Improve Process Capability The Quality Improvement Model Define

Improve Process Capability The Quality Improvement Model Define Process Select Measures Collect & Interpret Data Improve Process Capability Purpose: Determine/identify fundamental changes to the process to improve capability. Is Process Stable ? No Investigate & Fix Special Causes Yes Improve Process Capability No Is Process Capable ? Yes Use SPC to Maintain Current Process 9 -1

Improve Process Capability Improving Stable Processes Common causes of variation usually cannot be reduced by trying to explain the difference between high and low points when a process is stable. l All of the data, not just the high and low points, are relevant to further analysis. l Aspects of the system that are always present will need to be changed to improve common cause variation. l Stable systems usually require managerial attention for improvement. Fundamental changes in the system are often required. l Source: Brian Joiner 9 -2

Improve Process Capability Order Entry Process Week # Errors 1 15 2 22 3 18 4 10 5 13 6 9 7 27 8 12 9 24 10 22 11 8 12 8 13 26 14 16 15 20 16 10 17 16 18 9 19 15 20 20 Total 320 Control Chart 35 30 Number of Errors UCL=28. 0 25 20 Avg=16. 0 15 10 5 0 LCL=4. 0 5 10 15 20 Week It has been decided that this process requires further improvement How do we go about it? 9 -3

Improve Process Capability Order Entry Errors by Type Description Number of Errors Incorrect Account Number Error in Order Amount Inadequate Billing Information Priority Code Not Checked Incomplete Shipping Instructions Other Errors TOTAL 72 168 17 25 14 24 320 Pareto Chart 180 160 140 120 100 80 60 40 20 0 Error in Order Amount Incorrect Account Number Priority Code Not Checked Inadequate Billing Information Type Error Incomplete Other Errors Shipping Instructions 9 -4

Improve Process Capability Order Entry Process Results of efforts to reduce errors in order amount. Week # Errors 21 16 22 10 23 13 24 6 25 8 26 10 27 6 28 5 29 4 30 6 31 1 32 5 33 0 34 1 35 2 Total 93 Control Chart 35 Process Improvements Begin 30 Number of Errors UCL=28. 0 25 20 Avg=16. 0 15 10 5 LCL=4. 0 0 5 10 15 20 25 30 35 Week Limits based on first 20 weeks of data 9 -5

Improve Process Capability Order Entry Errors by Type Description Incorrect Account Number Error in Order Amount Inadequate Billing Information Priority Code Not Checked Incomplete Shipping Instructions Other Errors TOTAL Number of Errors 42 8 7 17 9 10 93 Pareto Chart 45 40 35 30 25 20 15 10 5 0 Incorrect Account Number Priority Code Not Checked Incomplete Shipping Instructions Error in Order Amount Type Error Inadequate Other Errors Billing Information 9 -6

Improving Stable Processes - Instrument Measures Common Problems with Stable Processes Off Target Lower Spec Improve Process Capability Excess Variation Upper Spec Lower Spec Upper Spec Or, Both 9 -7

Improving Stable Processes - Instrument Measures Common Improvement Techniques l Improve Process Capability Targeting Processes - Designed Experiments Change process variables in a planned manner to determine the effects of the variables on level and variability. § Design of Experiments Course § l Reducing Variation - Use Process Knowledge Break out process steps (Process Map and C&E information) § Isolate sources of variability (Exploratory Data Analysis or Designed Experiment) § Separate out common causes (stratification – Applied Statistical Methods Course) § Exploratory Data Analysis (Applied Statistical Methods Course) § § Multi-Vary Studies in Six Sigma § Analysis on existing process data § Done on key variables identified in C&E or FMEA 9 -8

Breaking Out Process Steps Improve Process Capability Use C&E matrix as a place to start data collection and analysis. 9 -9

Isolating Sources of Variability Improve Process Capability “Polymer Manufacturing Process” Conduct a study to evaluate measurement variability of b*. Two b* measurements are done on each sample. b* 3. 0 2. 5 Duplicate Measurements on Same Sample 2. 0 1. 5 1. 0 0. 5 First Measurement 0 Second Measurement 1 2 3 4 5 Sample 6 7 8 9 Possible Actions: Concentrate on improving the measurement process (Previous Module) 9 -10

Improve Process Capability Separating Out Common Causes “Shipping Process” Run Chart P r o p o r t i o n 0. 20 L a t e 0. 15 0. 10 0. 05 0. 00 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Week International orders <10% of total orders International orders 10 -20% of total orders International orders >20% of total orders Possible Actions: Improve process for shipping of international orders. 9 -11

Hypothesis: Are the Labs that Measure Color the Same? Improve Process Capability 9 -12

Minitab: Comparing Two or More Samples Improve Process Capability • Open Mintab Software • Open Color Round Robin Data in the Mintab Datasets Folder and follow the directions in the notes below. Note: The ASM course spends more time discussing Planning, Data Collection, Analysis and Interpretation from experiments similar to the one above. 9 -13

Comparing Two or More Labs Improve Process Capability Follow the instructions in the notes to perform the comparisons. 9 -14

Comparing Two or More Labs … Improve Process Capability Individual 95% CIs For Mean Based on Pooled St. Dev Level N Mean St. Dev HART 24 -1. 7658 0. 2235 Kuantan 41 -1. 3346 0. 1369 TED 37 -1. 0568 0. 0846 ---+---------+-----+-----(-*--) (-*-) ---+---------+------1. 75 -1. 50 -1. 25 -1. 00 Pooled St. Dev = 0. 1476 Tukey 95% Simultaneous Confidence Intervals All Pairwise Comparisons among Levels of Lab Individual confidence level = 98. 09% Lab = HART subtracted from: Lab Lower Center Upper Kuantan 0. 3408 0. 4312 0. 5216 TED 0. 6169 0. 7091 0. 8012 --+---------+-----+------(--*--) --+---------+-------0. 30 0. 00 0. 30 0. 60 Lab = Kuantan subtracted from: Lab Lower Center Upper TED 0. 1981 0. 2779 0. 3576 --+---------+-----+------(-*--) --+---------+-------0. 30 0. 00 0. 30 0. 60 9 -15

Hypotheses: Does Film IV, CHDM and DEG Effect Shrink Stress? Improve Process Capability 9 -16

Minitab : Analyze Relationships Between Two Continuous Variables Improve Process Capability • Open Minitab Software. • Open Shrink Stress in the Minitab Datasets Folder. • Follow the instructions below to create fitted line plots of the data. 9 -17

Analyze Relationships Between Two Continuous Variables Improve Process Capability What conclusions do you make from the analysis? 9 -18

Designed Experiments Improve Process Capability Outputs Variables Process Products or Services 103. 4 92. 6 2345 Input Variables Making planned and deliberate changes to the process input variables to determine the effect on the output variables. Properly designed experiments can yield useful cause-effect information. 9 -19

Designed Experiments - Example Improve Process Capability Objective: Choose a formulation for a new EMBRACE product. These 16 conditions were done on a manufacturing line in Kingsport. Material was taken to customers and run. Customer fitness for use measures will aid in determining new EMBRACE fromulation. 9 -20

Designed Experiments - Example Improve Process Capability 9 -21

Review • Improving Stable Processes takes intervention Improve Process Capability • All of the data is important, not just the "Special" Causes • Exploratory Data Analysis (EDA) on historical data • Use the C&E Matrix and the FMEA to determine where to start • Look for trends • Look for differences among qualitative variables (instruments, etc. ) • Information will be used in control plan • Variance Component Breakdowns (Test and Process) • Designed Experiments on Key Inputs • Key Inputs determined by C&E, FMEA and EDA • Information will be used in control plan 9 -22

Improve Process Capability Exercise 1. ) Your Catapult Team should complete page 12 of the “Catapult Process” handout. Limit yourselves to 30 minutes for this exercise. 9 -23