ARMY MIL-HDBK-683 CHG NOTICE 1-1993 STATISTICAL PROCESS CONTROL (SPC) IMPLEMENTATION AND EVALUATION AID《统计处理控制实现和估定辅助仪》.pdf

1、MIL-HDBK-683 QC 7979770 0067385 2 m MIL-HDBK-683(AT) - SUPERSEDING (SEE 9.2) . . MILITARY HANDBOOK STATISTICAL PROCESS CONTROL (SE) - I. . t- IMPLIBENTATION AND.EVALUATION AID i 7, *s ., . AMSC N/A . AREA QCIC :- Approved for public release; distributian ia unlimited. Provided by IHSNot for ResaleNo

2、 reproduction or networking permitted without license from IHS-,-,-c MIL-HDBK-683 CHG NOTICE 3 9999970 0390052 84T NOTICE OF CHANGE II NOT MEASUREMENT SENSITIVE MIL-HDBK-683(AT) NOTICE 1 23 November 1993 MILITARY HANDBOOK STATISTICAL PROCESS CONTROL (SPC) IMPLEMENTATION AND EVALUATION AID TO ALL HOL

3、DERS of MIL-HDBK-683(AT). 1. The following pages of MIL-HDBK-683(AT) have been revised and supersede the pages New page 3 4 11 12 13 14 19 20 25 26 31 32 33 34 35 36 41 42 53 54 59 60 listed: Date - 23 November 1993 23 November 1993 23 November 1993 23 November 1993 23 November 1993 30 October 1993

4、23 November 1993 23 November 1993 23 November 1993 30 October 1991 30 October 1991 23 November 1993 23 November 1993 30 October 1991 30 October 1991 23 November 1993 23 November 1993 23 November 1993 23 November 1993 30 October 1991 30 October 1991 23 November 1993 Superseded page 3 4 11 12 13 14 19

5、 20 L5 26 31 32 33 34 35 36 41 42 53 54 59 60 Date 30 October 1991 30 October 1991 30 October 1991 30 October 1991 30 October 1991 Reprinted without change 30 October 199i 30 October 1991 30 October 1991 Reprinted without change Reprinted without change 30 October 1991 30 October 1991 Reprinted with

6、out change Reprinted without change 30 October 1991 30 October 1991 30 October 1991 30 October 1991 Reprinted without change Reprinted without change 30 October 1991 AMSC N/A FSC QCIC DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. O 1 of 2 Provided by IHSNot for Re

7、saleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-683(AT) NOTICE 1 2. RETAIN THIS NOTICE AND INSERT BEFORE TABLE OF CONTENTS. e 3. Holders of MIL-HDBK-683(AT) will verify that page changes and additions indicated above have been entered. This notice page will be retai

8、ned as a check sheet. This issuance, together with appended pages, is a separate publication. Each notice is to be retained by stocking points until the military handbook is completely revised or cancelled. 4. Changes from previous issues. The margins of this handbook are marked with vertical lines

9、to indicate where changes from the previous issue were made. This was done as a convenience only and the Government assumes no liability whatsoever for any inaccuracies for these notations. Bidders and contractors are cautioned to evaluate the requirements of this document based on the entire conten

10、t irrespective of the marginal notations and relationship to the last previous issue. Custodian: Army - AT Preparing activity: Army - AT (Project QCIC-A140) e 2 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-683 QC 9977970 0069386 4 MI It-H

11、DBK-683 (AT) FOREWORD 1. This military handbook is approved for use by all Departments and Agencies cf the Department of Defense. 2. Beneficial comments (,recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed tu: U.S. Army Ta

12、nk-Automotive Command, ATTN: AMSTA-GDS, Warren, MI 48397-5000, by uaing the self-addresaed Standardization Document Improvement Proposal (DD Form 1426) appearing at the end of this document or by letter. a. The history of technological advancement has been a mix between breakthroughs in both the pri

13、vate sector and the military. For the body of technical knowledge involving statistical process control (SPC), we can look back to the pioneering work done by Doctor Shewhart in the days before World War II (WWII). During that war, the War Board taught SE techniques as part of its overall Statistica

14、l Quality Control (SQC) program. Following WWII, certain large manufacturers in the United States (U.S.) installed SPC; but for a number of reasons it was later discarded as not being appropriate for commercial application. b. The military had adopted MIL-STD-105 for attribute sampling, which served

15、 very well during WWII, but utilized the basic approach of detection rather than prevention. This resulted in batch rejection of material whenever it was found by inspection to be non-conforming to specification, after the fact. The usual scrap, rework and late deliveries were the natural result. c.

16、 With inexpensive energy, great demand for peace in the world and an unlimited market for American products with little competition, quality was not at the top of the list of priorities. Price and delivery often ranked higher. d. However, in the arena of higher volume production where quality was pa

17、ramount, the opportunities for the greatest gains offered by SPC first became evident, namely for: - Zero defects quality - Lower Cost - Timely delivery - Better products i Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-e. In- the commercial arena d

18、uring the mid-l970s, the-American. public 0 really started seeing better products, often with a lower price tag; and intereatingly enough from a source generally identified historically as producing inferior products, namely, the Japanese. By the mid-1980 Americas casual awareness of the Japanese in

19、vasion with their superior quality products and. designs had changed to an acute awareness that they were surpassing the U.S. by %heir industrial superiority- 1 i f During the 1980s, this invasion was. not- limited to Japan. Once other countries became aware that Japans secret weapon worked and that

20、 it was available to them as well, the flood gates opened. Yes, we now have the entire international spectrum of Japan, Hong Kong, Singapore, Taiwan and marketing list. % Korea battling for the world market with the U-S,. at the top of.their 2 . g. The U-g- industrial superiority that set the world

21、pace following WWII has taken a severe beating. Americas slide backwards does not have to continue. It does, however, require accurate assessment and. recognition of how we lost that ground and the need for development of a sound program to reinstate ourselves. h. American industry, as the major sup

22、plier of U.S. military equipment, is being-challenged to update its technic.al resources, knowledge anci commitment- The cornerstone for these would-be suppliers to the military, as defined in this document, is to recomize that one of the ma.ior reauirements for eligibility to participate in the cha

23、llenge is the actus implementation 0 of an SPC program. 4“ Purpose. a. The purpose of this handbook is to serve as a guide for SPC: implementation and program audit. It is designed for use by Government personnel for reviewing and assessing a contractors SPC system, Set-up, and performance. It may a

24、lso be used by suppliers in establishing their SPC: systems. . - MIL-HDBK-683 QC 0 9999970 00b9187 b b. This handbook also acts as a bridge between SET theory and application and as a reference document to evaluate SPC programs and tools. Quality and productivity improvements start with basic techni

25、cal knowledge, but will not be fully realized without a structured program for applying the knowledge and sustaining the improvements through continuous monitoring, feedback, and commitment to correct problems when identified. Formulas and examples of SPC are available in a wide variety of excellent

26、 textbooks. The problem remains, however, that knowledge of statistical methods alone is not sufficient to bring about improvements in quality and .productivity. iii I“ Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,- MIL-HDBK-683 QC 9999970 0069388

27、B 5. . Proper application of statistical theory is fundamen- program, but it is not enough by itself to get you to the required goal. The essential guide for an SFC program comes from management in the form of an implementation plan. Countless organizations, perhaps even your own, have learned that

28、classes in statistics are not enough. Effective control charts wont magically appear just because the company has sponsored a one day seminar. To make SPC work, a step-by-step process, whose emphasis is implementation, is required with supgart, participation, and visibility at all levels of manageme

29、nt and a follow-up system must be established to ensure timely completion of all critical steps and continued use of SFC techniques. For implementation purposes, contractors should consider the following: i i a. $W: W-. The contractors should provide a practical SFC . systems manual to define and su

30、pport their efforts. This manual should specify the following: (1) Their philosophy, including their quality commitment. (2) Their policy statements designed to implement their company philosophy- (3) Their standard operating procedure (SOP) designed to support the atated policies. The SOF in partic

31、ular should define the implementation elements of SE. b. InJilmt - . In-plant applications for SFC should be utilized by contractors, as follows: (I) At receiving inspection if your supplier is not using SPC control as required by this guide. Since this is detection, after-the-fact and contrary to t

32、he intent of this guide, this will be considered a temporary condition and will be governed by the terms of your individual purchase orders. Any approvals for contracts would be conditional and temporary. The lifting of such conditional approvals would be directly related to the suppliers having up-

33、graded their in-process systems to fully utilize SPC. (2) During manufacturing where the application of appropriate charts is mandatory. This is subject to survey and audit prior to purchase order release and on-going audit surveillance, thereafter, on both the prime and subcontractors. (3) At final

34、 inspection and audit. 6. -. The prime contractors SOP for subcontractor surveillance and control should define methodology for auditing, evaluating and controlling each supplier (subcontractor) in terma of both required SET and other SOP and policy statement areas in which the supplier is required

35、to provide adequate coverage. iv o Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-683 dC 9999970 0069389 T E 7. Eleotrpnic data xroce3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 4.8 4-9 4.10 CHAPTER 4 IMFLEMENTATION REQUIREMENTS FOR AN SPC PROGRAM

36、 SPC implementation requirements - . - . . . - . Upper management involvement - - - - - . - . - - - Education in SPC statistical techniques . . . . . Education in problem solving techniques - - - - - Problem solving techniques . - . - - . . . - - . . Events log - - - - - - . - - - - - - - - - - - -

37、 Diagnostic process audit - . - - - - . . . - . . - Cause and effect diagram - . . - - . - . - . . - . Cause analysis .) . - . . - - . - . - . - - . - . - Design of experiments . . - - - - - - . . - . . . Failure mode and effects analysis (J!MEA) . . - . . Prcicedure - . . . - . - . - . . . . . . .

38、 - . . . Example of how to conchct a FMEA - - - - - - . - . Organizationai structure . . . - . - - . - . . - - Presidents quality council . - - . - - - . - . Steering committees - - - - - - . - . - . - - - - Project teams - - - - - - - - - - . . . - . . . - Roles and responsibilities of project team

39、s - . - Team leader - - - . - - - - - . . . . . . . . - Team leader-s role and responsibilities . . . . - Te Synergism - . - - - - - - - . - - - . . . . - - - Facilitators (desirable-not mandatory) - - . ._ . . Skills of the facilitator . . . . . - . - . . - . SPC implementation plan - - - - . - . -

40、 - . - - . Contractors policy statement - . - - . - . - - - Contractors goals - - - - - - - . - . - - - - - . Master milestone plan . . - - . - .) - . - - - - - Project milestone plan . - - - . - . - - . - - - . Project detailed plan - . - - - . - - - - - - . - Management structure - - . - - - - . -

41、 . . - . . Trainingplan - - . - - - - . - - - . - . - . . Supplier SPC philosophy and policy . . . . . . . . Systematic process . . - . - - . - . - - . - - . . Quality target (attribute data only) . . . . . . . Pitfalls to implementing an SPC process - . - . - Pitfalls to implementing SPC techniques

42、 . - . . . 21 21 21 21 242 22 22 22 23 23 24 24 26 26 26 2 T 27 28 28 29 30 30 31 31 3: 32 32 32 33 33 34 34 34 38 39 39 c50 .L 1 Y . viii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-h83 QC E 9979970 0069173 L 5.1 5.2 5.3 5.3.1 5.3.2 5.3

43、2.1 5.3.2.2 5.3.2.3 5.3.2.4 5.4 5.5 5.6 5.7 5.8 I l 6.1 6.2 6 :3 6-4 6.4.1 6.4.2 6.4.2.1 6.4.2.2 6.4.2-3 6.4.3 6.4.4 6.4.5 6.4.5.1 6.4.5.2 6.4.6 6-4.7 7.1 7.2 7-3 7.4 CONTENTS CHAPTER 5 EVALUATION GUIDE FOR A SUPPLIERS SPI: PROGRAM Methods for evaluating a suppliers SE program - - . . . - - - . - -

44、 - - . . . . Other types of SE audits - - - - - : - - - . .I Preparation for the audit . . . . . . . . . . . . Management responsibilities . . . . - . - - - . Audit team - . . - . - - . . . . - - - . - - . Audit team membership . . . . . . . - . . . . . . . Audit team preparation responsibilities -

45、 . . . Supplier notification - - - - - . - _. - - .) Plant tour . . . . . . . . . . . . . . . . . . . . Joint supplier review - . - - . - - . - . - - . . Results of the audit evaluation - - - - - . - Audit team final report . . . . . . . . . . . . . Follow-up and corrective action - . - . . . - . M

46、onitoring and surveillance of incoming products CHAPTER 6 DESCRIETION OF PROPER SPC SOPTWARE Description of proper Spcl software - - - . . SPC software advantages - . . . - . . . . . . SN software disadvantages - . . - . . - . . Essentials .-., Real time data . . . . . . . . . . . . . . . . . . Cont

47、rol charts - - - - - - . - - - - . . . . Variables control charts - . - - - - . . - - Attributes control charts . . . . . . . . . . . . Control chart format I - - . - - . - - - - . - . . Data entry and display features . . - . . . . . . Dataanalyais . . - I I . - . . . . . . . . . . . Process capabi

48、lity analysis - . - . - . . - - . . Cp ratio . - - . - - - - . - . . - - . - Cpk ratio . . . . . . . . - . . . . . . . . . . . Inspection and test capability analysis . . - . . Report formatting . . - . . - - . . - - . . CHAPTER 7 EVALUATION GUIDE FOR SUPPLIERS SN SOPTWARE Evaluation guide for suppl

49、iers SEC software . . . Evaluating the software supplier . . - - - . . . Interface with other software - - . . . . . . . Hardware considerations . . . . - . - . - - . . . F!Am 60 60 60 60 61 61 61 62 62 62 63 63 63 64 73 73 73 74 74 75 75 75 75 76 76 76 76 77 77 77 80 . 80 81 81 ix Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-683