21/6/2002 1
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Siemens Electric Heating ASSiemens Electric Heating ASBratsbergvegan 5
N-7493TRONDHEIM
Norway
21/6/2002Tel No +47 73 95 90 00
ENBIS industrial visit
21/6/2002 2
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
E: Introduction of the team - 5 mins E: Introduction to ENBIS - 10 minsS: Introduction to Siemens Trondheim - 15 minsE: SQM survey, Design of Experiments, 6-sigma - 45 minsS: Topics to be covered in visit - 15 mins
On Site Visit - 45 mins
Discussions on opportunities - 30 mins Conclusion - 15 mins
Proposed agenda
(S - Siemens, E - ENBIS team)
21/6/2002 3
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Jon Tyssedal, [email protected] of Statistics, NTNUExpert in Statistics Maria Fernanda Ramalhoto, [email protected] of Statistics,Instituto Superior Tecnico, LisbonExpert in Reliability and Quality Improvement
Ron Kenett, [email protected] Management Consultant, CEO KPA Ltd.Expert in Industrial Statistics and Quality Management
ENBIS team
21/6/2002 4
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Jon Tyssedal, [email protected] of Statistics, NTNUExpert in Statistics Maria Fernanda Ramalhoto, [email protected] of Statistics,Instituto Superior Tecnico, LisbonExpert in Reliability and Quality Improvement
Ron Kenett, [email protected] Management Consultant, CEO KPA Ltd.Expert in Industrial Statistics and Quality Management
ENBIS team
21/6/2002 5
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Jon Tyssedal, [email protected] of Statistics, NTNUExpert in Statistics Maria Fernanda Ramalhoto, [email protected] of Statistics,Instituto Superior Tecnico, LisbonExpert in Reliability and Quality Improvement
Ron Kenett, [email protected] Management Consultant, CEO KPA Ltd.Expert in Industrial Statistics and Quality Management
ENBIS team
21/6/2002 6
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Industrial StatisticsIndustrial StatisticsIndustrial StatisticsIndustrial Statistics Multivariate Quality ControlMultivariate Quality ControlMultivariate Quality ControlMultivariate Quality Control
Six SigmaSix SigmaSix SigmaSix Sigma
Internet SurveysInternet SurveysInternet SurveysInternet SurveysSoftware Process QualitySoftware Process QualitySoftware Process QualitySoftware Process Quality
ManagementManagementDashboardsDashboardsManagementManagementDashboardsDashboards
SPCSPCSPCSPC
Design of Design of ExperimentsExperimentsDesign of Design of
ExperimentsExperiments
OrganizationalOrganizationaleffectivenesseffectiveness
OrganizationalOrganizationaleffectivenesseffectiveness
Ron Kenett (25 yrs of experience, 4 books)25 yrs of experience, 4 books)
21/6/2002 7
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
ENBIS
European Network for Business and Industrial Statistics
www.enbis.org
Introduction to ENBIS
21/6/2002 8
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
ENBIS Mission
- Foster and facilitate the application and understanding of statistical methods to the benefit of European business and industry
- Provide a forum for the dynamic exchange of ideas and facilitate networking among statistical practitioners
- Nurture interactions and professional development of statistical practitioners regionally and internationally.
21/6/2002 9
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
- To promote the widespread use of sound science driven, applied statistical methods in European business and industry,
- That membership consists primarily of statistical practitioners from business and industry,
- To emphasize multidisciplinary problem solving involving statistics,
- To facilitate the rapid transfer of statistical methods and related technologies to and from business and industry
ENBIS Vision
21/6/2002 10
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
- To link academic teaching and research in statistics with industrial and business practice,
- To facilitate and sponsor continuing professional development,
- To keep its membership up to date in the field of statistics and related technologies,
- To seek collaborative agreements with related organizations.
- ENBIS is a web based society
ENBIS Vision – continued
21/6/2002 11
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
During the first International Symposium on Industrial Statistics, some 20 statisticians and practitioners agreed to push forward a European society for industrial statistics.
August 21, 1999, Linköping, Sweden
Meeting of the provisional executive committee. The name ENBIS was chosen for the new network.
Febr. 26-27, 2000, Eindhoven, NL
More than 80 persons participated in the founding conference.
December 11, 2000, Amsterdam, NL
ENBIS History
21/6/2002 12
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
- General assembly- Council- Executive committee- Permanent office (Amsterdam)
Administration
ENBIS Organization
21/6/2002 13
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
- Design of experiments- Reliability and safety- Data mining / warehousing- General statistical modelling
Working groups
- Process modelling and control
- Quality improvement- Statistical consultancy
- bENBIS (Belgium)- nENBIS (Netherlands)- iENBIS (Israel)
Local networks
ENBIS Organization
21/6/2002 14
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
- No membership fee (for the time being)- 560 members (May, 2002)
Members
- 500 Euros per annum- 7 Corporate members (May, 2002)
Corporate Members
ENBIS Organization
21/6/2002 15
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
ENBIS Membership benefits
ENBIS offers its members:-Network facilities-Conferences-Courses-Thematic network Pro-ENBIS
21/6/2002 16
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
ENBIS Networking facilities
The website www.enbis.org offers:-ENBIS News-General announcements-Event lists-Links to relevant websites-Information on other members-Forum facilities
21/6/2002 17
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
www.enbis.org
21/6/2002 18
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Founding conference80 participants
December 11, 2000, Amsterdam, NL
First Annual Meeting on Business and Industrial Statistics101 participants43 submitted abstracts
September 17-18, 2001, Oslo, Norway
Second Annual Meeting on Business and Industrial Statistics105 submitted abstracts
September 23-24, 2002, Rimini, Italy
ENBIS Conferences
21/6/2002 19
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Pro-ENBIS
Pro-ENBIS is a thematic network of organisations contracted for three years with the European Commission.
Its mission is “to promote the widespread use of sound science driven, applied statistical methods in European business and industry.”
Pro-ENBIS was granted a budget from the EC of about 800 000 Euros.
21/6/2002 20
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Co-ordinator: University of Newcastle upon Tyne (UK).
Organisations from all over Europe, not just the EC.
Funding to achieve specific disemination outcomes, e.g., organising workshops, seminars, industrial industrial visitsvisits and publishing case-study based papers.
Pro-ENBIS
21/6/2002 21
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Objectives of Industrial Visits
- Disseminate Statistical Best Practices in Europe
- Foster new research collboration
- “Listen to the customers”:
Learn from industry
indifies needs of industry
21/6/2002 22
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
E: Introduction of the team - 5 mins E: Introduction to ENBIS - 10 minsS: Introduction to Siemens Trondheim - 15 minsE: SQM survey, Design of Experiments, 6-sigma - 45 minsS: Topics to be covered in visit - 15 mins
On Site Visit - 45 mins
Discussions on opportunities - 30 mins Conclusion - 15 mins
Proposed agenda
(S - Siemens, E - ENBIS team)
21/6/2002 23
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Reliability, Safety and Quality Improvement
Reliability is Quality over Time. Maintenance is a Reliability Function. Therefore “Reliability culture” and “Maintenance
Culture” clearly should be part of an “Extended Quality Culture”.
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 24
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Workshops, Round Tables
Claims from industry
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 25
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
ESREL’2001 Round Table
Industry: To find consultants is easy. They advertise. To find academics is not easy. The industry and the governmental institutions do not know what academics are doing.
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 26
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
ESREL’2001 Round Table
Industry: Do not have the time to read academic journals. The papers which shall be relevant are usually published in too many different journals. Even the multinational company is not able to follow what is going on in the academic world.
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 27
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
ESREL’2001 Round Table
Academics: We model such and the reliability is 99%.
Practitioners: The reliability 99% can be pushed to 99.8% if a certain specific change
is made, or if doing such the reliability drops to 98% and the cost will be, for
instance, cut to a 1/2. What matters is how to trigger on the design to improve it.
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 28
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
A Survey on Reliability and Quality Improvement
The following questionnaire distributed in print (7 pages) for discussion and future collaboration. Material of the WP4 first Industrial Visit-Nestle-very briefly mentioned and made available at request.
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 29
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Questionnaire on SQM
Company Profile: Size; Individuals directly involved in SQM activities; Industry nature; Benchmarking activities.
1. Use of Reliability Techniques. 2. Use of Maintenance Techniques
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 30
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Questionnaire (cont.)
3. Use of Control Charts Techniques. 4. Use of Acceptance Sampling Plans. 5. Use of Economic Design Techniques. 6. Use of Cost-Benefit Analysis.
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 31
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Questionnaire (cont.)
7. Use of Inventory Control/Supply Chain Techniques.
8. Use of Data Quality Control Techniques.
9. Use of Periodicals.
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 32
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Questionnaire (cont.)
10. Problems in Practice:– List of most relevant problems reported by industry and business.– List of identified problems to close the gap between
industry/business and academia.
SQM SurveySQM SurveySQM SurveySQM Survey
21/6/2002 33
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Management Management ApproachApproach
Management Management ApproachApproach
Statistical Statistical MethodMethod
Statistical Statistical MethodMethod
Quality by DesignDesigned Experiments
and Reliability
Process Control & Process
Improvement
Control Charts
Inspection Sampling Plans
Fire FightingBasic
Statistical Thinking
21/6/2002 34
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
““At Motorola we use statistical methods daily At Motorola we use statistical methods daily throughout all of our disciplines to synthesize an throughout all of our disciplines to synthesize an abundance of data to derive concrete actions….abundance of data to derive concrete actions….How has the use of statistical methods within How has the use of statistical methods within Motorola Six Sigma initiative, across disciplines, Motorola Six Sigma initiative, across disciplines, contributed to our growth? Over the past decade we contributed to our growth? Over the past decade we have reduced in-process defects by over 300 fold, have reduced in-process defects by over 300 fold, which has resulted in a cumulative manufacturing which has resulted in a cumulative manufacturing cost savings of over 11 billion dollars”*.cost savings of over 11 billion dollars”*.
““At Motorola we use statistical methods daily At Motorola we use statistical methods daily throughout all of our disciplines to synthesize an throughout all of our disciplines to synthesize an abundance of data to derive concrete actions….abundance of data to derive concrete actions….How has the use of statistical methods within How has the use of statistical methods within Motorola Six Sigma initiative, across disciplines, Motorola Six Sigma initiative, across disciplines, contributed to our growth? Over the past decade we contributed to our growth? Over the past decade we have reduced in-process defects by over 300 fold, have reduced in-process defects by over 300 fold, which has resulted in a cumulative manufacturing which has resulted in a cumulative manufacturing cost savings of over 11 billion dollars”*.cost savings of over 11 billion dollars”*.
Robert W. GalvinChairman of the Executive Committee
Motorola, Inc.*From the forward to MODERN INDUSTRIAL STATISTICS by Kenett and Zacks, Duxbury, 1998*From the forward to MODERN INDUSTRIAL STATISTICS by Kenett and Zacks, Duxbury, 1998
Ron Kenett (KPAKPA Ltd.)
21/6/2002 35
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Six Sigma Project Review Form
Black Belt Candidate: Date: 1 3 4 5
Project Name: Review er:
Six Sigma Black Belt Methodology Phases
Com
ple
ted
Incom
ple
te
Not sta
rted
N / A for
pro
ject
Action Items/Comments
A. MEASUREMENT
A1Problem identif ication. Key product/process selected, based on
business impact (DPU, Yield, COPQ, etc)3 2 1
A2 Project Customer, Mission, goals, metrics, client, measures of success established.
3 2 1
A3 Team members identif ied. 3 2 1
A4 Cashable return for Kodak identif ied (Return on investment) 3 2 1
A5 Potential barriers identif ied and listed. 3 2 1
Items above (A1-A5) should be complete by Week 1 review
A6 Team formed and fully functional 3 2 1
A7Project Baseline elements completed including scope, scale, analysis of
defects, cycle time, and costs3 2 1
A8 VOC collected, refined, and documented. 3 2 1
A9 Internal and external gaps identif ied through benchmarking 3 2 1
A10Detailed process map documented (inputs, outputs, product/ process
parameters, parameters classif ied, measurement points).3 2 1
A11Performance (key) parameters measured using basic Quality tools, basic
statistics, and Six Sigma measures3 2 1
A12Project Management plan established including milestone dates and
critical path3 2 1
Items above (A1-A12) should be complete by Week 3 review
B. ANALYSIS
B1Process/product data analyzed using control charts and other tools to
determine stability, capability, variability and process limits3 2 1
B2Failure Modes and Effects Analysis performed using identif ied steps
from product/process map.3 2 1 N/A
B3 Function Anaylsis Based Process Verif ication performed. 3 2 1 N/A
B4Systems Thinking tools applied (Reality Trees, Causal Loop Diagrams,
etc.).3 2 1 N/A
B5Key parameters prioritized based on capability analysis, defect pareto,
cost analysis, FMEA, FAB-PV, Value Analysis, etc.3 2 1
B6Measurement System Analysis performed on key measurement
processes (key parameters)3 2 1
B7"Measurement" phase elements updated (contract, baseline, metrics,
f low maps, etc.).3 2 1
B8Project Management plan updated w ith proposed improvement strategy
including milestone dates and critical path3 2 1
Items above (A and B) should be complete by Week 4 review
C. IMPROVEMENT
C1Key parameters selected for improvement. Response variables
documented.3 2 1
C2 Diagnostic studies completed (modeling, nested designs) 3 2 1
C3 Causal factor identif ication completed. Generate potential solutions. 3 2 1
C4Factor levels established, design selected and factors loaded, DOE plan
established3 2 1 N/A
C5 Experiment(s) conducted and data collected. 3 2 1 N/A
C6 DOE analysis. 3 2 1 N/A
C7 Select and test solution(s). Decision and risk analysis assessed. 3 2 1
C8 Implement solution(s). 3 2 1
C9"Measurement" phase elements updated (contract, baseline, metrics,
f low maps, etc.).3 2 1
Six Sigma project roadmapSix Sigma project roadmapSix Sigma project roadmapSix Sigma project roadmap
DEFINEDEFINE
MEASUREMEASURE
ANALYZEANALYZE
IMPROVEIMPROVE
CONTROLCONTROLwww.kpa.co.ilwww.kpa.co.il
Ron Kenett (KPAKPA Ltd.)
Technical Technical SkillsSkills
Soft SkillsSoft Skills
StatisticiansStatisticians
Industrial Industrial EngineersEngineers
Master Master Black BeltsBlack Belts
Black BeltsBlack Belts
Quality Improvement Quality Improvement FacilitatorsFacilitators
BBBBBBBB
MBBMBB
21/6/2002 36
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
R&DR&DEngr.Engr.
ProductionProductionPurchasingPurchasing
Cust. SupportCust. Support
R&DR&DEngr.Engr.
ProductionProductionPurchasingPurchasing
Cust. SupportCust. Support
IdeaIdeaIdeaIdea ProductProductProductProduct
Reqts.Reqts. Spec.Spec.Product andProduct and
Process DesignProcess Design
Industrial StatisticsQuality Management
Industrial StatisticsQuality Management
Market Market ResearcResearc
hh
ProductProductEvaluatioEvaluatio
nn
ProductProductEvaluatioEvaluatio
nn
Satisfaction Satisfaction SurveysSurveys
Satisfaction Satisfaction SurveysSurveysProcess Process
ImprovementsImprovementsProcess Process
ImprovementsImprovements
www.kpa.co.ilwww.kpa.co.il
Ron Kenett (KPAKPA Ltd.)
21/6/2002 37
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
"A Test for Detecting Outlying Cells in the Multinomial Distribution and Two-Way Contingency Tables", R. Kenett and C. Fuchs, Journal of the American Statistical Association , 75, pp. 395-398, 1980.
"Some Experiences Teaching Factorial Designs in Introductory Statistics
Courses", R. Kenett and D. Steinberg), Journal of Applied Statistics, 14, pp. 219-228, 1987.
"Two Methods for Comparing Pareto Charts", R. Kenett, Journal of Quality Technology, 23, pp. 27-31, 1991.
"Going Beyond Main-Effect Plots", R. Kenett and B. Vogel, Quality Progress, pp. 71-73, February 1991.
"Making Sense Out of Two Pareto Charts", R. Kenett, Quality Progress, pp. 71-74, May 1994.
Modern Industrial Statistics: Design and Control of Quality and Reliability ,R. Kenett and S. Zacks, Duxbury Press, San Francisco, 1998.
References
21/6/2002 38
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
My email:
Our website:
www.kpa.co.il
My email:
Our website:
www.kpa.co.il
Ron Kenett (KPAKPA Ltd.)
21/6/2002 39
PRO-ENBIS: G6RT-CT2001-05059
Siemens Electric Heating, Trondheim
Pro-Enbis Acknowledgement
All joint authors - presenters - are members of:
Pro-Enbis and ENBIS.
This presentation is supported by Pro-Enbis a Thematic Network funded under the ‘Growth’ programme of the European Commission’s 5th Framework research programme - contract number G6RT-CT-2001-05059
All joint authors - presenters - are members of:
Pro-Enbis and ENBIS.
This presentation is supported by Pro-Enbis a Thematic Network funded under the ‘Growth’ programme of the European Commission’s 5th Framework research programme - contract number G6RT-CT-2001-05059