using data analysis to improve quality, save money & increase … · 2018-02-14 · © 2014...

© 2014 Minitab, Inc.

Using Data Analysis to Improve

Quality, Save Money &

Increase Productivity

Ming Dong

Minitab Pty Ltd.

[email protected]

61-2-93123700

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mailto:[email protected]


Introduction – Who we are

Minitab PtySydney, Australia

Minitab LtdCoventry, England


Business Solutions using Statistical

Thinking

3

Business

Problems

Business

Solutions

Statistical

Solutions

Statistical

Thinking


► Case Study 1: Boston Scientific: Validating Changes to Packaging Process

► Case Study 2: Thales: Quality, A Vital Part of Medical Equipment

Overview

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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

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► 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.

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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

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► Potential Factors?

• Front temperature

• Rear temperature

• Pressure

• Speed

• Interactions

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9



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Regression Equation in Uncoded Units

Avg Pull = 22.85 - 0.1682 Rear Temp - 0.1430 Front Temp + 0.001128 Rear Temp*Front Temp



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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



Packaging Process► What is capability analysis?



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



Packaging Process



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



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



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.”


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

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► Challenge ?

• The electronic tubes they were

producing as a critical part of their

medical radiography equipment

were asymmetrical and didn’t

meet customer specifications

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► How Minitab Helped?

• Gage R&R

• DOE

• Capability Analysis

• Control Charts

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Gage R&R

► What is the probability of misclassifying a good

part as bad?

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Gage R&R

► Or worse, the probability of misclassifying a bad

part as good?

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Measurement System – Gage R&R

► What is a good measurement system?

= +

Observed Real Process Measurement System


Gage R&R

► Probabilities of Misclassification

• False Accept 11.8%

• False Reject 9.6%

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Gage R&R

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Gage R&R

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Control Charts

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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.


Minitab

► Minitab Pty Ltd (Australia)

• Telephone: +61 (0) 2 9312 3700

• E-mail: [email protected]

• Tech Support:

– Phone: +61 (2) 9312 3711

– Email:

[email protected]

► Training & Consulting

• E-mail: [email protected]




using data analysis to improve quality, save money & increase … · 2018-02-14 · © 2014...

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