation)
7-13
5.6.1)
(Variable data)
5.6.3) 2
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7-14
(Bell-Shaped Distribution)
(Double Peaked Distribution)
2 2 2 (Specification) 2
(Plateau Distribution) (Mode)
(Comb Distribution)
(Skewed Distribution) (Mode)
(Truncated Distribution)
(Isolated-Peak Distribution)
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5.7) (Control Chart) (monitor)
(Common Cause Variation)
(Special Cause Variation) (Control Limits) (Trend) (Cycle)
5.7.1) (control limits)
(monitor)
(Stability) (process capability) Specification
5.7.2) pH
- ( X - R chart)
25 4 5 ( X ) (R) ( X ) ( R ) 3
(CL X ) = X (UCL X ) = X + Az R
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(LCL X ) = X - A z R
(CL ) = R
(UCL ) = D4 R
(LCL ) = D3R
A2 D
3D
4(n) 3-7
Observations
in
Sample, n A A2 A3 c4 1/c4 B3 B4 B5 B6 d2 1/d2 d3 D1 D2 D3 D4
2 2.121 1.880 2.659 0. 7979 1. 2533 0 3.267 0 2.606 1.128 0. 8865 0.853 0 3.686 0 3.267
3 1.732 1.023 1.954 0. 8862 1. 1284 0 2.568 0 2.276 1.693 0. 5907 0.888 0 4.358 0 2.574
4 1.500 0.729 1.628 0. 9213 1. 0854 0 2.266 0 2.088 2.059 0. 4857 0.880 0 4.698 0 2.282
5 1.342 0.577 1.427 0. 9400 1. 0638 0 2.089 0 1.964 2.326 0. 4299 0.864 0 4.918 0 2.114
6 1.225 0.483 1 .287 0. 9515 1. 0510 0.030 1 .970 0.029 1.874 2.534 0. 3946 0.848 0 5.078 0 2.004
7 1 .134 0 .419 1 .182 0. 9594 1. 0423 0 .118 1 .882 0 .113 1 .806 2 .704 0. 3698 0 .833 0 .204 5 .204 0 .076 1 .924
8 1 .061 0 .373 1 .099 0. 9650 1. 0363 0 .185 1 .815 0 .179 1 .751 2 .847 0. 3512 0 .820 0 .388 5 .306 0 .136 1 .864
9 1 .000 0 .337 1 .032 0. 9693 1. 0317 0 .239 1 .761 0 .232 1 .707 2 .970 0. 3367 0 .808 0 .547 5 .393 0 .184 1 .816
10 0 .949 0 .308 0 .975 0. 9727 1. 0281 0 .284 1 .716 0 .276 1 .669 3 .078 0. 3249 0 .797 0 .687 5 .469 0 .223 1 .777
11 0 .905 0 .285 0 .927 0. 9754 1. 0252 0 .321 1 .679 0 .313 1 .637 3 .173 0. 3152 0 .787 0 .811 5 .535 0 .256 1 .744
12 0 .866 0 .266 0 .886 0. 9776 1. 0229 0 .354 1 .646 0 .346 1 .610 3 .258 0. 3069 0 .778 0 .922 5 .594 0 .283 1 .717
13 0 .832 0 .249 0.85 0. 9794 1 .021 0 .382 1 .618 0 .374 1 .585 3 .336 0. 2998 0 .770 1 .025 5 .647 0 .307 1 .693
14 0 .802 0 .235 0 .817 0. 9810 1. 0194 0 .406 1 .594 0 .399 1 .563 3 .407 0. 2935 0 .763 1 .118 5 .696 0 .328 1 .672
15 0 .775 0 .223 0 .789 0. 9823 1. 0180 0 .428 1 .572 0 .421 1 .544 3 .472 0. 2880 0 .756 1 .203 5 .741 0 .347 1 .653
16 0 .750 0 .212 0 .763 0. 9835 1. 0168 0 .448 1 .552 0 .440 1 .526 3 .532 0. 2831 0 .750 1 .282 5 .782 0 .363 1 .637
17 0 .728 0 .203 0 .739 0. 9845 1. 0157 0 .466 1 .534 0 .458 1 .511 3 .588 0. 2787 0 .744 1 .356 5 .820 0 .378 1 .622
18 0 .707 0 .194 0 .718 0. 9854 1. 0148 0 .482 1 .518 0 .475 1 .496 3 .640 0. 2747 0 .739 1 .424 5 .856 0 .391 1 .608
19 0 .688 0 .187 0 .698 0. 9862 1. 0140 0 .497 1 .503 0 .490 1 .483 3 .689 0. 2711 0 .734 1 .487 5 .891 0 .403 1 .597
20 0 .671 0 .180 0 .680 0. 9869 1. 0133 0 .510 1. 49 0 .504 1 .470 3 .735 0. 2677 0 .729 1 .549 5 .921 0 .415 1 .585
21 0 .655 0 .173 0 .663 0. 9876 1. 0126 0 .523 1 .477 0 .516 1 .459 3 .778 0. 2647 0 .724 1 .605 5 .951 0 .425 1 .575
22 0.64 0 .167 0 .647 0. 9882 1. 0119 0 .534 1 .466 0 .528 1 .448 3 .819 0. 2618 0 .720 1 .659 5 .979 0 .434 1 .566
23 0 .626 0 .162 0 .633 0. 9887 1. 0114 0 .545 1 .455 0 .539 1 .438 3 .858 0. 2592 0 .716 1 .710 6 .006 0 .443 1 .557
24 0 .612 0 .157 0 .619 0. 9892 1. 0109 0 .555 1 .445 0 .549 1 .429 3 .895 0. 2567 0 .712 1 .759 6 .031 0 .451 1 .548
25 0 .600 0.153. 0 .606 0. 9896 1. 0105 0 .565 1 .435 0 .559 1 .420 3 .931 0. 2544 0 .708 1 .806 6 .056 0 .459 1 .541
S Charts
Factors for Control Limits
R Charts
Factors forFactors for Factors for
Central Line
Charts
Control Limits Central Line Factors For Control Limits
X
7-7
R
R
R
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x
105Subg roup 0
70
65
60
Sample
Mean
Mean= 65.36
UCL= 70. 12
LCL= 60. 59
20
10
0SampleRange
R= 8.267
UCL= 17. 48
LCL=0
Xbar/R Chart for Heights
7-15
- (Individual and Moving Range : X R I MR Chart) 1
1
2
(CL X ) = X
(UCL X ) = +
(LCL X ) = -
(CL ) = R (UCL
) = D
4R
(LCL ) = D3 R
2
3
d
R
2
3
d
Rx
R
R
R
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605040302010Subgr oup 0
80
70
60
50
Individua
lValue
Mean=65.36
UCL= 76. 98
LCL= 53. 74
15
10
5
0MovingRange
R= 4.369
UCL= 14. 28
LCL=0
I and MR Chart for Heights
7-15
- ( X - S Chart ) X -R
10 2
S = =
n =
x =
= (CL X ) =
(UCL X ) = + A 3S
(LCL X ) = - A 3S
(CL S ) = S
(UCL S ) = B 4 S
(LCL S ) = B 3 S
B 3-7
1
)(1
2
=
n
xxn
i
i
1
1
22
=
n
xnxn
i
i
x
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105Subgroup 0
70
65
60
SampleMean
Mean= 65.36
UCL= 70. 22
LCL= 60. 49
8
7
6
5
43
2
10
Sa
mpleStDev
S= 3.409
UCL= 7.122
LCL=0
Xbar/S Chart for Heights
7-16
- R ( S)
R - X ( X)
X ( X I)
: X ( X I) R(S) R ( S)
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(Cycles)
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
7-16
(Trends)
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
7-17
(Gradual Changes in Level) (Steady State)
UCL
LCL
CL
UCL
LCL
CL
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0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
7-18 (Mixtures)
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
7-19
Stratification Stratification
UCL
LCL
CL
UCL
LCL
CL
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0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
7-20 Stratification
(Overadjustment)
0
5
10
15
20
25
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
7-21
- (Fraction nonconforming , p Chart)
1
UCL
LCL
CL
UCL
LCL
CL
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Ford (1985) n p 5 (n) 50 ( n ) n 25% n 25%
p
25 (p) ( p )
(CLp) = p
(UCLp) = p
+ 3
(LCLp) = p - 3
7-22
nPP /)1(
nPP /)1(
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- (Number Nonconforming , np chart)np
np 25 (np) (n p )
(CL np) = n p
(UCL np) = n p + 3
(LCL np) = n p - 3
3020100
10
5
0
Sample Number
SampleCount
NP Chart for NonConf
NP=5.533
UCL=12.34
LCL=0
7-23
- (Nonconformities per unit , u chart)
(CL u) = u
(UCL u) = + 3 nu
(LCL u) = - 3 nu
)1( Ppn
)1( Ppn
u
u
u
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7-24
- (Number of Nonconformities , c chart)
(CL c) = c
(UCL c) = c + 3 c
(LCL c) = c
- 3 c
c
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20100
8
7
6
5
4
3
2
1
0
Sample Number
SampleCount
C Chart for RegLtn
C=2.636
UCL=7.507
LCL=0
7-25
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7-8
I-MR
(X-R)
1
-R ( 10)
,
(Quantitative
Data, Variable
Data) -S
( 10 )
1.2.
1.Specification2.
p
np
u
,
(Qualitative
Data,
Attribute
Data) c
1.2.
3.
1.2.
x
x
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7
1. 5 5
2.5
3. (Just In Time JIT) JIT
JIT
- Pull System
- Leveled Production
- Continuous-Flow
-
Tact Time
Autonomation
Quality Build in Process
- Visual Control
- Poka-Yoke
- ANDON
Standardize work
KAIZEN
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4. - 10
- 5
-
5 - 20 - 30 - 10
0.5 /
- 600
-
20 40 OEE 8 OEE
( , ) ( 6 Big Losses )
5. ( Self Maintenance ) ?
6. ( RX Chart)