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

2. 9-2 Improve Process Capability Improving Stable Processes l 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. Source: Brian Joiner

3. 9-3 Improve Process Capability Order Entry Process Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Total # Errors 15 22 18 10 13 9 27 12 24 22 8 26 16 20 10 16 9 15 20 320 0 5 10 15 20 25 30 35 5101520 Avg=16.0 LCL=4.0 UCL=28.0 Week Number of Errors Control Chart It has been decided that this process requires further improvement How do we go about it?

4. 9-4 Improve Process Capability Order Entry Errors by Type Incorrect Account Number72 Error in Order Amount168 Inadequate Billing Information17 Priority Code Not Checked25 Incomplete Shipping Instructions14 Other Errors24 TOTAL320 DescriptionNumber of Errors Error in Order Amount Incorrect Account Number Priority Code Not Checked Inadequate Billing Information Incomplete Shipping Instructions Other Errors 0 20 40 60 80 100 120 140 160 180 Type Error Pareto Chart

5. 9-5 Improve Process Capability Order Entry Process Results of efforts to reduce errors in order amount. Week 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Total # Errors 16 10 13 6 8 10 6 5 4 6 1 5 0 1 2 93 0 5 10 15 20 25 30 35 5101520 Avg=16.0 LCL=4.0 UCL=28.0 Week Number of Errors Control Chart 253035 Limits based on first 20 weeks of data Process Improvements Begin

6. 9-6 Improve Process Capability Order Entry Errors by Type Incorrect Account Number42 Error in Order Amount8 Inadequate Billing Information7 Priority Code Not Checked17 Incomplete Shipping Instructions9 Other Errors10 TOTAL93 DescriptionNumber of Errors Incorrect Account Number Error in Order Amount Priority Code Not Checked Inadequate Billing Information Incomplete Shipping Instructions Other Errors 0 5 10 15 20 25 30 35 40 45 Type Error Pareto Chart

7. 9-7 Improve Process Capability Improving Stable Processes - Instrument Measures Common Problems with Stable Processes Lower SpecUpper SpecLower SpecUpper Spec Off TargetExcess Variation Or, Both

8. 9-8 Improve Process Capability Improving Stable Processes - Instrument Measures Common Improvement Techniques l 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. 9-9 Improve Process Capability Breaking Out Process Steps Use C&E matrix as a place to start data collection and analysis.

10. 9-10 Improve Process Capability Isolating 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

11. 9-11 Improve Process Capability Separating 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 24681012141618202224262830 Proportion Proportion Week Late Late Possible Actions:Improve process for shipping of international orders.

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

13. 9-13 Improve Process Capability Minitab: 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. Note: The ASM course spends more time discussing Planning, Data Collection, Analysis and Interpretation from experiments similar to the one above.

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

15. 9-15 Improve Process Capability Comparing 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

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

17. 9-17 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

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

19. 9-19 Improve Process Capability Designed 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 103.492.62345 Properly designed experiments can yield useful cause-effect information. Input Variables

20. 9-20 Improve Process Capability 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.

21. 9-21 Improve Process Capability Designed Experiments - Example

22. 9-22 Improve Process Capability Review 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

23. 9-23 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