1. Section VI, Measure - Data & Process Analysis

2. Group Activity Launch #1
Using what you are given, baseline the process for shooting the statapult.
Remember:
Customer desires a rapid-fire, precise, and accurate launcher that can launch projectiles over mountain ranges.
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3. Statapult Instructions Launch #1
Objective: To fire the statapult and record the distance for each of the launches. The measured distance will be from the back of the launcher to the point where the ball first lands. Record the distances in the order in which they were obtained.
Every shot will be launched from a pull back angle of 177/65 degrees.
Each person on the team will perform an equitable number of launches (or as close as possible).
"Launching” means pulling back and releasing.
Time between each shot cannot exceed 15 seconds.
Record the distances on the table to the left.
Record the longest distance (Max) and the shortest distance (Min) and compute Range = Max - Min.
Range = ______________
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4. Statapult Launch #1
See graphing.pdf
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5. Sigma Values Short term data is considered free of assignable causes
One shift, one operator
Long term data is considered to contain both assignable and common caused variation
Multiple shifts, multiple operators
Processes tend to exhibit more variation in the long term than the short
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6. Levels of Maps
Maps can be created for many different levels of the process. Just like highway maps…
You can use a map of the USA…
or if you need more detail, a map of the state...
or if you need more detail, a map of the city.
Mapping works much the same way. Depending on the detail you need, create the map at that level. If you need more detail, then create a more detailed map of the sub-process.
High Level
Detail
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7. Visually sets the process steps in order
High Level Process Map
Process Flow Diagram
Used to identify the steps in a process
Good for process documentation and knowledge gathering
May be used in definition, detail design, analysis and control portions of a project
Visually sets the process steps in order
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8. Swim Lane (Functional or Deployment Maps)
To provide a graphical representation of the process with regards to
the people involved,
their responsibilities,
functional interfaces and dependencies,
as well as process steps over time where necessary.
Critical tool for transactional processes and when mapping information flow for industrial processes
Segregates steps by who does them or where they are done
Makes handoffs visible
A Swim Lane is a process flow diagram with resource responsibilities
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9. Functional or Deployment Flow Diagram
Process Steps
Business Unit
Define needs
Review & approve
Prepare paperwork
Receive & use
Review & approve standard
Configure & install
I.T.
Finance
Issue payment
Review & approve
Top Mgt/ Corporate
Review & approve
Resources Responsible for Process Steps
Sourcing
Acquire equipment
Supplier
Supplier
Graphical summary or roles & responsibilities for a process
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10. Process Flow Chart Objective:
Develop a process flow diagram that explains how to launch a ball.
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11. SIPOC Suppliers Inputs Process Outputs Customers
(Providers of the required resources)
(Resources required by the process)
(Process require-ments for the Inputs)
(Top level description of activity)
(Deliverables from the process)
(CustomerRequire-ments of the Outputs)
(Anyone who receives a deliverable from the process)
Documents a process as it moves from suppliers’ parts to customers’ product/service
Includes information:
necessary to balance competing customer requirements
identify “gaps”
verify team and information resource requirements
Helps drive Process Owners to use the right metrics and verify them continuously with the customers and suppliers
SIPOC is a process scoping tool that provides a high level definition of a process – SIPOC should be used on all Six Sigma projects
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12. SIPOC – The Process Steps
Suppliers
Inputs
Process
Outputs
Customers
(Providers of the required resources)
(Resources required by the process)
Process Requirements for the Inputs
( Top level description of activity)
(Deliverables from the process)
Customer’s Requirements of the Outputs
(Anyone who receives a deliverable from the process) 2
When does the
process end?
Boundary
Process start? 6
What Inputs are required to enable this process to occur?
The numbers in the graphic correspond to the numbers of the steps that follow. 3
What are the outputs from the process? 4
Who is the customer of each output? 1
What is the process? 7
Who is the supplier of each input? 8
What does the process expect from each input? 5
What does each customer expect from each output?
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13. Group Exercise - SIPOC
INPUTS
PROCESS
OUTPUTS
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14. *Input/Output relationships can be rated as:
Relationship Matrix
Create a relationship matrix for the previous SIPOC
*Input/Output relationships can be rated as:
Strong: 9
Moderate: 3
Weak: 1
Nonexistent: Blank or 0
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15. Basic Structure – C&E Diagram (Fishbone)
Project Y
Inputs (X’s)
Output (Y)
Level 1 Cause
Level 2 Cause
Main Category
Measurements
Materials
People
Environment
Methods
Machines
C = Control Factor (controllable)
N = Noise factor (out of our control)
X = Experimental variable C N X
By identifying the correct inputs, you can achieve optimal results in the shortest time.
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16. STANDARD OPERATING PROCEDURES (SOPs)
Cause & Effect C/N/X’s
C = those variables which must be held constant and require standard operating procedures to insure consistency. Consider the following examples: the method used to enter information on a billing form, the method used to load material in a milling or drilling process, the autoclave temperature setting.
N = those variables which are noise or uncontrolled variables and cannot be cheaply or easily held constant. Examples are room temperature or humidity.
X = those variables considered to be key process (or experimental) variables to be tested in order to determine what effect each has on the outputs and what their optimal settings should be to achieve customer-desired performance.
STANDARD OPERATING PROCEDURES (SOPs)
Which sources of variability do you control? How do you control them and what is your method of documentation?
To successfully accomplish this task you have to consider every source of variability or failure, and develop simple, low cost Standard Operating Procedures (SOPs) for holding most of these variables constant and for fool proofing most of the causes of failures. These SOPs should be clearly stated, and all employees trained and motivated to understand and comply with the SOPs. This is a critical step toward getting any process/activity into control and/or preventing product/service failures. Whether you are trying process improvements, or a process is already proved out, SOPs should be developed and followed. When trying out proposed process improvements develop SOPs, and try out the proposed improvement(s) on a small scale in a controlled environment. Monitor the improved process and document the result with data.
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17. Cause and Effect Diagram
Objective:
Develop a C&E diagram that explains the variability of the launching process. Label as C/N/X.
METHOD
MOTHER
NATURE
MEASUREMENT
MANPOWER
MACHINE
MATERIAL
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18. FMEA In groups Conduct a process FMEA for “shooting the statapult”
Generate Risk Priority Numbers and develop controls that will minimize risk
Product or Process
Failure Mode
Failure Effects
SEV
Causes
OCC
Controls
DET
RPN
Actions
Plans PS PO PD
prpn
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19. SOP
Objective:
Develop a SOP that accurately defines each controlled step of the launching process.
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20. Statapult Instructions Launch #2
Objective: To fire the statapult and record the distance for each of the launches. The measured distance will be from the back of the launcher to the point where the ball first lands. Record the distances in the order in which they were obtained.
Every shot will be launched from a pull back angle of 177/65 degrees.
Each person on the team will perform an equitable number of launches (or as close as possible).
"Launching” means pulling back and releasing.
Time between each shot cannot exceed 15 seconds.
Record the distances on the table to the left.
Record the longest distance (Max) and the shortest distance (Min) and compute Range = Max - Min.
Range = ______________
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21. Statapult Launch #2
See graphing.pdf
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22. Concentration Chart www.duetsblog.com/uploads/image/AT&T.jpg VI-22
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23. Measures of Variation
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24. Population vs. Sample
Data is collected using samples because the entire population may not be known or it may be too costly to measure.
Population is every possible item
Sample is a subset of the population
Population
Sample
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25. Calculating Standard Deviation
Step #1 Add the data points and divide by the number of data point to determine the mean (average)
Step #2 Subtract the mean from each individual data point and square the result (data point – Mean)2
Step #3 Add together all the squared data points
Step #4 Divide the total of the squared data points by n-1 if a sample, or n if a population (n= number of data points)
Step #5 Calculate the square root of the sum of step #4. The result is the standard deviation for the process.
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26. Launch #1
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27. Launch #2
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28. Graphical View of Variation and Six Sigma Performance
Each unit of measure is a numerical value
on a continuous scale
Variation common and special
causes
Pieces vary from
each other
Size
Size
Size
Size
But they form a pattern that, if stable, is called a normal distribution
Normal Distribution
Histogram or
Frequency Distribution
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29. There are three terms used to describe distributions
Normal Distribution
There are three terms used to describe distributions
1. Shape
Bell
2. Spread
Standard Deviation
3. Location
Mean
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30. Scatter Diagram example:
Angle
Distance
Distance
Angle
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31. Histograms examples
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32. Histograms examples
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33. Computing Cost Of Poor Quality
Instructions
Refer to Launch #1 and #2 and convert the run charts shown on these pages to histograms, using 4-inch intervals as the class width.
The student may then choose the 12-inch range (3 consecutive 4-inch intervals) centered around the average to be the specification range.
Draw those spec limits on the histogram and complete the following table:
Launch #1
Launch #2
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34. Calculate our statistics
Heights
Dev. from
Avgerage.
Total
Xbar
(average)
Sigma!!
Let’s practice
Find:
Mean
Median
Mode
Range
Sigma
-population
-sample
5’ = 60”
6’ = 72”
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35. Plot height data and use the statistics
Step 2
Create a
Histogram
Xbar =
Step 3
Add Sigma
Limits
Scale
- (Use 2"
increments)
Sigma
Area %
Height Span
Realistic? (Y/N)
+/- 1 Sigma
+/- 2 Sigma
+/- 3 Sigma
+/- 6 Sigma
Step 4
Analyze
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