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1SPC与FMEA報告品名:EE19M02.35-B1长短、脚品名:6M0900成員:郑忠辉廖玉贞陈晓芳、赵伯元2繞線理線焊锡组合測試(一)烘烤喷印烘烤切脚二次焊测耐压检查切脚时造成长短脚测试(二)贴麦拉片合脚,包装品名：EE19M02、35-B1管制项目：长短脚一吉廠SPC分析3EE19M02、35-B1Pin脚长不良規格尺寸:3.0mm--3.6mm3.3mm3.73mm一吉廠SPC分析標準樣品4改善前管控方式:1.仅在切脚板靠近两排距旁边分别贴上厚度为1.1mm的垫木板;将材料固定在中间进行切脚.2.品管定期(頻率:20PCS/每天兩次)抽檢PIN腳尺寸.一吉廠SPC分析改善前作業5制程能力分析、改善前数据收集及CPK单位（MM）一组二组三组四组五组六组七组八组九组十组3.073.373.033.313.183.243.393.53.333.423.253.393.383.173.262.993.473.393.613.223.383.423.293.233.343.383.323.033.33.293.523.323.313.123.43.43.283.453.313.433.33.082.953.263.343.573.563.573.393.13X=3.304X=3.316X=3.192X=3.218X=3.304X=3.316X=3.404X=3.308X=3.388X=3.298R=0.45R=0.34R=0.43R=0.19R=0.22R=0.58R=0.28R=0.42R=0.31R=0.14十一组十二组十三组十四组十五组十六组十七组十八组十九组二十组3.363.363.383.193.193.133.133.133.373.313.243.462.993.243.233.663.663.563.363.23.123.223.393.443.443.483.483.063.213.323.313.043.333.33.563.233.233.093.423.273.553.033.373.513.123.553.552.973.333.47X=3.316X=3.222X=3.296X=3.336X=3.308X=3.41X=3.41X=3.162X=3.314X=3.14R=0.43R=0.43R=0.4R=0.32R=0.44R=0.53R=0.53R=0.59R=0.21R=0.27二十一组二十二组二十三组二十四组二十五组3.43.363.333.383.153.333.53.353.23.453.343.413.393.552.983.573.393.253.123.383.343.43.473.363.37X=3.396X=3.412X=3.358X=3.322X=3.266X总平均值=3.3086R=0.24R=0.14R=0.22R=0.43R=0.47R总全距=0.3504一吉廠SPC分析6李建華2004年10/22在磨該品名GAP规格中,增加掃磨鐵心平面製程;並统一平磨5-8條.總的高度控具体方案执行者完成日期所有规格要求切脚之品名；切脚板统一申请在规格中心线偏上线0.15mm.胥红勇2004年10/15具体实施方案一吉廠SPC分析7实际中心值-规格中心值规格公差T6标准差6标准差R0.3504X-Ud22.326T/23.3086-3.30.60.30.904（1-Ca）*CP0.6449(A级)CPK=CPK=*0.1506CP=0.664(D级）100%Ca=2.87%CP=6标准差=Ca=100%规格公差/2100%CP=改善前制程能力分析、CA、CP、CPK說明CPK1.33需进行改善一吉廠SPC分析66792215148113844530510152025ABCDEFGHIJKLMNO8问题二次因对策拟定点胶后CORE未压平线包胖的材料点胶时压不平绕线人员在绕好一个材料后；用铁芯套线包；将套不进的线包挑选出。為何出現長短腳現象一次因原铁芯厚度不一致誤差在0.3mm切脚板孔径大；受气压震动。在送铁芯磨GAP时,未在外磨单上注明两铁芯磨后的尺寸.切脚板使用时间长。受磨损。切脚时材料压不平点胶时未压平重新申请切脚板,针对此系例材料切脚板由以前使用期半年；改为4个月更换。同时之前孔径为1.0mm现改为0.9mm,且将切脚板厚由以前的3.4mm铁芯厚度不一致后续在送每批铁芯去外磨时,IPQC要将该品名磨后的两铁芯尺寸填写于外磨单上,由磨场人员固定两铁芯尺寸-15.7-15.9mm.长短脚不良之改善对策拟定一吉廠SPC分析9管制方式:1.增加切脚板的厚度;由以前的3.5mm增加到3.55mm;2.将孔径由以前的1.0mm改到0.9mm.3.磨鐵心總高度控制在15.7-15.9mm.一吉廠SPC分析改善后作业10步骤:1.整脚距1.作业前先检查切脚板是否经QC确认.2.切脚时,材料脚不可歪斜.2.切脚2.取检验OK之切脚板装于切脚机上,右手拿整好脚之材料,放入切脚板内,放平.材料底部紧贴切脚板.脚踏气压.启动切脚机切好后1.切脚时,材料应与切脚板垂直.2.切脚时,脚有无带钩之现象.***材料不可堆积***1.材料要整齐排放在盘中.1.2把整好的脚距材料(脚朝上)放在木盘内.作业前1.1取一材料,用平口钳整脚距,使脚不歪斜.YJ作业指导书制程:切脚作业方法注意事项设备:切脚机治工具:平口钳,切脚板版本版次:A0制表日期:2004-2-11修订日期:产品:EE19M02.35-B1作业后作业中放入材料盒内.切脚为:3.5mm改善前切脚板3.5mm改善前后O/I标准化对照一吉廠SPC分析11前一站制程单是否填写完整.板上,脚踏气压,启动切脚机,切好后放入左边材料盒中.3)有脚歪之材料须挑出,用平口钳将其夹直后,重新切脚.3.自主检查:长短脚,脚带钩.切脚OK与待切脚的材料有无区分标示.制程单是否填写完整.版本版次：A1核准：制表：赵伯元准备事项图示的PIN脚对准切脚板之孔径轻轻插入,放平.材料底部紧贴于切脚操作步骤设备：切脚机治工具：平口钳,切脚板制表日期：2004-2-11修订日期：2004-11-022)将检验OK之切脚板装于切脚机上,右手拿点胶OK之材料,将材料品名：EE19M02.35-B11.顺序检查:BN破.漏点胶.2.操作步骤1)找出该品名所用的切脚板(厚度为3.55mm).切脚过程中脚带钩长短脚改善前后O/I标准化对照改善后切脚板3.55mm12一组二组三组四组五组六组七组八组九组十组3.453.213.153.313.313.153.193.213.253.43.23.293.253.153.323.213.343.413.353.353.323.43.363.253.243.43.263.313.313.323.463.323.313.313.43.313.43.353.413.353.253.353.353.253.323.53.313.353.363.26X=3.336X=3.314X=3.284X=3.254X=3.318X=3.314X=3.30X=3.326X=3.336X=3.336R=0.26R=0.0.19R=0.21R=0.16R=0.16R=0.35R=0.21R=0.2R=0.16R=0.14十一组十二组十三组十四组十五组十六组十七组十八组十九组二十组3.363.453.43.413.323.353.313.413.263.453.353.263.213.363.333.363.263.263.373.263.193.193.343.323.423.283.373.283.293.273.263.363.43.253.353.293.283.293.323.383.453.293.253.273.273.333.393.353.413.38X=3.322X=3.314X=3.32X=3.322X=3.338X=3.32X=3.322X=3.318X=3.336X=3.348R=0.26R=0.26R=0.19R=0.16R=0.15R=0.08R=0.13R=0.15R=0.15R=0.19二十一组二十二组二十三组二十四组二十五组3.273.473.313.403.4083.0363.393.253.273.363.273.321443.343.313.263.293.384.3593.423.213.383.323.370.174363.43.323.313.353.3X总平均值=3.321X=3.364X=3.312X=3.306X=3.344X=3.344R总全距=0.1744R=0.15R=0.26R=0.12R=0.11R0.13制程能力分析、改善后数据收集及CPK单位（MM）一吉廠SPC分析13改善后CPK數據分布状况一吉廠SPC分析RelativeFrequenciesIntervalmaskLowerClassLimitUpperClassLimitcountA~3.60000B3.6000~3.55380C3.5538~3.50772D3.5077~3.46157E3.4615~3.415424F3.4154~3.369224G3.3692~3.323131H3.3231~3.276925I3.2769~3.23089J3.2308~3.18463K3.1846~3.13850L3.1385~3.09230M3.0923~3.04620N3.0462~3.00000O3.0000~014实际中心值-规格中心值规格公差T6*标准差6标准差R0.1744X-Ud22.326T/23.32-3.30.60.30.45（1-Ca）*CP(A级)(B级）1.24CPK=CPK=0.075CP=1.33100%Ca=6.67%CP=CP=标准差=Ca=100%规格公差/2100%制程能力分析、改善后CA、CP、CPK一吉廠SPC分析0.6560.6280.6480.640.6290.6270.62105101520253035ABCDEFGHIJKLMNOFrequency**===15製程繼續X、R管制123456789101112131415161718192021222324253.373.273.353.393.343.393.353.413.393.323.333.353.323.403.433.413.453.363.263.313.403.353.383.413.430.190.260.130.350.360.370.210.170.200.370.210.250.220.220.210.250.170.240.160.260.120.150.210.250.240.1/格3.37UCL=0.4650.22cl=0.22CL=00.1/格UCL=3.497CL=3.373.24LCL=3.243日期平均值全距管制图3.4970.4650XRChart品名:EE19M02.35-B1制造部门:201组制程:切脚站制定人:郑忠辉时间:2004/10/15-2004/11/20一吉廠SPC分析161主題及成員確定品質展開表(VOC&VOE)流程展開表(Kpiv&Kpov)制程展開表重要制程PFMEA制作由顧客需求(VOC)展出產品重要品質特性(VOE)對制造工序進行KPIV和KPOV分析,選出關鍵工序以確定重要管制制程找出制程與品質特性VOE之關系,以確定需做FMEA的重要制程成員腦力激蕩完成PFMEA:1.找出影響最大失效現象2.魚骨圖分析失效原因3.現行管制方式列出及RPN計算4.對風險值(RPN)較大的給出建議措施並實施.標準化FMEA運作步驟一吉廠FMEA分析17一吉廠FMEA分析組長:鄭忠輝品管:廖玉貞制造:周春蘭侯會棉工程:馮德春TeamMembers主題:6M09.00181234567891011Li加電流CPLK耐壓DCRTRL電感外观外形尺寸銲錫質量PIN錫尖1电气特性5分2焊锡性5分3尺寸4分4美观3分