6sigma- control phase

8/9/2019 6sigma- Control Phase

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1

SIX SIGMA GREENBELT PROGRAM

- Moving towards defect free processesD M A I C

W W W . E C C I N T E R N A T I O N A L . C O M

Alexiv Villas

PHILIPPINES MALAYSIA VIETNAM INDONESIA INDIA CHINA


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2

Control PhaseControl Phase

Defect PreventionDefect Prevention


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3

Defect Controls

Six Sigm Control !lns

Six Sigm Control !lns

Defect Controls

Defect Controls

Sttisticl !rocess Control "S!C#

Sttisticl !rocess Control "S!C#

Wr$ %$ & Action Items

Wr$ %$ & Action Items

Realistic Tolerance and Si Si!"a Desi!n

Realistic Tolerance and Si Si!"a Desi!n

Process A#to"ation or Interr#$tion

Process A#to"ation or Interr#$tion

Po%a&Yo%e

Po%a&Yo%e


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'

!(r$ose of Defect !re)ention in Control !*se

!rocess im$ro)ement efforts often flter +(ring im$lementtion of ne,

o$erting met*o+s lerne+ in t*e Anl-e !*se.

S(stin/le im$ro)ements cn not /e c*ie)e+ ,it*o(t control tctics

to g(rntee $ermnenc-.

Defect !re)ention see0s to gin $ermnenc- /- eliminting or rigi+l-

+efining *(mn inter)ention in $rocess.

Yes sir, we are in CONTROL!


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s Le)el for !roect S(stining in Control

4s5 Six Sigm $ro+(ct n+6or $rocess +esign elimintes n errorcon+ition OR n (tomte+ s-stem monitors t*e $rocess n+

(tomticll- +(st criticl 78s to correct settings ,it*o(t *(mninter)ention to s(stin $rocess im$ro)ements

's5 A(tomte+ mec*nism s*(ts +o,n t*e $rocess n+ $re)entsf(rt*er o$ertion (ntil re9(ire+ ction is $erforme+

3s5 Mist0e $roofing $re)ents $ro+(ct6ser)ice from $ssing ontot*e next ste$

3's5 S!C on 78s ,it* t*e s$ecil c(ses re i+entifie+ n+ cte+($on /- f(ll- trine+ o$ertors n+ stff ,*o +*ere to t*e r(les

2's5 S!C on :8s

13s5 De)elo$ment of SO!s n+ $rocess (+its

;1s5 Trining n+ ,reness

BESTBEST

WORSTWORST


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4

4s !ro+(ct6!rocess Design

Designing $ro+(cts n+ $rocesses s(c* t*t t*e o(t$(t : meets or

excee+s t*e trget c$/ilit-.

When designing the part or process, specifications on X are set such that

the target capability on Y is achieved.

Both the target and tolerance of the X must be addressed in the spec

limits.

20111"1#1$1%1&121110

2%

22

21

1

1"

Distribution of X

Distribution

of Y

Relationship

Y !"#$ S

' e (

i ) i (

a *

i + n

+ n

Y


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20111"1#1$1%1&121110

2%

22

21

1

1"

Distribution of X

Distribution

of YRelationship

Y !"#$

S '

e (

i ) i (

a *

i + n

+ n

Y

%pper

&rediction

'nterval

(ower

&rediction

'nterval

If t*e reltions*i$ /et,een 7 n+ : is em$iricll- +e)elo$e+ t*ro(g*

Regressions or DOE8s (ncertint- exists.

As res(lt= confi+ence inter)ls s*o(l+ /e (se+ ,*en est/lis*ing t*e

s$ecifictions for 7.

4s !ro+(ct6!rocess Design


8/130>

!ro+(ct6!rocess Design Exm$le

%sing ?@ $re+iction /n+s ,it*in MINITATM

Stat > Regression>Fitted Lin Plot …..Options…Display Prediction Interval

) * +)

)

+)

)

-)

)

*)

/)

0)

1)

2)

'nput

3 u t p u t

Y 0.0*- 4 *.1++)X

R567 11.) 8

Regression

2*8 &'

Regression &lot

Wa* are *e

s'e( -i.i*s )+r*e +/*'/*

W*t is t*e tolernce rnge for t*e in$(tB

If -o( ,nt 4 $erformnce= -o( ,ill remem/er to tig*ten t*e o(t$(t8s

s$ecifiction to select t*e tolernce rnge of t*e in$(t.


9/130?

(

+

*(

O # t $ # t )

Y , )-')./* & (-).)0))1

R&S2 , /0-* 3

Re!ression Plot

(

*(

)(

'(

4(

+(

0(

5(

.(

/(

O # t $ # t

Y , 5-5+4'4 6 +-.**(41

R&S2 , ..-( 3

Re!ression Plot

N+*e i3 +/*'/* s'e( (+nne(*swi* *+' -ine in 4+* (ases5

L+wer in'/* s'e(

Using top output spec deterines !ig! or lo" tolerance for inputdepending on slope of Regression.

!ro+(ct6!rocess Design Exm$le


10/1301;

(

*(

)(

'(

O # t $ )

6 (-04+4501

Y , *-404/*0'-( 3

R&S2 ,

Re!ression Plot

(

*(

)(

O # t $ *

6 (-.**'*)1

Y , &4-5E&(*

/(-4 3

R&S2 ,

Re!ression Plot

Poor #orrelation does not

allo" for tig!tertolerancing.

!oor Regression Im$cting Tolerncing


11/13011

4 (ll A(tomtion

Full Automation: S7ste"s that "onitor the $rocess and a#to"aticall7ad8#st critical 19s to correct settin!s-

: A#to"atic !a#!in! and s7ste" ad8#st"ents

: A#to"atic detection and s7ste" activation s7ste"s & landin! !ear

etension ;ased on aircraft s$eed and $o


12/13012

(ll A(tomtion Exm$le

A >reen ?elt is


13/13013

' s !rocess Interr($tion

Process Interruption: Mechanis" installed that sh#ts do


14/1301'

' s !rocess Interr($tion

Exm$le5

: A reen elt is ,or0ing on l(nc*ing ne, electric +ri)e (nit on trnsfer s-stem One common fil(re mo+e of t*e s-stem is /ering fil(re on t*e

min motor s*ft It ,s +etermine+ t*t *ig* $ress fit t /ering instlltion ,s

c(sing t*ese fil(res

T*e root c(se of t*e $ro/lem t(rne+ o(t to /e (n+ersie+ /eringsfrom t*e s($$lier

: %ntil t*e s($$lier co(l+ /e /ro(g*t into control or re$lce+= t*e temim$lemente+ $ress lo+ monitor t t*e /ering $ress ,it* in+ictor If t*e monitor +etects $ress lo+ *ig*er t*n t*e set $oint= it s*(ts

+o,n t*e $ress n+ ,ill not llo, t*e (nit to /e remo)e+ from $ress

(ntil n interloc0 0e- is t(rne+ n+ t*e rm reset in t*e mn(l mo+e Onl- t*e line le+ $erson n+ t*e s($er)isor *)e 0e-s to t*e

interloc0 T*e nonconforming $rt is (tomticll- mr0e+ ,it* re+ +-e

Pr+(ess In*err/'*i+n


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3 Mist0e !roofing

Mistake Proofing is ;est defined as@

sin!


16/13014

Tr+itionl F(lit- )s. Mist0e !roofing

$raditional InspectionResult

Wor9er orMachine :rror

Don;t Do


17/1301<

ERROR ABO


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1>

Mist0e !roofing De)ices Design

Gints to *el$ +esign mist0e

$roofing +e)ice5 Sim$le

Inex$ensi)e

i)e $rom$t fee+/c0

i)e $rom$t ction "$re)ention# oc(se+ $$liction

G)e t*e rig*t $eo$le8s in$(t

,'S$ ...ma9es it impossible for errors to occur

,'$$'R @@allows for detection while error is being made

*OOD ...detects defect before it continues to the ne#toperation


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1?

Contact Method

!*-sicl or energ- contct ,it*

$ro+(ct: Limit s,itc*es

: !*otoelectric /ems

Fixed Value Method

N(m/er of $rts to /e ttc*e+6ssem/le+

etc. re constnt

N(m/er of ste$s +one in

o$ertion

: Limit s,itc*es

Motion-step Method

C*ec0s for correct se9(encing

C*ec0s for correct timing

: !*otoelectric s,itc*es n+

timers

++

Auide &ins of Different 6ies

:rror Detectionand


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2;

Mist0e !roofing Exm$les

Everda examples of mistake-proofing:

: Gome

A(tomte+ s*(toffs on electriccoffee $ots

ro(n+ f(lt circ(it /re0ers for

/t*room in or o(tsi+e electric

circ(its

!ilotless gs rnges n+ *ot ,ter

*eters

C*il+ $roof c$s on me+ictions

(tne lig*ters ,it* sfet- /(tton

: Com$(ters

Mo(se insertion

%S c/le connection

tter- insertion

!o,er s)e fet(re

: A(tomo/ile

Set /elts

Air /gs

Cr engine ,rning lig*ts

: Office

S$ell c*ec0 in ,or+ $rocessing

soft,re

F(estioning HDo -o( ,nt to +elete

fter +e$ressing t*e HDelete /(tton

on -o(r com$(ter

: ctor-

D(l $lm /(ttons n+ ot*er g(r+s

on mc*iner-

: Retil

Tm$er $roof $c0ging


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21

A+)ntges of Mist0e !roofing s A Control Met*o+

Mist0e !roofing +)ntges incl(+e5

Onl- sim$le trining $rogrms re re9(ire+

Ins$ection o$ertions re eliminte+ n+ t*e $rocess is sim$lifie+

Relie)es o$ertors from re$etiti)e ts0s of t-$icl )is(l ins$ection

!romotes creti)it- n+ )l(e ++ing cti)ities

Res(lts in +efect free ,or0

Re9(ires imme+ite ction ,*en $ro/lems rise !ro)i+es 1;;@ ins$ection internl to t*e o$ertion

T*e /est reso(rce for $ictoril exm$les of Mist0e !roofing is5

P+:a;Y+:e I.'r+in3 Pr+9/(* /a-i*8 48 Preen*in3 De)e(*s5Oeriew 48 ir+8/:i iran+5 Pr+9/(*ii*8 Press, 15>


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Involve ever7one in defect $revention

Esta;lish $rocess ca$a;ilit7 thro#!h SPC

Esta;lish and adhere to standard $roced#res

Ma%e dail7 i"$rove"ents

Invent Mista%e&$roofin! devices

Ma%e i""ediate feed;ac% and action $art of c#lt#re

Don9t 8#st sto$ at one "ista%e $roofin! device $er $rod#ct

Defect Prevention is needed for all $otential defects

Defect Prevention i"$le"ented MST ;e doc#"ented in 7o#r livin!GMEA for the $rocess$rod#ct

Defect !re)ention C(lt(re n+ oo+ Control !lns


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Clss Exercise

re0 into -o(r gro($s n+ +isc(ss mist0e $roofing s-stems c(rrentl-t -o(r fcilities

I+entif- one (tomtion exm$le n+ one $rocess interr($tion exm$le$er gro($

e $re$re+ to $resent /ot* exm$les to t*e clss

Ans,er t*e follo,ing 9(estions s $rt of t*e +isc(ssion n+$resenttion5

Go, ,s t*e nee+ for t*e control s-stem i+entifie+B If Criticl 7is mist0e $roofe+= *o, ,s it i+entifie+ s /eing criticlB

Go, re t*e- mintine+B Go, re t*e- )erifie+ s ,or0ing $ro$erl-B Are t*e- e)er +is/le+B

:o( *)e 3; min(tesJ


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2'

Clss Exercise /o(t Defect !re)ention

Pre$are a $ro;a;le Defect Prevention "ethod to a$$l7 to

7o#r $ro8ect-

List an7 $otential ;arriers to i"$le"entation-


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2

S(mmr-

At t*is $oint= -o( s*o(l+ /e /le to5

: Descri;e so"e "ethods of Defect Prevention

: nderstand ho< these techni2#es can hel$


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Control PhaseControl PhaseStatistical Process ControlStatistical Process Control


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2<

Sttisticl !rocess Control

MethodologyMethodology

:lements and &urpose:lements and &urpose

6pecial Cause =ests6pecial Cause =ests

:#amples:#amplesSi Si3.a C+n*r+- P-ansSi Si3.a C+n*r+- P-ans

De)e(* C+n*r+-sDe)e(* C+n*r+-s

S*a*is*i(a- Pr+(ess C+n*r+- =SPC>S*a*is*i(a- Pr+(ess C+n*r+- =SPC>

Wra'


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2>

S!C O)er)ie,5 Collecting Dt

Population:

An entire !ro#$ of o;8ects that have ;een "ade or


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2?

S!C Selection !rocess

C++seA''r+'ria*e

C+n*r+- Car*

type

of data

type of

attribute

data

subgroup

sie

I MRCar*

X RCar*

X SCar*

C Car*<

Car*NP

Car*P Car*

type

of defecttype of

subgroups

ATTRIB


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3;

S!C O)er)ie,5 IMR C*rt: An IMR c*rt com/ines Control C*rt of t*e )erge mo)ing rnge ,it* t*e In+i)i+(l8s

C*rt.

: :o( cn (se in+i)i+(ls c*rts to trc0 t*e $rocess le)el n+ to +etect t*e $resence of

S$ecil C(ses ,*en t*e sm$le sie is 1.

: Seeing /ot* c*rts toget*er llo,s -o( to trc0 /ot* t*e $rocess le)el n+ $rocess

)rition t t*e sme time= $ro)i+ing greter sensiti)it- t*t cn *el$ +etect t*e $resence of

S$ecil C(ses.

In+i)i+(ls C*rt

&4

&'

&)

&*

(

*

)'

4

* ) ' 4 + 0 5 . / *( ** *) *' *4 *+ *0 *5 *. */ )( )* )) )' )4 )+ )0 )5 ). )/ '(

O/ser)tion

M e s ( r e

Data

LCL

1;ar

CL

MR/r C*rt

(

*

)

'

4

+

* ) ' 4 + 0 5 . / *( ** *) *' *4 *+ *0 *5 *. */ )( )* )) )' )4 )+ )0 )5 ). )/ '(O/ser)tion

R n g e

Ran!e

LCL

R;ar

CL


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31

S!C O)er)ie,5 7/rR C*rtIf each of 7o#r o;servations consists of a subgroup of data= rather than 8#st individ#al

"eas#re"ents= an 1;ar&R chart $roviders !reater sensitivit7- Gail#re to for" rational

s#;!ro#$s correctl7


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32

S!C O)er)ie,5 % C*rt

: C Charts and Charts are for trac%in! defects-

: A Chart can do ever7thin! a C Chart can= so


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33

S!C O)er)ie,5 ! C*rt

: NP Charts and P Charts are for trac%in! defectives-

: A P Chart can do ever7thin! an NP Chart can= so


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3'

T-$e 1 Correcti)e Action K Co(ntermes(re@ i"$rove"ent "ade to the $rocess


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3

!(r$ose of Sttisticl !rocess Control

E)er- $rocess *s C(ses of rition 0no,n s5

Common Cause: Nt(rl )ri/ilit-

!pecial Cause: %nnt(rl )ri/ilit-: Assign/le5 Reson for +etecte+ ri/ilit-

: !ttern C*nge5 !resence of tren+ or (n(s(l $ttern

S!C is /sic tool to monitor n+ im$ro)e )rition in $rocess.

S!C is (se+ to +etect S$ecil C(se )rition telling (s t*e $rocess is

Ho(t of control /(t +oes NOT tell (s ,*-.

S!C gi)es glim$se of ongoing $rocess c$/ilit- AND is )is(l

mngement tool.

El t f C t l C* t


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34

Observation

I n d i v

i d u a l V a l u e

28252219161310741

60

50

40

30

20

10

0

_ X=29.06

UCL=55.24

LCL=2.87

1

Control Chart of Recycle

Elements of Control C*rts

De)elo$e+ /- Dr Wlter A. S*e,*rt of ell L/ortories from 1?2'

r$*icl n+ )is(l $lot of c*nges in t*e +t o)er time

T*is is necessr- for )is(l mngement of -o(r $rocess.

Control C*rts ,ere +esigne+ s met*o+olog- for in+icting c*nge in

$erformnce= eit*er )rition or Men6Me+in.

C*rts *)e Centrl Line n+ Control Limits to +etect S$ecil C(se )rition.

&rocess Center"usually the Mean$

6pecial Cause

Eariation Detected

Control (imits

%n+erstn+ing t*e !o,er of S!C


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3<

%n+erstn+ing t*e !o,er of S!C

Control C*rts in+icte ,*en $rocess is Ho(t of control or ex*i/iting S$ecil C(se )rition

/(t NOT ,*-J

S!C C*rts incor$orte ($$er n+ lo,er Control Limits.

T*e limits re t-$icll- 6 3 from t*e Center Line.

T*ese limits re$resent ??.


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3>

*eneral Steps for #onstructing #ontrol #!arts

T*e Control C*rt Coo0/oo0

*- Select characteristic critical 1F or CTJ to ;e charted-

)- Deter"ine the $#r$ose of the chart-

'- Select data&collection $oints-

4- Esta;lish the ;asis for s#;&!ro#$in! onl7 for Y9sJ-

+- Select the t7$e of Control Chart-

0- Deter"ine the "eas#re"ent "ethodcriteria-5- Esta;lish the sa"$lin! intervalfre2#enc7-

.- Deter"ine the sa"$le siBe-

/- Esta;lish the ;asis of calc#latin! the Control Li"its-

*(- Set #$ the for"s or soft


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3?

=o get results, should we focus our behavior on the Y or XF

Y

Dependent

3utput

:ffect

6ymptom

Monitor

X+ . . . X?

'ndependent

'nput

Cause

&roblem

Control

'f we find the Gvital fewH X;s, first consider using

6&C on the X;s to achieve a desired YF

Y6=>

oc(s of Six Sigm n+ t*e %se of S!C

Control C*rt Antom


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';

Control C*rt Antom-

C+..+n Ca/se

Faria*i+nPr+(ess is JInC+n*r+-K

S'e(ia- Ca/seFaria*i+n

Pr+(ess is JO/*+) C+n*r+-K

S'e(ia- Ca/seFaria*i+n

Pr+(ess is JO/*+) C+n*r+-K

R/n Car* +)9a*a '+in*s

Pr+(ess Se/en(e?Ti.e S(a-e

L+wer C+n*r+-Li.i*

Mean

G?;

&si3

.a


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'1

Control n+ O(t of Control

O/*-ier

O/*-ier

#!M

$M

5"M

&

2

1

;1

;2

;&

Sie of S(/gro($s


42/130

'2

T7$ical s#;!ro#$ siBes are '&*) for varia;le data@

If diffic#lt7 of !atherin! sa"$le or e$ense of testin! eists the siBe= n= is

s"aller '= += and *( are the "ost co""on siBe of s#;!ro#$s ;eca#se of ease

of calc#lations


43/130

'3

T*e Im$ct of rition

5 ?atural &rocess Eariation

as defined by subgroupselection


5 Different 3perators

S+/r(es +) Faria*i+n S+/r(es +) Faria*i+nS+/r(es +) Faria*i+n


5 Different 3perators5 6upplier 6ource

An9, +) (+/rse, i) *w+ a99i*i+na-s+/r(es +) aria*i+n arrie, we wi--

9e*e(* *a*, *++!

6irs*, se-e(* *e s'rea9 *a*we wi-- 9e(-are as *e

JNa*/ra- Pr+(ess Faria*i+nK,

s+ *a* weneer an8 '+in*-an9s +/*si9e *ese

JC+n*r+- Li.i*sK, an a-ar.wi-- s+/n9

S+, wen a se(+n9 s+/r(e+) aria*i+n a''ears, we

wi-- :n+w!

If you ase your liits on all t!ree sources of variation "!at "ill sound t!e alar/

;


44/130

''

re9(enc- of Sm$ling

Sapling Fre0uency is a 4a-an(e 4e*ween (+s* +) sa.'-in3 an9 *es*in3ers/s (+s* +) n+* 9e*e(*in3 si)*s in Mean +r aria*i+n5

Pr+(ess :n+w-e93e is an in'/* *+ )re/en(8 +) sa.'-es a)*er *e s/43r+/'siHe as 4een 9e(i9e95

I I) a 'r+(ess si)*s 4/* (ann+* 4e 9e*e(*e9 4e(a/se +) *++ in)re/en*sa.'-in3, *e (/s*+.er s/))ers

I I) (+i(e is 3ien +) -ar3e s/43r+/' sa.'-es in)re/en*-8 +r s.a--er

s/43r+/'s .+re )re/en*-8, .+s* (++se *+ 3e* in)+r.a*i+n .+re)re/en*-85

I In s+.e 'r+(esses, wi* a/*+.a*e9 sa.'-in3 an9 *es*in3 )re/en*sa.'-in3 is eas85

I) /n9e(i9e9 as *+ sa.'-e )re/en(8, sa.'-e .+re )re/en*-8 *+ (+n)ir.

9e*e(*i+n +) 'r+(ess si)*s an9 re9/(e )re/en(8 i) 'r+(ess aria*i+n iss*i-- 9e*e(*a4-e5

A r/-e +) */.4 a-s+ s*a*es Jsa.'-e a 'r+(ess a* -eas* 10X .+re )re/en**an *e )re/en(8 +) +/* +) (+n*r+-7 (+n9i*i+nsK5

re9(enc- of Sm$ling


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'

re9(enc- of Sm$ling

Sa.'-in3 *++ -i**-e wi-- n+* a--+w )+r s/))i(ien* 9e*e(*i+n +) si)*s in *e'r+(ess 4e(a/se +) S'e(ia- Ca/ses5

Observation

I n d i v i d u a l V a l u e

13121110987654321

7.5

7.0

6.5

6.0

5.5

5.0

_ X=6.1

UCL=7.385

LCL=4.815

I Chart of Sample_3

Observation

I n d i v i d u a l V

a l u e

7654321

8

7

6

5

4

_ X=6.129

UCL=8.168

LCL=4.090

I Chart of Sample_6

Observation

I n d i v i d u a l V

a l u e

4321

6.6

6.4

6.2

6.0

5.8

5.6

5.4

5.2

5.0

_ X=5.85

UCL=6.559

LCL=5.141

I Chart of Sample_12

A-- '+ssi4-e sa.'-es

Sa.'-e eer8 +/r Sa.'-e % 'er si)*

Sa.'-e eer8 a-) +/r



46/130

'4


C++se A''r+'ria*eC+n*r+- Car*

typeof data

type of

attribute

data

subgroupsie

I MRCar*

X RCar*

X SCar*

C/.S/.Car*

EWMACar*

C Car* < Car* NP Car* P Car*

type

of defecttype of

subgroups

ATTRIB


47/130

'<

%n+erstn+ing ri/le Control C*rt Selection

$ype of #!art 1!en do you need it/

!ro+(ction is *ig*er )ol(me llo,s $rocess Men n+)ri/ilit- to /e )ie,e+ n+ ssesse+ toget*er more sm$ling

t*n ,it* In+i)i+(ls C*rt "I# n+ Mo)ing Rnge C*rts "MR#

/(t ,*en s(/gro($s re +esire+. O(tliers cn c(se iss(es

,it* Rnge "R# c*rts so Stn+r+ De)ition c*rts "S# (se+

inste+ if concerne+.

!ro+(ction is lo, )ol(me or c-cle time to /(il+ $ro+(ct is long

or *omogeneo(s sm$le re$resents entire $ro+(ct "/tc* etc.#

sm$ling n+ testing is costl- so s(/gro($s re not +esire+.

Control limits re ,i+er t*n 7/r C*rts. %se+ for S!C on

most in$(ts.

Aera3e Ran3e+r S

=X4ar an9 R +rX4ar an9 S>

M+s* (+..+n

In9ii9/a- an9M+in3 Ran3e

%n+erstn+ing Attri/(te Control C*rt Selection


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'>1

%n+erstn+ing Attri/(te Control C*rt Selection

Nee+ to trc0 t*e frction of +efecti)e

(nits sm$le sie is )ri/le n+ (s(ll- ;

W*en -o( ,nt to trc0 t*e n(m/er of +efecti)e

(nits $er s(/gro($ sm$le sie is (s(ll-

constnt n+ (s(ll- ;

W*en -o( ,nt to trc0 t*e n(m/er of +efects

$er s(/gro($ of (nits $ro+(ce+ sm$le sie is

constnt

W*en -o( ,nt to trc0 t*e n(m/er of+efects $er (nit sm$le sie is )ri/le

P

nP

C

<

1!en do you need it/$ype of #!art

Detection of Assign/le C(ses or !tterns


49/130

'?


Control C*rts in+icte S$ecil C(ses /eing eit*er ssign/le

c(ses or $tterns.

T*e follo,ing r(les re $$lic/le for /ot* )ri/le n+ Attri/(te

Dt to +etect S$ecil C(ses.

T*ese fo(r r(les re t*e onl- $$lic/le tests for Rnge "R#=

Mo)ing Rnge "MR# or Stn+r+ De)ition "S# c*rts.

One $oint more t*n 3 Stn+r+ De)itions from t*e Center

Line.

4 $oints in ro, ll eit*er incresing or ll +ecresing.

1' $oints in ro, lternting ($ n+ +o,n.

? $oints in ro, on t*e sme si+e of t*e center line.



50/130

;


Control C*rts in+icte S$ecil C(ses /eing eit*er ssign/le c(ses or

$tterns.

T*ese remining fo(r r(les re onl- for )ri/le +t to +etect S$ecil

C(ses.

2 o(t of 3 $oints greter t*n 2 Stn+r+ De)itions from t*e Center

Line on t*e sme si+e.

' o(t of $oints greter t*n 1 Stn+r+ De)ition from t*e Center

Line on t*e sme si+e.

1 $oints in ro, ll ,it*in one Stn+r+ De)ition of eit*er si+e of

t*e Center Line.

> $oints in ro, ll greter t*n one Stn+r+ De)ition of eit*er

si+e of t*e Center Line.

S$ecil C(se R(le Def(lt in MINITATM


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1

S$ecil C(se R(le Def(lt in MINITA

If a ?elt is #sin! MINITA?TM= 7o# "#st ;e a#ontrol #!arts and 2uality $ools>Define $ests

=his would be

changed to 1 if

you prefer the

Western:lectric Rules.

S$ecil C(se R(le Selection in MINITATM


52/130

2

S$ecil C(se R(le Selection in MINITA

Khen a ?elt is #sin! MINITA?TM= the defa#lt tests can ;e set $ests to Perfor

S$ecil C(se Test Exm$les


53/130

3

Test 1 One $oint ;e7ond Bone A

A

CC

A

1

T*is is t*e MOST common S$ecil C(se test (se+ in S!C c*rts.

+

$ $



54/130

'

Tis *es* is an in9i(a*i+n +) a si)* in *e 'r+(ess Mean5

$ $

Test 2 Nine $oints in a ro< on

sa"e side of center line

A

C

C

A

2



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$ $

A

CC

A

3

Test 3 Si $oints in a ro


56/130

4

$ $

Tis *es* is in9i(a*in3 a n+n;ran9+. 'a**ern5

A

C

C

A

'

Test ' Go#rteen $oints in a

ro


57/130

<

$ $

Tis *es* is in9i(a*in3 a si)* in *e Mean +r a w+rsenin3 +)aria*i+n5

Test T


58/130

>

$ $

Tis *es* is in9i(a*in3 a si)* in *e Mean +r 9e3ra9a*i+n +)aria*i+n5

Test 4 Go#r o#t of five $oints in

Bone ? or ;e7ond Ione side of

center lineJ

A

C

C

A

4

4



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?

$ $

Tis *es* is in9i(a*in3 a 9ra.a*i( i.'r+e.en* +) *e aria*i+n in*e 'r+(ess5

Test


60/130

4;

Test > Ei!ht $oints in a ro<

;e7ond Bone C I;oth sides of center lineJ

A

C

C

A

>

Tis *es* is in9i(a*in3 a seere w+rsenin3 +) aria*i+n5

S!C Center Line n+ Control Limit Clc(ltions


61/130

41

Clc(lte t*e $rmeters of t*e In+i)i+(l n+ MR Control C*rts ,it* t*e

follo,ing5

Were

X4ar Aera3e +) *e in9ii9/a-s, 4e(+.es *e Cen*er Line +n *e In9ii9/a-s Car*Xi In9ii9/a- 9a*a '+in*s

: N/.4er +) in9ii9/a- 9a*a '+in*s

R i M+in3 ran3e 4e*ween in9ii9/a-s, 3enera--8 (a-(/-a*e9 /sin3 *e 9i))eren(e 4e*ween

ea( s/((essie 'air +) rea9in3s

MR4ar Te aera3e .+in3 ran3e, *e Cen*er Line +n *e Ran3e Car*

σ "st. dev. :stimate$

S!C Center Line n+ Control Limit Clc(ltions


62/130

42

Clc(lte t*e $rmeters of t*e 7r n+ R Control C*rts ,it* t*e

follo,ing5

k

x

X

k

1i

i∑==

k

R

R

k

i

i∑=

R AXUCL 2x +=

R AXLCL 2x −=

R DUCL 4R =

R DLCL 3R =

Cen*er Line C+n*r+- Li.i*s

Were

Xi


63/130

43

Clc(lte t*e $rmeters of t*e 7/r n+ S Control C*rts ,it* t*e

follo,ing5

Were

Xi


64/130

4'

Clc(lte t*e $rmeters of t*e ! Control C*rts ,it* t*e follo,ing5

Were

'


65/130

4

Clc(lte t*e $rmeters of t*e n! Control C*rts ,it*

t*e follo,ing5

Were

n'


66/130

44

Clc(lte t*e $rmeters of t*e % Control C*rts ,it* t*e

follo,ing5

Were

/ =otal number of defects divided by the total number of unitsinspected.

ni ?umber inspected in each subgroup

LCL/

(ower Control (imit on % Chart.


67/130

4<

Clc(lte t*e $rmeters of t*e C Control C*rts

,it* t*e follo,ing5

Were

( =otal number of defects divided by the total number of subgroups.

LCL( (ower Control (imit on C Chart.


68/130

4>

Pre-Control Charts #se li"its relative to the s$ecification li"its- This is thefirst and ONLY chart 7o#


69/130

4?

#alif7in! Process: To 2#alif7 a $rocess= five consec#tive $arts "#st fall


70/130


71/130


72/130


73/130


74/130


75/130


76/130

5 Inter$ret fin+ings= in)estigte S$ecil C(se )rition=

& m0e im$ro)ements follo,ing t*e O(t of Control Action !ln"OCA!#

Notice the ne< '


77/130


78/130

ec(se of t*e S$ecil C(se= t*e $rocess m(st refer to t*e OCA! or O(t of Control Action !ln t*t sttes,*t root c(ses nee+ to /e in)estigte+ n+ ,*t ctions re t0en to get t*e $rocess /c0 in control.

After t*e correcti)e ctions ,ere t0en= ,it (ntil t*e next sm$le is t0en to see if t*e $rocess *s c*nge+to not s*o, S$ecil C(se ctions.

If still o(t of control= refer to t*e OCA! n+ t0e f(rt*er ction to im$ro)e t*e $rocess. DO NOTm0e n- more c*nges if t*e $rocess s*o,s /c0 in control fter t*e next re+ing.

: E)en if t*e next re+ing seems *ig*er t*n t*e Center LineJ Don8t c(se more )ri/ilit-.

If $rocess c*nges re +oc(mente+ fter t*is $roect ,s close+= t*e Control Limits s*o(l+ /e reclc(lte+s in ste$ ? of t*e S!C met*o+olog-.

Sample

r o p o r t i o n

2321191715131197531

0.30

0.25

0.20

0.15

_ !=0.2038

UCL=0.2802

LCL=0.1274

1

Chart of "mpl_#_"rrors

ri/le S!C Exm$le


79/130


80/130

>;

The ea"$le has Contin#o#s Data= s#;!ro#$s and


81/130

>1

S$ecifications


82/130

>2

Re"e";er to clic% on the O$tionsF and TestsF ta; to clarif7 the

r#les for detectin! S$ecial Ca#ses-

Ke


83/130

>3

Also confir" the R;ar "ethod is #sed for esti"atin! Standard Deviation-

Stat>#ontrol #!arts>7ariale #!arts for Sugroups>6ar-R>6ar-R #!art Options>'stiate

ri/le S!C Exm$le "cont.#


84/130

>'

No S$ecial Ca#ses


85/130

>

Re"e";er=


86/130

>4

!lce t*e men from t*e IRST c*rt ,ecrete+ in t*e estimtes t/. T*e Stn+r+De)ition is R/r6+2. T*is ,ill $re)entMINITATM from clc(lting ne, ControlLimits ,*ic* is Ste$ ?. +2 is fo(n+ /-fin+ing t*e t/le of constnts s*o,n erlier.

:T*e ne, ($+te+ S!C C*rt is s*o,n ,it*no in+icte+ S$ecil C(ses in t*e 7/r

C*rt. T*e Men= %CL n+ LCL re(nc*nge+ /ec(se of t*e com$lete+o$tion /o)e.

……..6ar-R #!art Options>Paraeters

Sample

S a m p l e $ e a n

51464136312621161161

35

30

25

20

_ _ X=26.33

UCL=33.07

LCL=19.59

Sample

S a m p l e R a n % e

51464136312621161161

24

18

12

6

0

_ "=11.69

UCL=24.72

LCL=0

1

&bar'R Chart of art1( )))( art*

ri/le S!C Exm$le "cont.#


87/130

><

ec(se of no S$ecil C(ses= t*e $rocess +oes not refer to t*e OCA! or O(t ofControl Action !ln n+ NO ctions re t0en.

If $rocess c*nges re +oc(mente+ fter t*is $roect ,s close+= t*e Control Limitss*o(l+ /e reclc(lte+ s in Ste$ ? of t*e S!C met*o+olog-.

Sample

S a m p l e $ e a n

51464136312621161161

35

30

25

20

_ _ X=26.33

UCL=33.07

LCL=19.59

Sample


51464136312621161161

24

18

12

6

0

_ "=11.69

UCL=24.72

LCL=0

1


Sample

S a m p l e $ e a n

51464136312621161161

35

30

25

20

_ _ X=26.33

UCL=33.07

LCL=19.59

Sample


51464136312621161161

24

18

12

6

0

_ "=11.69

UCL=24.72

LCL=0

1


Reclc(ltion of S!C C*rt Limits


88/130

>>

: Ste$ / of the "ethodolo!7 refers to recalc#latin! SPC li"its-

: Processes sho#ld see i"$rove"ent in variation after #sa!e of SPC-

: Red#ction in variation or %no


89/130

>?

At t*is $oint= -o( s*o(l+ /e /le to5

: Descri;e the ele"ents of an SPC Chart and the $#r$oses of SPC

: nderstand ho< SPC ran%s in Defect Prevention

: Descri;e the *' ste$ ro#te or "ethodolo!7 of i"$le"entin! a chart

: Desi!n s#;!ro#$s if needed for SPC #sa!e

: Deter"ine the fre2#enc7 of sa"$lin!

: nderstand the Control Chart selection "ethodolo!7

: ?e fa"iliar


90/130

Control PhaseControl Phase

Si Si!"a Control PlansSi Si!"a Control Plans

Sttisticl !rocess Control


91/130

?1

#$l%ti$& #ele'ti$$l%ti$& #ele'ti$&

C$&t($l !la& )le*e&tsC$&t($l !la& )le*e&ts

Si Si3.a C+n*r+- P-ansSi Si3.a C+n*r+- P-ans

De)e(* C+n*r+-sDe)e(* C+n*r+-s

S*a*is*i(a- Pr+(ess C+n*r+- =SPC>S*a*is*i(a- Pr+(ess C+n*r+- =SPC>

Wra'


92/130

?2

+$%,ve al(ead- de'ided $& te s$*e de/e't (ed%'ti$& *et$d$l$-.

i&al de'isi$&s &eed t$ 'la(i/- i' de/e't (ed%'ti$& t$$ls t$ %se.

Caital exe&dit%(es *a- e (e%i(ed. (ai&i& %(dles t$ $ve('$*e.

a&ae*e&t %-i& &$t '$*leted.

is *$d%le ill el sele't s$l%ti$&s it a /a*ilia( t$$l.

e C$&t($l !ase all$s te elt a&d its tea* t$ ta':le $te(($'esses i& te /%t%(e.

e ele*e&ts $/ a C$&t($l !ase aid t$ d$'%*e&t $ t$*ai&tai& te ($'ess.

is *$d%le ide&ti;es te ele*e&ts $/ st($& C$&t($l !la&s.

"e*e*e( e $e'tive is t$ s%stai& te ai&s i&itiall-/$%&d i& te ??A?@ !ases.

Selecting Sol(tions


93/130

?3

Selectin! i"$rove"ents to i"$le"ent@

Hi!h&level o;8ective eval#ation of all $otential i"$rove"ents

: I"$act of each i"$rove"ent: Cost to i"$le"ent each i"$rove"ent

: Ti"e to i"$le"ent each i"$rove"ent

?alance desire


94/130

?'

Im$ct of t*e im$ro)ement5

Ti"e fra"e of i"$rove"ents

: Lon!&ter" vs- Short&ter" effectiveness If a s#$$lier


95/130

?

Cost to im$lement im$ro)ement5

Initial cost to i"$le"ent i"$rove"ent

: Cost to train eistin!


96/130

?4

Ti"e to i"$le"ent i"$rove"ent@

Technical ti"e constraints

: Khat is the "ini"#" ti"e it


97/130

?<

Im$lementing t*is fmilir tool to $rioritie $ro$ose+

im$ro)ements is /se+ on t*e t*ree selection criteri of time= cost

n+ im$ct. All the $rocess o#t$#ts are rated in ter"s of their relative

i"$ortance to the $rocess

: The o#t$#ts of interest


98/130

?>

Solution (atri8.8ls

Im$ro)ement Selection Mtrix !roect O(t$(ts


99/130

??

Pri"ar7 and Secondar7 Metrics of 7o#r Pro8ect-

List each of the Y9s across the horiBontal ais Rate the i"$ortance of the $rocess Y9s on a scale of * to *(

: * is not ver7 i"$ortant= *( is critical

: The Si!nificance ran%in!s "#st "atch 7o#r #$dated 1&Y

Matri ran%in!s

I"$rove"ent Selection Matri


100/130

1;;

Im$ct Rtings

5 1s are re"oved fro" i"$actin! the $rocess o#t$#t-

0 Contin#al control and ad8#st"ent of critical 1s i"$actin! the$rocess o#t$#t-

+Contin#al control of critical 1s $revents defects in the $rocess

o#t$#t fro" 1-

4Defect detection of the $rocess o#t$#t $revents #n%no


101/130

1;1

Cost to Im$lement Rtings

5I"$rove"ent Costs are "ini"al


102/130

1;2

Time to Im$lement Rtings

5 Less than a


103/130

1;3

Improvement Selection Matrix Output

I"$rove"ents


104/130

1;'

I"$le"entation $lans sho#ld e"$hasiBe the need to@

Or!aniBe the tas%s and reso#rces

Esta;lish realistic ti"e fra"es and deadlines Identif7 actions necessar7 to ens#re s#ccess

Co"$onents of an i"$le"entation $lan incl#de@

Kor% ;rea%do


105/130

1;

A Control Plan is:

: Kritten s#""ar7 descri;in! s7ste"s #sed for "onitorin!controllin! $rocess or

$rod#ct variation

: Doc#"ent allo


106/130

1;4

e tea* $(:i& $& te ($e't

AB+B) $ as a ($le i& de;&i&? exe'%ti& $(

'a&i& te ($'ess

Ass$'iates

e'&i'al )xe(ts

#%e(vis$(s

a&ae(s

#ite a&ae(

D%*a& "es$%('es

e did it..

Kh7 Do Ke Need a Control PlanQ


107/130

1;<

Pro8ect res#lts need to ;e s#stained-

: Control Plan re2#ires o$eratorsen!ineers= "ana!ers= etc- to

follo< desi!nated control "ethods to !#arantee $rod#ct2#alit7 thro#!ho#t s7ste"

: Allo


108/130

1;>

I$4"$"+!"5I$4"$"+!"5I$ROV"$"+!I$ROV"$"+!

SS

Control Plan

-li%nin%

Systems

Structures

5ocumentationlan

$onitorin%lan

Responselan

!rainin%lan

Veri7ed 8inancialVeri7ed 8inancialImpactImpact

rocess o#nersaccountable tomaintain ne#

level ofprocess

performance

Control !ln Informtion


109/130

1;?

The tea" develo$s the Control Plan ;7 #tiliBin! all availa;le infor"ation

fro" the follo


110/130

11;

W*o6W*t orgnitions re9(ire triningB

Those i"$acted ;7 the i"$rove"ents: Peo$le


111/130

111

W*o ,ill com$lete t*e triningB

I""ediate trainin!

: The $lannin!= develo$"ent and eec#tion is a res$onsi;ilit7 of the $ro8ect tea"

: T7$icall7 so"e of the trainin! is cond#cted ;7

the $ro8ect tea"

#alified trainers

: T7$icall7 o


112/130

112

Ee& ill t(ai&i& e '$&d%'tedF

Eat is te ti*eli&e t$ t(ai& eve(-$&e

$& te &e ($'essGesHF

Eat ill t(ie( $&$i& t(ai&i&F

Be e*l$-ee $(ie&tati$&F

"e/(ese( t(ai&i&F

!a(t $/ te (es$&se la& e& *$&it$(i&s$s e(/$(*a&'e de(adi&F

!rainin%

lan

Trining !ln


113/130

113

!rainin% lan Outline

Trainin! Mod#le

Kho Kill Create

Mod#les

Sched#le for

Trainin! Mod#les

Co"$letion

Kho Kill ;e

Trained

Sched#le for

Trainin! TrainersJ

Inte!ration into

On!oin! Ne<

E"$lo7ee

Trainin!

Ginal Location of

E"$lo7ee

Man#als

!rainin%

lan

Doc(menttion !ln

t ti i t t t tD+(/.en*a*i+nD+(/.en*a*i+n


114/130

11'

$'%*e&tati$& is &e'essa(- t$ e&s%(e tat at

as ee& lea(&ed /($* te ($e't is sa(ed a&d

i&stit%ti$&aliIed Used t$ aid i*le*e&tati$& $/ s$l%ti$&s

Used /$( $&$i& t(ai&i&

is is $/te& te a't%al i&al "e$(t s$*e $(a&iIati$&s %se.

Documentation must be kept current to beuseful

D+(/.en*a*i+nD+(/.en*a*i+n

P-anP-an5ocumentation

lan

Doc(menttion !ln

b i l d d i h


115/130

11

Items to be included in the5ocumentation lan9

rocess documentation

J :pdated rocess $aps;

J 8$"-

Control lan documentation

J !rainin% manuals

J $onitorin% plan?process mana%ement charts( reports( sops

J Response plan?8$"-

J Systems and structures?@ob descriptions( performancemana%ement ob@ectives

5ocumentationlan

Doc(menttion !ln

A i i i/ilit f D t ti !l


116/130

114

Assigning res$onsi/ilit- for Doc(menttion !ln5

Res$onsi;ilit7 at i"$le"entation

: ?lac% ?elt ens#res all doc#"ents are c#rrentat hand off

: ?lac% ?elt ens#res there is a $rocess to "odif7

doc#"entation as the $rocess chan!es in $lace

: ?lac% ?elt ens#res there is a $rocess in $lace to revie<

doc#"entation on re!#lar ;asis for c#rrenc7acc#rac7

Res$onsi;ilit7 for on!oin! $rocess or!aniBationall7 ;asedJ

: Plan "#st o#tline


117/130

11<

5ocumentation lan Outline5ocumentation

lan

Monitorin! Plan

P f M it i Pl


118/130

11>

$onitorin%

lan

P#r$ose of a Monitorin! Plan@ Ass#res !ains are achieved and s#stained Provides insi!ht for f#t#re $rocess i"$rove"ent activities

Develo$"ent of a Monitorin! Plan@ ?elt is res$onsi;le for the develo$"ent of the "onitorin! $lan Tea" "e";ers


119/130

11?

!ests9

Ee& t$ #a*le

J A/te( t(ai&i&J "e%la( i&te(vals

J "a&d$* i&te(vals G$/te& i& a%diti& se&seH

D$ t$ #a*le

D$ t$ eas%(e

$onitorin%lan

I /ne# I should have paid more attention.

Monitorin! Plan


120/130

12;

Sttisticl !rocess Control5

Control Charts: Posted in area


121/130

121

8$"- is a %reat tool to use for the$onitorin% lan

-llo#s process mana%er and those involved in the process to

see the entire process and ho# everyone contributes to adefect free product;service)

rovides the means to /eep the document current?reassessin%R+s as the process chan%es

Process

G#nction

ISte$J

Potential

Gail#re Modes

I$rocess

defectsJ

Potential

Gail#re Effects

IYsJ

S

E

V

C

l

a

s

Potential

Ca#ses of

Gail#re I1sJ

O

C

C

C#rrent

Process

Controls

D

E

T

R

P

N

Reco""end

Actions

Res$onsi;le

Person U

Tar!et Date

Ta%en

Actions

S

E

V

O

C

C

D

E

T

R

P

N

*

)

'

4

+

0

Process

G#nction

ISte$J

Potential

Gail#re Modes

I$rocess

defectsJ

Potential

Gail#re Effects

IYsJ

S

E

V

C

l

a

s

Potential

Ca#ses of

Gail#re I1sJ

O

C

C

C#rrent

Process

Controls

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lan

Monitoring !ln

C*ec0 Lists6Mtrices


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C*ec0 Lists6Mtrices

e7 ite"s to chec%

Decision criteria decision road "a$ M#lti&varia;le ta;les

is(l Mngement

Alerts or si!nals to tri!!er action-

: E"$t7 ;ins ;ein! ret#rned to


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Res$onse !lns o#tline $rocessesJ to follo<


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Com$onents of Res$onse !ln5

The tri!!ers for a res$onse

: Khat are the Gail#re Modes to chec% forQ: s#all7 "onitor the hi!hest ris% 1s in the $rocess

The reco""ended res$onse for the Gail#re Mode

The res$onsi;ilities for res$ondin! to the Gail#re Mode

Doc#"entation of res$onse $lan ;ein! follo


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: Detile+ +oc(menttion,*en fil(re mo+esocc(r.

: !ro)i+e met*o+ for ongoing contin(o(sim$ro)ement.

: Reinforcecommitment toeliminting +efects.

: its ,it* ISO ?;;; stn+r+ of*)ing

CAR or Correcti)e Action Re9(est.

: Met*o+ to collect fre9(enc- of

correcti)e ctions.

Responselan

Aligning S-stems n+ Str(ct(res

#-ste*s a&d st(%'t%(es a(e te asis /$( all$i&


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#-ste*s a&d st(%'t%(es a(e te asis /$( all$i&

e$le t$ 'a&e tei( eavi$(s e(*a&e&tl-

!e(/$(*a&'e $alsK$e'tives !$li'iesK($'ed%(es

$ des'(iti$&s

@&'e&tive '$*e&sati$&

@&'e&tive ($(a*s? '$&tests? et'

!here are long" and short"term strategiesfor alignment of s#stems and structures

-li%nin%

Systems

Structures

Aligning S-stems n+ Str(ct(res

: >et rid of "eas#re"ents that do not ali!n


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>et rid of "eas#re"ents that do not ali!n et rid of "#lti$le "eas#res for the sa"e

desired ;ehaviors

: I"$le"ent "eas#res that ali!n


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?est "ethod to ass#re acce$tance of Control Plan

is havin! s#$ervisors and "ana!e"ent for the area

involved-

Meetin! for a s#""ar7 re$ort

S$ecific chan!es to the $rocess hi!hli!hted

Infor"ation


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-t this point( you should be able to9

J @de&ti/- all 5 ases $/ te #ix #i*a *et$d$l$-

J @de&ti/- at least 3 t$$ls /($* ea' ase

J #$ ($(ess $& -$%( $&$i& ($e't


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6sigma- control phase

Documents