project no : project 명 : 압축공기 사용량 감소 ( 압축기 전력량 감소 )...
DESCRIPTION
SAMSUNG ELECTRONICS CO., LTD Six Sigma Improvement Process. Project No : Project 명 : 압축공기 사용량 감소 ( 압축기 전력량 감소 ) 사업부 : DS 총괄 DP 센터 제조팀 부서명 : Utility 그룹. D. M. A. I. C. 1. 상세 PROCESS MAP. KPIA. KPOV. A. 압축기 START. VA. 전력량 (KWH) 1 단 압축 압력 , 2 단 압축 압력 1 단 냉각수 OUT TEMP - PowerPoint PPT PresentationTRANSCRIPT
DMAIC DM Template : DS DP
INTAKE FILTER(-45mbar) (N)
CH/WATER(, ) (X)
B
B
12% NM3/H)
6
60
7.32%
24.39%
4
4
40
4.88%
48.78%
8
4
40
4.88%
75.61%
14
3
30
3.66%
79.27%
15
3
30
3.66%
82.93%
16
2
20
2.44%
92.68%
20
60
7.32%
24.39%
0
0
4
40
4.88%
48.78%
8
20
2.44%
67.07%
13
0
20
2.44%
69.51%
0
0
0
0
0
0
0
0
0
0
0
0
0
%
FMEA
Potential Failure Effects (KPOVs)
O C C
Current Process Controls
D E T
R P N
10
9
Major disruption to production line. 100% of product may have to be scrapped. Vehicle / item inoperable, loss of primary function. Customer very dissatisfied.
8
High
Minor disruption to production line. Product may have to be sorted and a portion (less than 100%) scrapped. Vehicle operable, but at a reduced level of performance. Customer dissatisfied.
7
Moderate
Minor disruption to production line. A portion (less than 100%) may have to be scrapped (no sorting). Vehicle / item operable, but some comfort / convenience item(s) inoperable. Customers experience discomfort.
6
Low
Minor disruption to production line. 100% of product may have to be reworked. Vehicle / item operable, but some comfort / convenience item(s) operable at reduced level of performance. Customer experiences some dissatisfaction.
5
Minor disruption to production line. The product may have to be sorted and a portion (less than 100%) reworked. Fit / finish / squeak / rattle item does not conform. Defect noticed by most customers.
4
Minor
Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line but out-of-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by average customers.
3
Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line but in-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by discriminating customers.
2
None
: · Constant-C / Noise-N / Controllable-X
Y’s
X’s
X’s
( )
x
KG/Cm2
DRYER
( )
x
NM3
Y
The regression equation is
PRESS = - 3.49 + 0.151 AMP
Constant -3.485 2.407 -1.45 0.171
AMP 0.15093 0.03204 4.71 0.000
S = 0.02013 R-Sq = 63.1% R-Sq(adj) = 60.2%
Analysis of Variance
Residual Error 13 0.0052696 0.0004054
Total 14 0.0142645
Correlations: AMP, PRESS
P-Value = 0.000
0.794 p 0.000 0.05 AMP PRESS
(R-Sq)
Analysis Tool :
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P-Value = 0.000
(R-Sq)
Analysis Tool :
The regression equation is
KW = 386 + 391 DP
Constant 385.93 30.50 12.65 0.000
DP 391.40 22.41 17.47 0.000
S = 13.05 R-Sq = 91.6% R-Sq(adj) = 91.3%
Analysis of Variance
Residual Error 28 4769 170
Total 29 56738
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().
X1 : dryer
Analysis Tool :
().
P-Value < 0.05
Analysis Tool :
X4
ΔP
AIR & SIZE LOSS
1. LOSS 2. LOSS SIZE-UP
[Brain Storming] [MW Matrix]
X2
DRYER LOSS
1. SOP 2. DRYER TYPE
[Brain Storming]
COMP
( )
[Brain Storming]
1.
AIR COMP AIR COMP
& SPEC
PRESS( LOSS)
: COMPRESSOR (8kg/) → FINAL FILTER (6.64kg/) : P (1.36kg/)
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2.
[ #1 : Loss ]
(Alternatives)
Risk ()
2
3.
Air Dryer : 6,050 NM3/H 2
2 (10→12)
2 (8→10)
2 (08→10)
: , PRESS( ) ?
Analysis Tool : Mann-Whitney-test
H0 : M D-P M D-P1 ( P P )
H1 : M 1D-P > M 1D-P ( P P )
1) : , Normal: P-Value 0.000
2)
D-P N = 30 Median = 1.3200
1D-P N = 30 Median = 0.8850
Point estimate for ETA1-ETA2 is 0.4400
95.3 Percent CI for ETA1-ETA2 is (0.4101,0.4800)
W = 740.0
Test of ETA1 = ETA2 vs ETA1 > ETA2 is significant at 0.0001
The test is significant at 0.0000 (adjusted for ties)
P-Value < 0.05
H0
: P-Value 0.000( < 0.05) H0 P
..
8-4. X1: ΔP
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X1 : COMP .
: , ( ) ?
Analysis Tool : Mann-Whitney-test
H0 : M PRESS1 M PRESS2 ( PRESS PRESS )
H1 : M PRESS1 > M PRESS2 ( PRESS PRESS )
1) : Normal: P-Value 0.000 , Normal: P-Value 0.000
2)
: P-Value 0.000( < 0.05) H0 PRESS
..
8-5. X2:
Mann-Whitney Test and CI: 1PRESS, 2PRESS
1PRESS N = 30 Median = 8.0050
2PRESS N = 30 Median = 7.6100
Point estimate for ETA1-ETA2 is 0.3900
95.3 Percent CI for ETA1-ETA2 is (0.2900,0.4200)
W = 765.0
Test of ETA1 = ETA2 vs ETA1 > ETA2 is significant at 0.0000
The test is significant at 0.0000 (adjusted for ties)
P-Value < 0.05
1.
AIR DRYER AIR COMP AIR DRYER
STAND-BY TOWER AIR
AIR LOSS
2.
#1,2 : DRYER 1,2
(Alternatives)
Risk ()
- TEST -DP SENSOR
TEST
(a)
3.
1.
2.
#2 : DOWN
1 FAN & FAN 100%
2 HEAT DRYER (8 )
(Alternatives)
Risk ()
-
No
8.0 KG/CM3
8,640NM3/D
4,529NM3/D
(PLAN)
126,363KW/D
123,620KW/D
2,743KW/D
2.2%↓
5% 2.2% 2.8% : 6 AIR DATA
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Potential Failure Effects (KPOVs)
O C C
Current Process Controls
D E T
R P N
10
9
Major disruption to production line. 100% of product may have to be scrapped. Vehicle / item inoperable, loss of primary function. Customer very dissatisfied.
8
High
Minor disruption to production line. Product may have to be sorted and a portion (less than 100%) scrapped. Vehicle operable, but at a reduced level of performance. Customer dissatisfied.
7
Moderate
Minor disruption to production line. A portion (less than 100%) may have to be scrapped (no sorting). Vehicle / item operable, but some comfort / convenience item(s) inoperable. Customers experience discomfort.
6
Low
Minor disruption to production line. 100% of product may have to be reworked. Vehicle / item operable, but some comfort / convenience item(s) operable at reduced level of performance. Customer experiences some dissatisfaction.
5
Minor disruption to production line. The product may have to be sorted and a portion (less than 100%) reworked. Fit / finish / squeak / rattle item does not conform. Defect noticed by most customers.
4
Minor
Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line but out-of-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by average customers.
3
Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line but in-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by discriminating customers.
2
None
: UTILITY
6
7
8
9
10
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DCS SYSTEM AIR SETTING
ALARM SETTING
DCS (24 MONITORING)
14.Mistake Proofing
1 Limit
24
AIR COMP 1/ DATA
I-MR
,
.
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15-2.Monitoring()
AIR 1/ DATA
I-MR
DATA
(, )
FILTER , FILTER
: POINT
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16. Process capability
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297.txt
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( )
> AIR COMP PM
> PEAK
\ 4,603,200
-. AIR COMP [Logic] ( / – /) * 30 * 56,000/MW [] (126.36MW – 123.62MW) * 30 * 56,000/MW = 4,603,200(/)
(* 1) AIR 2) : )
UTILITY LOSS
Project Mission
UT (46%) PEAK , ,
Project Y’s
No
8.0 KG/CM3
7.7 KG/CM3
8,640NM3/D
4,529NM3/D
(PLAN)
2. PROCESS
Y's Matrix
INTAKE FILTER(-45mbar) (N)
CH/WATER(, ) (X)
B
B
12% NM3/H)
6
60
7.32%
24.39%
4
4
40
4.88%
48.78%
8
4
40
4.88%
75.61%
14
3
30
3.66%
79.27%
15
3
30
3.66%
82.93%
16
2
20
2.44%
92.68%
20
60
7.32%
24.39%
0
0
4
40
4.88%
48.78%
8
20
2.44%
67.07%
13
0
20
2.44%
69.51%
0
0
0
0
0
0
0
0
0
0
0
0
0
%
FMEA
Potential Failure Effects (KPOVs)
O C C
Current Process Controls
D E T
R P N
10
9
Major disruption to production line. 100% of product may have to be scrapped. Vehicle / item inoperable, loss of primary function. Customer very dissatisfied.
8
High
Minor disruption to production line. Product may have to be sorted and a portion (less than 100%) scrapped. Vehicle operable, but at a reduced level of performance. Customer dissatisfied.
7
Moderate
Minor disruption to production line. A portion (less than 100%) may have to be scrapped (no sorting). Vehicle / item operable, but some comfort / convenience item(s) inoperable. Customers experience discomfort.
6
Low
Minor disruption to production line. 100% of product may have to be reworked. Vehicle / item operable, but some comfort / convenience item(s) operable at reduced level of performance. Customer experiences some dissatisfaction.
5
Minor disruption to production line. The product may have to be sorted and a portion (less than 100%) reworked. Fit / finish / squeak / rattle item does not conform. Defect noticed by most customers.
4
Minor
Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line but out-of-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by average customers.
3
Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line but in-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by discriminating customers.
2
None
: · Constant-C / Noise-N / Controllable-X
Y’s
X’s
X’s
( )
x
KG/Cm2
DRYER
( )
x
NM3
Y
The regression equation is
PRESS = - 3.49 + 0.151 AMP
Constant -3.485 2.407 -1.45 0.171
AMP 0.15093 0.03204 4.71 0.000
S = 0.02013 R-Sq = 63.1% R-Sq(adj) = 60.2%
Analysis of Variance
Residual Error 13 0.0052696 0.0004054
Total 14 0.0142645
Correlations: AMP, PRESS
P-Value = 0.000
0.794 p 0.000 0.05 AMP PRESS
(R-Sq)
Analysis Tool :
D
M
A
I
C
265.bin
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P-Value = 0.000
(R-Sq)
Analysis Tool :
The regression equation is
KW = 386 + 391 DP
Constant 385.93 30.50 12.65 0.000
DP 391.40 22.41 17.47 0.000
S = 13.05 R-Sq = 91.6% R-Sq(adj) = 91.3%
Analysis of Variance
Residual Error 28 4769 170
Total 29 56738
D
M
A
I
C
270.bin
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().
X1 : dryer
Analysis Tool :
().
P-Value < 0.05
Analysis Tool :
X4
ΔP
AIR & SIZE LOSS
1. LOSS 2. LOSS SIZE-UP
[Brain Storming] [MW Matrix]
X2
DRYER LOSS
1. SOP 2. DRYER TYPE
[Brain Storming]
COMP
( )
[Brain Storming]
1.
AIR COMP AIR COMP
& SPEC
PRESS( LOSS)
: COMPRESSOR (8kg/) → FINAL FILTER (6.64kg/) : P (1.36kg/)
D
M
A
I
C
279.unknown
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2.
[ #1 : Loss ]
(Alternatives)
Risk ()
2
3.
Air Dryer : 6,050 NM3/H 2
2 (10→12)
2 (8→10)
2 (08→10)
: , PRESS( ) ?
Analysis Tool : Mann-Whitney-test
H0 : M D-P M D-P1 ( P P )
H1 : M 1D-P > M 1D-P ( P P )
1) : , Normal: P-Value 0.000
2)
D-P N = 30 Median = 1.3200
1D-P N = 30 Median = 0.8850
Point estimate for ETA1-ETA2 is 0.4400
95.3 Percent CI for ETA1-ETA2 is (0.4101,0.4800)
W = 740.0
Test of ETA1 = ETA2 vs ETA1 > ETA2 is significant at 0.0001
The test is significant at 0.0000 (adjusted for ties)
P-Value < 0.05
H0
: P-Value 0.000( < 0.05) H0 P
..
8-4. X1: ΔP
D
M
A
I
C
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X1 : COMP .
: , ( ) ?
Analysis Tool : Mann-Whitney-test
H0 : M PRESS1 M PRESS2 ( PRESS PRESS )
H1 : M PRESS1 > M PRESS2 ( PRESS PRESS )
1) : Normal: P-Value 0.000 , Normal: P-Value 0.000
2)
: P-Value 0.000( < 0.05) H0 PRESS
..
8-5. X2:
Mann-Whitney Test and CI: 1PRESS, 2PRESS
1PRESS N = 30 Median = 8.0050
2PRESS N = 30 Median = 7.6100
Point estimate for ETA1-ETA2 is 0.3900
95.3 Percent CI for ETA1-ETA2 is (0.2900,0.4200)
W = 765.0
Test of ETA1 = ETA2 vs ETA1 > ETA2 is significant at 0.0000
The test is significant at 0.0000 (adjusted for ties)
P-Value < 0.05
1.
AIR DRYER AIR COMP AIR DRYER
STAND-BY TOWER AIR
AIR LOSS
2.
#1,2 : DRYER 1,2
(Alternatives)
Risk ()
- TEST -DP SENSOR
TEST
(a)
3.
1.
2.
#2 : DOWN
1 FAN & FAN 100%
2 HEAT DRYER (8 )
(Alternatives)
Risk ()
-
No
8.0 KG/CM3
8,640NM3/D
4,529NM3/D
(PLAN)
126,363KW/D
123,620KW/D
2,743KW/D
2.2%↓
5% 2.2% 2.8% : 6 AIR DATA
D
M
A
I
C
- * / 32 -
Potential Failure Effects (KPOVs)
O C C
Current Process Controls
D E T
R P N
10
9
Major disruption to production line. 100% of product may have to be scrapped. Vehicle / item inoperable, loss of primary function. Customer very dissatisfied.
8
High
Minor disruption to production line. Product may have to be sorted and a portion (less than 100%) scrapped. Vehicle operable, but at a reduced level of performance. Customer dissatisfied.
7
Moderate
Minor disruption to production line. A portion (less than 100%) may have to be scrapped (no sorting). Vehicle / item operable, but some comfort / convenience item(s) inoperable. Customers experience discomfort.
6
Low
Minor disruption to production line. 100% of product may have to be reworked. Vehicle / item operable, but some comfort / convenience item(s) operable at reduced level of performance. Customer experiences some dissatisfaction.
5
Minor disruption to production line. The product may have to be sorted and a portion (less than 100%) reworked. Fit / finish / squeak / rattle item does not conform. Defect noticed by most customers.
4
Minor
Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line but out-of-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by average customers.
3
Minor disruption to production line. A portion (less than 100%) of the product may have to be reworked on-line but in-station. Fit / finish / squeak / rattle item does not conform. Defect noticed by discriminating customers.
2
None
: UTILITY
6
7
8
9
10
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DCS SYSTEM AIR SETTING
ALARM SETTING
DCS (24 MONITORING)
14.Mistake Proofing
1 Limit
24
AIR COMP 1/ DATA
I-MR
,
.
D
M
A
I
C
292.txt
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15-2.Monitoring()
AIR 1/ DATA
I-MR
DATA
(, )
FILTER , FILTER
: POINT
D
M
A
I
C
293.txt
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16. Process capability
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297.txt
- * / 32 -
( )
> AIR COMP PM
> PEAK
\ 4,603,200
-. AIR COMP [Logic] ( / – /) * 30 * 56,000/MW [] (126.36MW – 123.62MW) * 30 * 56,000/MW = 4,603,200(/)
(* 1) AIR 2) : )
UTILITY LOSS
Project Mission
UT (46%) PEAK , ,
Project Y’s
No
8.0 KG/CM3
7.7 KG/CM3
8,640NM3/D
4,529NM3/D
(PLAN)
2. PROCESS
Y's Matrix