using data analysis to improve quality, save money & increase … · 2018-02-14 · © 2014...
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© 2014 Minitab, Inc.
Using Data Analysis to Improve
Quality, Save Money &
Increase Productivity
Ming Dong
Minitab Pty Ltd.
mdong@minitab.com.au
61-2-93123700
1
© 2014 Minitab, Inc.
Introduction – Who we are
Minitab PtySydney, Australia
Minitab LtdCoventry, England
© 2014 Minitab, Inc.
Business Solutions using Statistical
Thinking
3
Business
Problems
Business
Solutions
Statistical
Solutions
Statistical
Thinking
© 2014 Minitab, Inc.
► Case Study 1: Boston Scientific: Validating Changes to Packaging Process
► Case Study 2: Thales: Quality, A Vital Part of Medical Equipment
Overview
4
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to Packaging Process
► Who?
• One of the world’s largest developers, manufacturers, and
marketers of medical devices
• Employs approximately 23,000 worldwide
• Products used to treat a wide range of medical conditions,
including heart, digestive, pulmonary, vascular, urological,
women’s health, and chronic pain
• Heredia, Costa Rica
5
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to Packaging Process
► Challenge ?
• Evaluate the guidewire pouch-
sealing process in order to define
optimum process conditions and
reduce material costs.
• The packaging engineers needed
to make sure that the strength of
the seal on the smaller pouches
met or exceeded standards.
6
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to
Packaging Process
What is DOE?
► To gain the most information with the least effort
Process
Controllable factors
x1 x2 x3
Inputs Output
7
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to Packaging Process
► Potential Factors?
• Front temperature
• Rear temperature
• Pressure
• Speed
• Interactions
8
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to Packaging Process
9
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to Packaging Process
10
Regression Equation in Uncoded Units
Avg Pull = 22.85 - 0.1682 Rear Temp - 0.1430 Front Temp + 0.001128 Rear Temp*Front Temp
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to Packaging Process
11
Rear Temp
Fro
nt
Tem
p
1 251 201 1 51 1 01 051 00
1 40
1 35
1 30
1 25
1 20
>
–
– –
–
< 1 .6
1 .6 1 .8
1 .8 2.02.0 2.2
2.2 2.4
2.4
Avg Pull
Contour Plot of Avg Pull vs Front Temp, Rear Temp
Worksheet: boston scientific; Ming's project
Rear Temp = 104.61 1
Front Temp = 126.596
Avg Pull = 2.08940
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to
Packaging Process► What is capability analysis?
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to
Packaging Process
► What is capability analysis?
• Capability analysis is a graphical or statistical tool that visually
or mathematically compares actual process performance to the
performance standards established by the customer
► When to use Capability Analysis
• The measurement system is reliable
• The process is in control
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to
Packaging Process
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to
Packaging Process
Normality Test
Results PassP-value 0.570
(Anderson-Darling)
5
4
3
Mean
4641363126211 61 161
4
2
0
Ran
ge
Xbar-R ChartConfirm that the process is stable.
Normality PlotThe points should be close to the line.
Capability Analysis for Seal StrengtDiagnostic Report
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to
Packaging Process
► RESULTS
• Used data analysis to validate the pouch sealing process
and identify key inputs
• Introduced a new pouch that increased material cost savings
• Streamlined packaging for guidewires across several areas
of the corporation
© 2014 Minitab, Inc.
Boston Scientific: Validating Changes to
Packaging Process
► RESULTS
• The team’s process validation confirms that the changes —
and savings — can be sustained
• “At the end of the day,” The packaging engineer Calve
Camacho notes, “the more money we save, the more
additional savings we can pass on to the people we serve.”
© 2014 Minitab, Inc.
Thales: Quality, A Vital Part of Medical Equipment
► Who?
• Global technology leader
• Employs 68,000 people in over 50 countries
• Thales Electron Devices Division produces electro-optical
equipment for the medical industry. In particular, healthcare
practitioners use radiological equipment, which includes
Thales X-Ray image intensifiers, to perform fine diagnostic
and delicate clinical procedures
18
© 2014 Minitab, Inc.
Thales: Quality, A Vital Part of Medical Equipment
► Challenge ?
• The electronic tubes they were
producing as a critical part of their
medical radiography equipment
were asymmetrical and didn’t
meet customer specifications
19
© 2014 Minitab, Inc.
Thales: Quality, A Vital Part of Medical Equipment
► How Minitab Helped?
• Gage R&R
• DOE
• Capability Analysis
• Control Charts
20
© 2014 Minitab, Inc.
Gage R&R
► What is the probability of misclassifying a good
part as bad?
21
© 2014 Minitab, Inc.
Gage R&R
► Or worse, the probability of misclassifying a bad
part as good?
22
© 2014 Minitab, Inc.
Measurement System – Gage R&R
► What is a good measurement system?
= +
Observed Real Process Measurement System
© 2014 Minitab, Inc.
Gage R&R
► Probabilities of Misclassification
• False Accept 11.8%
• False Reject 9.6%
24
© 2014 Minitab, Inc.
Gage R&R
25
© 2014 Minitab, Inc.
Gage R&R
26
© 2014 Minitab, Inc.
Control Charts
27
© 2014 Minitab, Inc.
Thales: Quality, A Vital Part of Medical
Equipment
► RESULTS
• Explained 54% of the asymmetry problems and significantly
increased the process capability from a Cpk of 0.49 to 1.13.
• Not only was Thales able to meet these customer
specifications, but the tubes made using the improved
process were incorporated into the equipment without
adversely affecting the overall quality of the finished product.
© 2014 Minitab, Inc.
Minitab
► Minitab Pty Ltd (Australia)
• Telephone: +61 (0) 2 9312 3700
• E-mail: sales@minitab.com.au
• Tech Support:
– Phone: +61 (2) 9312 3711
– Email:
techsupport@minitab.com.au
► Training & Consulting
• E-mail: training@minitab.com.au
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