9-1

Improve Process

Capability

Improve Process

Capability

TheQualityImprovementModel

Use SPC to Maintain Current Process

Collect & Interpret

Data

Select Measures

Define Process

IsProcessCapable

?

Improve Process

Capability

Improve Process

Capability

IsProcessStable

?

Investigate & Fix

Special Causes

No

Yes

No

Yes

Improve Process Capability

Purpose:Determine/identify fundamental changes to the process to improve capability.

9-2

Improve Process

Capability

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.

All of the data, not just the high and low points, are relevant to further analysis.

Aspects of the system that are always present will need to be changed to improve common cause variation.

Stable systems usually require managerial attention for improvement. Fundamental changes in the system are often required.

Source: Brian Joiner

9-3

Improve Process

Capability

Improve Process

CapabilityOrder Entry Process

Week123456789

1011121314151617181920

Total

# Errors15221810139

2712242288

26162010169

1520

320

0

5

10

15

20

25

30

35

5 10 15 20

Avg=16.0

LCL=4.0

UCL=28.0

Week

Numberof Errors

Control Chart

It has been decided that this process requires further improvementHow do we go about it?

9-4

Improve Process

Capability

Improve Process

CapabilityOrder Entry Errors by Type

Incorrect Account Number 72

Error in Order Amount 168

Inadequate Billing Information 17

Priority Code Not Checked 25

Incomplete Shipping Instructions 14

Other Errors 24

TOTAL 320

Description Number of Errors

Error in Order

Amount

Incorrect Account Number

Priority Code Not Checked

Inadequate Billing

Information

Incomplete Shipping

Instructions

Other Errors0

20

40

60

80

100

120

140

160

180

Type Error

Pareto Chart

9-5

Improve Process

Capability

Improve Process

CapabilityOrder Entry ProcessResults of efforts to reduce errors in order amount.

Week212223242526272829303132333435

Total

# Errors16101368

10654615012

93

0

5

10

15

20

25

30

35

5 10 15 20

Avg=16.0

LCL=4.0

UCL=28.0

Week

Numberof Errors

Control Chart

25 30 35

Limits based on first 20 weeks of data

Process Improvements Begin

9-6

Improve Process

Capability

Improve Process

CapabilityOrder Entry Errors by Type

Incorrect Account Number 42

Error in Order Amount 8

Inadequate Billing Information 7

Priority Code Not Checked 17

Incomplete Shipping Instructions 9

Other Errors 10

TOTAL 93

Description Number of Errors

Incorrect Account Number

Error in Order

Amount

Priority Code Not Checked

Inadequate Billing

Information

Incomplete Shipping

Instructions

Other Errors0

5

10

15

20

25

30

35

40

45

Type Error

Pareto Chart

9-7

Improve Process

Capability

Improve Process

CapabilityImproving Stable Processes - Instrument Measures Common Problems with Stable Processes

Lower Spec Upper Spec Lower Spec Upper Spec

Off Target Excess Variation

Or, Both

9-8

Improve Process

Capability

Improve Process

Capability

Improving Stable Processes - Instrument Measures Common Improvement Techniques

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

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

9-9

Improve Process

Capability

Improve Process

CapabilityBreaking Out Process Steps

Rating of Importance to

Customer10 1 9 9 5 8

1 2 3 4 5 7

Bre

ak %

Melt T

em

p

Bott

le O

utp

ut

Cla

rity

Weig

ht

Wall

Variation

Total

Process Step Process Input

Melt Resin Resin 9 9 3 9 9 9 324Blow Bottle Mold Design 9 0 9 9 0 9 324

Extrude Parison Programing 3 3 9 0 9 9 231Extrude Parison Die Tip Temp 3 3 3 9 3 9 228

Blow BottleMold Water Temp

9 0 9 3 0 0 198

Blow BottleWater Volume/Cooling Rate

9 0 9 3 0 0 198

Extrude Parison Head Design 3 9 3 3 3 9 180Extrude Parison Tooling 3 3 3 3 3 9 174

Blow Bottle Pinch Design 9 0 9 0 0 0 171Melt Resin Barrell Temp 3 9 9 1 3 3 168Melt Resin Screw Speed 3 9 9 1 3 3 168Melt Resin Screw Design 3 9 9 1 1 1 142

Blow Bottle# of Mold Cooling Zones

9 0 3 0 0 0 117

Tail DetabTime from extraction to Detab

9 0 3 0 0 0 117

Use C&E matrix as a place to start data collection and analysis.

9-10

Improve Process

Capability

Improve Process

CapabilityIsolating Sources of Variability

“Polymer Manufacturing Process”

Conduct a study to evaluate measurement variability of b*.Two b* measurements are done on each sample.

Possible Actions: Concentrate on improving the measurement process (Previous Module)

Duplicate Measurements on Same Sample

Sample

b*3.0

2.5

2.0

1.5

1.0

0.5

0

1 2 3 4 5 6 7 8 9

First Measurement

Second Measurement

9-11

Improve Process

Capability

Improve Process

CapabilitySeparating Out Common Causes

“Shipping Process”

International orders <10% of total orders

International orders 10-20% of total orders

International orders >20% of total orders

Run Chart

0.00

0.05

0.10

0.15

0.20

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Proportion Wee

k

Late

Possible Actions: Improve process for shipping of international orders.

9-12

Improve Process

Capability

Improve Process

CapabilityHypothesis: Are the Labs that Measure Color the Same?

9-13

Improve Process

Capability

Improve Process

CapabilityMinitab: Comparing Two or More Samples

•Open Mintab Software•Open Color Round Robin Data in the Mintab Datasets Folder and follow the directions in the notes below.

Lab

b*

TEDKuantanHART

-1.0

-1.2

-1.4

-1.6

-1.8

-2.0

-2.2

Interval Plot of b* vs Lab95% CI for the Mean

Note: The ASM course spends more time discussing Planning, Data Collection, Analysis and Interpretation from experiments similar to the one above.

9-14

Improve Process

Capability

Improve Process

CapabilityComparing Two or More Labs

Follow the instructions in the notes to perform the comparisons.

9-15

Improve Process

Capability

Improve Process

CapabilityComparing Two or More Labs …Individual 95% CIs For Mean Based on

Pooled StDev

Level N Mean StDev ---+---------+---------+---------+------

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 StDev = 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

9-16

Improve Process

Capability

Improve Process

CapabilityHypotheses: Does Film IV, CHDM and DEG Effect Shrink Stress?

9-17

Improve Process

Capability

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.

Minitab : Analyze Relationships Between Two Continuous Variables

9-18

Improve Process

Capability

Improve Process

CapabilityAnalyze Relationships Between Two Continuous Variables

Film IV

Avg S

hrink

Str

ess

:

0.700.690.680.670.66

11.5

11.0

10.5

10.0

9.5

9.0

8.5

8.0

7.5

S 1.04108R-Sq 8.9%R-Sq(adj) 2.3%

Fitted Line PlotAvg Shrink Stress: = - 9.12 + 26.81 Film IV

Film DEG

Avg S

hrink

Str

ess

:

14131211109

11.5

11.0

10.5

10.0

9.5

9.0

8.5

8.0

7.5

S 0.805410R-Sq 45.5%R-Sq(adj) 41.6%

Fitted Line PlotAvg Shrink Stress: = 15.10 - 0.5321 Film DEG

Film CHDM

Avg S

hrink

Str

ess

:

272625242322212019

11.5

11.0

10.5

10.0

9.5

9.0

8.5

8.0

7.5

S 1.01422R-Sq 13.5%R-Sq(adj) 7.3%

Fitted Line PlotAvg Shrink Stress: = 12.58 - 0.1600 Film CHDM

What conclusions do you make from the analysis?

9-19

Improve Process

Capability

Improve Process

CapabilityDesigned Experiments

Making planned and deliberate changes to the process input variables to determine the effect on the output variables.

Outputs Variables

Process

Products or Services

103.4 92.6 2345

Properly designed experiments can yield useful cause-effect information.

Input Variables

9-20

Improve Process

Capability

Improve Process

Capability

IV CHDM DEG0.75 20 90.71 23.6 11.20.743 23.6 120.731 25.9 10.80.741 24.2 13.40.743 24.2 13.60.732 23.8 10.80.742 19.5 10.30.756 24.3 13.50.71 23.7 11.10.729 23.6 12.10.708 18.9 11.40.733 19.4 10.40.723 23.4 13.50.727 19.4 9.40.702 19.6 11.5

Designed Experiments - Example

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.

9-21

Improve Process

Capability

Improve Process

Capability

Horiz Vert

Film IVFilm DEGFilm CHDMTemp

Factor 0.657 9.3 24.2 95

Current X

Pred Formula 10s TD ShrinkagePred Formula 10 s MD ShrinkagePred Formula Avg Shrink StressPred Formula Glycol Sum

Response-5.140107-10.335256.4315566

28.8

Contour81.756686-9.9958258.0112861

33.5

Current Y 70 . . .

Lo Limit . .

7.1 35

Hi Limit

24.2

Film

CH

DM

19.5

Pred Formula Avg Shrink Stress

75

7065

60

8.2

8

7.8

7.6

7.4

7.2

7

6.8

6.6

6.4

9.3 Film DEG 13.4

Contour Profiler

Profiler

Designed Experiments - Example

9-22

Improve Process

Capability

Improve Process

CapabilityReview

•Improving Stable Processes takes intervention

•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

9-23

Improve Process

Capability

Improve Process

Capability

1.)Your Catapult Team should complete page 12 of the “Catapult Process” handout.

Limit yourselves to 30 minutes for this exercise.

Exercise