111. 222 launch #1 using what you are given, baseline the process for shooting the statapult....
TRANSCRIPT
111
Section VI, Measure - Data
& Process Analysis
222
Group Activity
Launch #1Using what you are given, baseline
the process for shooting the statapult.
Remember: Customer desires a rapid-fire, precise, and accurate launcher that can launch projectiles over mountain ranges.
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LaunchSequence
Distance
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Statapult Instructions Launch #1
Every shot will be launched from a pull back angle of 177/65 degrees.
Each person on the team will perform an equitable number of launches (or as close as possible).
"Launching” means pulling back and releasing.
Time between each shot cannot exceed 15 seconds.
Record the distances on the table to the left.
Record the longest distance (Max) and the shortest distance (Min) and compute Range = Max - Min.
Range = ______________
Objective: To fire the statapult and record the distance for each of the launches. The measured distance will be from the back of the launcher to the point where the ball first lands. Record the distances in the order in which they were obtained.
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Statapult Launch #1
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Launch Sequence
Distance
See graphing.pdfVI-2
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Short term data is considered free of assignable causes◦ One shift, one operator
Long term data is considered to contain both assignable and common caused variation◦ Multiple shifts, multiple operators
Processestend to exhibit more variation in the long term than the short
Sigma Values
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Levels of Maps
Maps can be created for many different levels of the process. Just like highway maps…
You can use a map of the USA…or if you need more detail, a map of the state...or if you need more detail, a map of the city.
Mapping works much the same way. Depending on the detail you need, create the map at that level. If you need more detail, then create a more detailed map of the sub-process.
High Level
Detail
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Skin/Core Assembly
Upper Skin Assembly
Spar Assembly
Misc Details
65VLay-up
6A3Cure
Press L, M, or N
6A3Clean Tool
6P4Band SawHenri Line
6PAMech Assy
6PABond ClosuresBond Details
65QTap and Ziess
Post Bond
Closures
Misc Details
6PBClean Part
6P4Devlieg
Lay-up and Cure Clean and Inspect
65VTest Heater
Balnket
65QInspect
6PABond Details
65QInspect
6PAFill A/STRP
Electrical Assy
6PBLeak Test
6P8Paint
6PGStatic Balance
6PAElectrical Assy
Mech Assy
6PGTouch-up Paint
65QFinal Inspect
Fairings
6PA GatherComponents
Process Flow Diagram◦ Used to identify the steps in a
process◦ Good for process documentation
and knowledge gathering◦ May be used in definition, detail
design, analysis and control portions of a project
High Level Process Map
Visually sets the process steps in
order
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To provide a graphical representation of the process with regards to ◦ the people involved, ◦ their responsibilities, ◦ functional interfaces and dependencies,◦ as well as process steps over time where
necessary.
Critical tool for transactional processes and when mapping information flow for industrial processes
Segregates steps by who does them or where they are done
Makes handoffs visible
Swim Lane (Functional or Deployment Maps)
A Swim Lane is a process flow diagram with resource responsibilities
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Functional or Deployment Flow Diagram
Business Unit
I.T.
Finance
Top Mgt/ Corporate
Define needs
Prepare paperwork
Review &
approve
Review & approve standard
Review &
approve
Review &
approve
Acquire equipment
Supplier
Configure & install
Receive & use
Issue payment
Supplier
Sourcing
Process Steps
Resources Responsible for Process Steps
Graphical summary or roles & responsibilities for a process
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Process Flow Chart
Objective:
Develop a process flow diagram that explains how to launch a ball.
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SIPOC
Input Output
Supplier Customer
SIPOC is a process scoping tool that provides a high level definition of a process –
SIPOC should be used on all Six Sigma projects
Suppliers Inputs Process Outputs Customers
(Providers of the required resources)
(Resources required by the process)
(Process require-ments for the Inputs)
(Top level description of activity)
(Deliverables from the process)
(CustomerRequire-ments of the Outputs)
(Anyone who
receives a deliverable
from the process)
Process
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SIPOC – The Process Steps
Process Customers
Requirements Requirements
Brg suppliers, D/S Structures
Brg data, shaft diaShaft dia, life, brg capacity, TRL's, cost, wt, reliability
Assess brg choices and select
brg selection or new bearing design
brg spec Brg supplier
Shaft suppliers
Shaft mat'l characteristics, cost, special handling and machining reqm'ts
strength, buckling stability, fatigue life, dyn tuning, cost, wt, repairability, thermal compatibility with T/B
Assess shaft mat'l choices and select
Shaft material selectionSpecial handling reqm'ts
Manufacturing
" Cost, repairability Product support
Shaft suppliersShaft length availability, cost
cost, wt, tuning, handling, shaft length availability
Select one vs two piece shaft
handling, shipping Product support
VOC, Product SupportAcceptability of long shaft handling, stocking, cost
"
Shaft suppliersShaft mat'l characteristics, cost
Static strength, torsional buckling, stiffness and wt for dyn tuning, overall wt, cost, impact on sizing of bearing and end fittings
Size shaft Shaft sizing Shaft sizing D/S Design
Shaft size, plus existing data on damper sizing
Sizing as previously tested, fatigue strength, stiffness, clearances for shaft motion, compact design
Sizing as previously tested, fatigue strength, stiffness, clearances for shaft motion, compact design
Layout damper damper designdrawing, build-to-print PO
Lord Corp
Fatigue, D/S StructuresStructural allowables and fastening options. New test data as req'd.
Strength, ease of assembly and installation
Design end fittings End fitting design dwgs End fitting design dwgs Manufacturing
Fatigue, D/S StructuresStruct allowables and detail sizing
Strength, compact design, bearing retention
Design bearing housing and damper attachments
Brg housing dwgs Brg housing dwgs Manufacturing
Fatigue, D/S StructuresStruct allowables and detail sizing
Ease of assembly, heat dissipation, compact sizing
Design shaft sleeve for bearing mount
Sleeve designSleeve design with ease of assembly
Manufacturing
Fatigue, D/S StructuresStruct allowables and detail sizing
Shaft clearance for run-up motion, no shaft damage when sleeve and snubber contact
Design snubber and sleeve assembly
Snubber and sleeve dwgs
Ease of assembly Manufacturing
D/S Dynamics, D/S Design, Propulsion Design (oil cooler responsibility)
Natural freqs and mode shapes, allowable mods to oil cooler blower
Dynamic tuning, structural mods req'd to T/B struct., attachment options to oil cooler blower
Determine damper placement and forward attachment location
Best geometry for damper placement and forward end
Best geometry for damper placement and forward end
D/S Design
D/S Dynamics, D/S Design, Propulsion Design (oil cooler responsibility)
Natural freqs and mode shapes, allowable mods to oil cooler blower
Lightest overall wt, oil cooler attachment possibilities, minimize number of bearings, overall cost impact
Determine options for attachment of forward end of shaft
Best forward attachment concept
Best forward attachment concept
D/S Design
D/S Design, Airframe Structures, A/F Design
Prefered placements of damper and snubber supports, T/B stiffness, T/B deflections
Damper placement requirements, tailboom strength and stiffness
Determine impact to T/B structure & design the mods
Dwgs of T/B mods Dwgs of T/B mods Manufacturing
Suppliers Inputs Outputs
Suppliers Inputs Process Outputs Customers
(Providers of the required resources)
(Resources required by the process)
Process Requirements for the Inputs
( Top level description of activity)
(Deliverables from the process)
Customer’s Requirements of the Outputs
(Anyone who
receives a deliverable
from the process)
1What is the process?
4Who is the customer of each output?
5What does
each customer
expect from each output?
8What does
the process expect
from each input?
6What
Inputs are required to enable this process to
occur?
7Who is the supplier of
each input?
3What are
the outputs from the
process?
2When does the process end?
Boundary
2When does theProcess start?
Boundary
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Group Exercise - SIPOC
INPUTS OUTPUTSPROCESS
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Create a relationship matrix for the previous SIPOC
Relationship Matrix
*Input/Output relationships can be rated as:
Strong: 9Moderate: 3
Weak: 1Nonexistent: Blank or 0
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Basic Structure – C&E Diagram(Fishbone)
Project Y
Inputs (X’s) Output (Y)
Level 1 Cause
Level 2 Cause
Main Category
MeasurementsMaterials People
EnvironmentMethods Machines
C = Control Factor (controllable)N = Noise factor (out of our control)X = Experimental variable
C
N
X
N
C
N
X
C
C
By identifying the correct inputs, you can achieve optimal results in the shortest time.
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Cause & Effect C/N/X’s
C = those variables which must be held constant and require standard operating procedures to insure consistency. Consider the following examples: the method used to enter information on a billing form, the method used to load material in a milling or drilling process, the autoclave temperature setting.
N = those variables which are noise or uncontrolled variables and cannot be cheaply or easily held constant. Examples are room temperature or humidity.
X = those variables considered to be key process (or experimental) variables to be tested in order to determine what effect each has on the outputs and what their optimal settings should be to achieve customer-desired performance. VI-12
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Cause and Effect Diagram Objective:
Develop a C&E diagram that explains the variability of the launching process. Label as C/N/X.
METHOD
MOTHERNATURE
MEASUREMENT
MANPOWER MACHINE
MATERIAL
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In groups Conduct a process FMEA for “shooting the
statapult” Generate Risk Priority Numbers and
develop controls that will minimize risk
FMEA
Product or
ProcessFailure Mode Failure Effects SEV Causes OCC Controls DET RPN Actions Plans PS PO PD prpn
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SOP
Objective:
Develop a SOP that accurately defines each controlled step of the launching process.
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LaunchSequence
Distance
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Statapult Instructions Launch #2
Every shot will be launched from a pull back angle of 177/65 degrees.
Each person on the team will perform an equitable number of launches (or as close as possible).
"Launching” means pulling back and releasing.
Time between each shot cannot exceed 15 seconds.
Record the distances on the table to the left.
Record the longest distance (Max) and the shortest distance (Min) and compute Range = Max - Min.
Range = ______________
Objective: To fire the statapult and record the distance for each of the launches. The measured distance will be from the back of the launcher to the point where the ball first lands. Record the distances in the order in which they were obtained.
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Statapult Launch #2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Launch Sequence
Distance
See graphing.pdfVI-14
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Concentration Chart
www.duetsblog.com/uploads/image/AT&T.jpg
http://www.qualitytrainingportal.com/resources/problem_solving/problem-solving_tools-concentration_diagrams.htm
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Measures of Variation
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Data is collected using samples because the entire population may not be known or it may be too costly to measure.◦ Population is every possible item◦ Sample is a subset of the population
Population vs. Sample
X
µ
Sample
Population
Population
Sample
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Step #1 Add the data points and divide by the number of data point to determine the mean (average)
Step #2 Subtract the mean from each individual data point and square the result (data point – Mean)2
Step #3 Add together all the squared data points
Step #4 Divide the total of the squared data points by n-1 if a sample, or n if a population (n= number of data points)
Step #5 Calculate the square root of the sum of step #4.
The result is the standard deviation for the process.
Calculating Standard Deviation
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Launch #1
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Launch #2
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Graphical View of Variation and Six Sigma Performance
Each unit of measure is a numerical value on a continuous scale
Size Size Size Size
Pieces vary from each other
Variation common and special causes
But they form a pattern that, if stable, is called a normal distribution
Histogram or
Frequency Distribution
Normal Distribution
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Normal Distribution
There are three terms used to describe distributions
3. Location Mean
1. ShapeBell
2. Spread
Standard
Deviation
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Scatter Diagram example:
Dis
tanc
e
Angle
Angle Distance
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Histograms examplesWhat speculations can you make about the following processes
based on the histograms?
LSL USL 10 9 X 8 X 7 X 6 X 5 X 4 X X 3 X X X 2 X X X X 1 X X X X X
.493 .494 .495 .496 .497 .498 .499 .500 .501 .502 .503 .504 .505 .506 .507
1.
LSL USL 10 9 X 8 X 7 X X X X 6 X X X X 5 X X X X 4 X X X X X X X 3 X X X X X X X X X X 2 X X X X X X X X X X X X X X X 1 X X X X X X X X X X X X X X X
.493 .494 .495 .496 .497 .498 .499 .500 .501 .502 .503 .504 .505 .506 .507
2.
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Histograms examples
LSL USL 10 9 X 8 X 7 X 6 X 5 X X X 4 X X X 3 X X X 2 X X X X X 1 X X X X X X X
.493 .494 .495 .496 .497 .498 .499 .500 .501 .502 .503 .504 .505 .506 .507
3.
LSL USL 10 X 9 X 8 X 7 X X X 6 X X X X 5 X X X X X 4 X X X X X 3 X X X X X X X 2 X X X X X X X X 1 X X X X X X X X
.493 .494 .495 .496 .497 .498 .499 .500 .501 .502 .503 .504 .505 .506 .507
4.
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Instructions◦ Refer to Launch #1 and #2 and convert the run
charts shown on these pages to histograms, using 4-inch intervals as the class width.
◦ The student may then choose the 12-inch range (3 consecutive 4-inch intervals) centered around the average to be the specification range.
◦ Draw those spec limits on the histogram and complete the following table:
Computing Cost Of Poor Quality
Launch #1
Launch #2
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Calculate our statistics
The HeightExample
Inches? Inches?
Hey buddy...whatchagot in the case?
Step 1Collect
Data
HeightsDev. from
Avgerage.
Total
Xbar(average) »Sigma!!
Let’s practice
Find:
MeanMedianModeRangeSigma -population -sample
5’ = 60”6’ = 72”
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Plot height data and use the statistics
Step 2Create a
Histogram
Xbar =
Scale - (Use 2"increments)
Sigma Area % Height Span Realistic? (Y/N)+/- 1 Sigma+/- 2 Sigma+/- 3 Sigma+/- 6 Sigma
Step 3Add Sigma
Limits
Step 4
Analyze
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