I.4 Implementation Issues  Fundamentals of Problem Solving  DOE Implementation Issues – DOE Stages – Helicopter Experiment – Project Reports  Problem Solving/DOE Levels of Understanding

Fundamentals of Problem Solving The Scientific Method Science is built of facts the way a house is built of bricks; but an accumulation of facts is no more science than a pile of bricks is a house. -Henri Poincare -Henri Poincare

Fundamentals of Problem Solving The Scientific Method  The Scientific Method – Cycle Between Theories (or Hypotheses) and Data Collection/Analysis to Repute or Refute the Theories – The Shewhart/Deming Plan-Do-Study-Act Cycle Is Based on This

Fundamentals of Problem Solving PDSA Cycle--The Shewhart/Deming Cycle o Most Problem Solving Strategies Are Elaborations on the PDSA Cycle ACT DO STUDY PLAN

Fundamentals of Problem Solving The PDSA Cycle PLAN Problem And Its Scope Processes Define Assess Current Situation Analyze Causes DO Experiment With Theories STUDY Analyze The Results Verify Conclusions ACT Adopt or Abandon The Change Revise The Standard Operating Procedure Plan Continuous Improvement

Fundamentals of Problem Solving Comments  Getting Rid Of ACV (Assignable Or Special Cause Variation) Is NOT Process Improvement!  Conclusions Drawn From Data Collected When The Process Is Not Stable Are Suspect!

DOE Implementation Issues DOE Stages DOE Implementation Issues DOE Stages  Stages and Substages Are Just An Elaboration Of The PDSA Cycle and The Seven Steps

DOE Implementation Issues DOE Stages  A DOE Project Is Composed Of A Number Of Stages – The Preliminary Stage – The Basic Understanding Stage – The Refinement Stage – The Verification Stage  Each One Of These Stages And Their Substages Have Certain Objectives

DOE Implementation Issues DOE Stages - Objectives  The Overall Objective Of The Project – Oftentimes Broad And Not Specific – E.g, The Overall Objective May Be To Simply Improve A Process  Stage Objectives Are Specific

DOE Implementation Issues DOE Stages The Preliminary Stage  Considerations – Measurement Methods – Factor Selection – Process and Measurement Variation  Some Relevant Objectives For This Stage – Determining The Quality Of The Measurement Process – Understanding The Current Situation

DOE Implementation Issues DOE Stages To Fix These Ideas Let’s Design a Helicopter  Background – Product Development at ‘We R Toys’ is developing a cheap "distraction" toy for use at restaurants to keep young children entertained while waiting for service. The toy - a paper helicopter - needs to be simple in design since the children will be assembling it using scissors, tape, paper clips, etc. A study done using the prototype has discovered that customer satisfaction is directly related to the the total flight time of the helicopter.

DOE Implementation Issues DOE Stages To Fix These Ideas Let’s Design a Helicopter  Background – Engineering has been assigned the task to optimize the flight time. Because of the assembly requirements, the modifications should not result in a design that is drastically different in form for that of the prototype.

DOE Implementation Issues DOE Stages Helicopter Experiment - The Basic Design

DOE Implementation Issues DOE Stages Helicopter Experiment - Stage Objectives  Overall Objective: To increase flight time.  Stage One Objectives: Brainstorm to decide on factors that possibly influence flight time. Decide which factors are control factors and which ones are noise factors.  Stage Two Objectives: Decide on factors that are to be included in an eight run screening design and determine their levels for the design.

DOE Implementation Issues DOE Stages Helicopter Experiment - Stage Objectives  Stage Three Objectives: Run the DOE from Stage Two to screen out active factors from inactive ones. For the active factors, decide on possible settings for the next DOE Decide on what new factors might be included in the next design.  Stage Four Objectives: Run the DOE for the factors and their settings decided in the previous stage.

DOE Implementation Issues DOE Stages Helicopter Experiment - Stage Objectives  Stage Five Objective: ???????  Stage ???? (The Validation Stage) Objective: Your sequence of DOE's have led you to some "Ideal Factor Setting" that "Optimize" the performance of the helicopter with regard to its flight time. This was done under laboratory conditions. Will this performance be replicated under normal operating conditions? This is the purpose of the validation stage.

Problem Solving/DOE Levels of Understanding  The Operational Level - Empirical Model Building – What Factors Affect the Response – How Do They Affect the Response  The Basic Research Level - Fundamental Theories – Why Do They Affect The Response

Problem Solving/DOE Levels of Understanding  Two Approaches To Correct Defects - Theoretical and Empirical 1. Theoretical Approach (Mechanistic Models and Technical Analysis) - Theoretical Principles are Used to Search for Cause-and- Effect Relationships 2. Statistical Based (Empirical Model Building) Allows One to Discover Corrective Measures.

Problem Solving/DOE Levels of Understanding Tale of the TV Tuner (Karatsu)  Statistical analysis discovered that a TV tuner should be placed as far as possible from the speaker to avoid malfunction. There was no good theoretical explanation for this.