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Control Chart 管制圖
管制圖是一種可用來決定製程可繼續運作或因有問題須解決而必須停止的圖形 工具。管制圖是依時間次序將數據劃圖,會加上 3 條特別的線。 Centerline(CL)管制中心線: 當製程是 In-control 時,表示製程平均成果(平均值,標準差,良率等等…..) Upper and Lower Control Limits(UCL and LCL)上下管制界限: 當製程是 In-control 時,製程成果的限制範圍 管制界限是在中心線上下 3 個標準差的位置。
P r o c e s s P e r f o r m a n c e UCL

CL

LCL

Time Order

Centerline and Control Limits 管制中心線和管制界限 Centerline 管制中心線:是量測值的中值(mean)或平均值,由中心線可知穩定製程 的量測值是否接近中心。 Control Limits 管制界限:是以中心線上下 3 個標準差劃出的線。定義一個穩定製 程的量測值出現的範圍 如果量測值落在管制界限外,我們必須關心,因為這是非常強的證據顯示製程不 穩定。

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規格界限和管制界限的差別 Specification(Spec) Limits(規格界限): (1) 根據客戶需求而定義。 (2) 定義一個產品參數的可接受範圍。 (3) 定義何種為可接受產品,何種為不可接受產品。 (4) 用來決定製程的性能。 Control limits(控制界限): (1) 根據實際製程性能的資料計算而來的。 (2) 描述一個穩定製程的性能自然範圍。 (3) 描述自然製程偏差值的量。 (4) 用來決定製程穩定度。

Control Chart Development Procedure(管制圖建立程序): 1. 最初的數據收集(Initial data collection) 至少收集 30 個數據,目的是收集足夠數據正確的描述長期變異和檢查參數的穩 定性。 PDC 所收集的數據亦可用做此用途,但 PDC 的樣本數頻率須和 PCS 所使用的相 同。另外,所有新 data 必須被收集,如同量測計劃中所要求的。 2.管制界限計算(Control Limit Calculation ) 數據會用做計算管制界限,然後長期使用在管制圖上。 3.建立永久管制圖(Permanent Control Chart Setup ) 制訂永久管制圖做為長期使用,同時以 SPC 準則(SPC Rules) 決定參數是否超出管制(out of control),亦做為製程更新管制圖的界限之用。 Step1---Initial Data Collection(最初的數據收集) 從製程中收集數據,須為一致的方式(即沒有異於平常的製程改變或調整)。建議 數據來自 30 個獨立的製程作業或批次,以得到充份地正確地製程變異的估計值 必須經由量測計劃收集 30 組數據的原因如下﹕ (1)管制界限的計算需要製程變異的估計值,細節不在此課程範圍。統計理論說 明,一個充分正確的製程變異估計值需要至少 30 組獨立數值。少於 30 個數據就 沒有非常正確的製程變異估計值。 (2)我們要計算的管制界限來代表製程的真實長期變異,這包括每天來自人、物 料設備等變異的波動。如果數據收集自較短的期間,此數據可能無法包括該製程 所有長期變異的來源。

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註:有數個方法適用於難以取得 30 批或 30 組數據的情況,請參考 ISM 教材。 Step2---Control Limit Calculation(控制界限的計算) a) 依時間依序劃趨勢圖(Trend Chart),量測計劃的結果以單點表示在趨勢圖上。 b) 檢查“noisy data”,(例 outliers,非常態(non-Normality)和 Autocorrelation ) 對數據執行必要的調整和更正: 1. 移除所有的 Outliers (無法解釋原因的 outlier,不能移除) 2. 變換(Transform)數據以得到常態分配。 3. 注意任何顯著的 Autocorrelation。 (Note:依 ISM 教材上的工具和步驟,須測和處理 Noisy

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