Green Belt – SIX SIGMA OPERATIONAL Intro to Analyze Phase

FSG-S-A00C Flextronics Corporate Presentation The Big Picture…. Process Map Cause and Effects Matrix FMEA OUTPUTS INPUTS Functional Assembly Label Body 2 Insert Spirol Pin 3 Assemble Pistons 4 Assemble Cover 5 Paperwork 1 1 Functional Assembly Rework Route Ticket Orientation Label adhesion Greased O ring Screw position adj. Flush w/ surface O ring position Cover orientation Snap ring inserted Test 6 Is the pin seated correctly? Does the O ring function properly? Is the cover aligned correctly? S Bills of materials S ISO Procedures S Cleanliness C Material X Press Force C Material S Assy Technique C Amount of Grease C Material S Assy technique N Adjustment Pos. C Snap Ring C Insertion C Material X Test Capability S Calibration  11 T USL p(d)  Process Measurement

FSG-S-A00C Flextronics Corporate Presentation GB Projects progress potential

FSG-S-A00C Flextronics Corporate Presentation If we are so good at X, why do we constantly test and inspect Y? n Y n Dependent n Output n Effect n Symptom n Monitor n X 1... X N n Independent n Input-Process n Cause n Problem n Control To get results, should we focus our behavior on the Y or X? f (X) Y= Focus on X rather than Y, as done historically The Focus of Six Sigma KPIV KPOV

FSG-S-A00C Flextronics Corporate Presentation The Improvement Strategy (MAIC) Focus__ Vital Few x i Y Y Y Y Y x 1, x 2,... x n x 1, x 2,... x n Vital Few x i x i x i x i Phase_ Measure Analyze Improve Control x i Select Product or Process Key Characteristic(s); e.g.., Customer Y Define Performance Standards For Y Validate Measurement System for Y Establish Process Capability of Creating Y Define Improvement Objectives For Y Identify Variation Sources In Y Screen Potential Causes For Change In Y & Identify Vital Few X i Discover Variable Relationships Between Vital Few X i Establish Operating Tolerances On Vital Few X i Validate Measurement System For X i Determine Ability To Control Vital Few X i Implement Process Control System On Vital Few X i i SIX SIGMA METHODS GENERATEDATA-BASED DECISIONS

FSG-S-A00C Flextronics Corporate Presentation Some Thoughts Regarding Analyze Phase DataKnowledgeInformationDecisions Basic Statistics Descriptors Hypothesis Testing, Modeling Engineering Judgement *

FSG-S-A00C Flextronics Corporate Presentation Analyze Phase: What’s the Big Idea ? Many potential KPIV’s have been identified, but which ones are truly the sources of variability? Now it’s necessary to shorten the list and Identify the Critical KPIVs: Quantify the variability from different input sources Determine their effect on the KPOV Study both between- and within-variability So that all the important variables are identified, and we know where to focus our process improvement efforts!

FSG-S-A00C Flextronics Corporate Presentation Goals of Analyze Phase Two areas of focus  Refine: KPOV = F(KPIVs)  Understand:  2 Total =  2 Between +  2 Within Learn and apply statistical tools that will help you make the best decisions The tools that you learn in Analyze Phase can be applied to almost any area of your life. When applied, these tools will improve most of your important decisions. By using these tools, you will be far more likely to “Do it right the first time”

FSG-S-A00C Flextronics Corporate Presentation Narrow the Scope of Input Variables Optimized Process Key Process Input Variables (KPIVs) KPIVs Critical KPIVs 3-6 Key Leverage KPIVs Inputs Variables Process Map Multi-Vari Studies, Correlations Screening DOE’s, RSM C&E Matrix and FMEA Gage R&R, Capability T-Test, ANOM, ANOVA Quality Systems SPC, Control Plans Measure Analyze Improve Control

FSG-S-A00C Flextronics Corporate Presentation Process Capability Study Confidence Intervals Indicators: Performance & Entitlement DPMO; Sigma Score Cp Pp Cp k Pp k Generates/Determines Gather Historical Data or Sample (Size & Subgroup) Determine Cost of Quality Review Internal & External Costs Potential Benefits Analytical Tools Minitab Trends & Behaviors in KPIV/KPOV relationships Measure Analyze Applies throughout Six Sigma RoadMap

FSG-S-A00C Flextronics Corporate Presentation Hypothesis for Variables - Means (t-tests) Generates/Determines Variables Data Hypotheses for Attributes (Contingency Tables, Non-parametric study) Proportion Defects Proportion Defectives Answers: Differences in % Def. Between pop.; Diff. in % Def. from overall mean Variables Data Answers: Difference in Means? One Pop. to Another; Before/After; to Spec Answers: Difference in Spread? One Pop. to another; to baseline; multiple Pops. Collecting data on several variables at the same time Hypotheses for Variables - Std. Dev. (Chi Sq., F-Test, Test for Equal Variances) Multi-Vari Studies Points to variables warranting further analyses Analyze Six Sigma RoadMap

FSG-S-A00C Flextronics Corporate Presentation ANOVA Generates/Determines Answers: Difference in Means? One Variable (Factor) Multiple Types Variables Data Correlation & Regression Confirm which Input Variables most directly affect the Output Variables: Move on to Optimize - Settings or Procedures For pairs of continuous Data Variables Answers: If know X; Predict Y Strength & Direction Analyze Six Sigma RoadMap

FSG-S-A00C Flextronics Corporate Presentation Analyze Phase: Agenda 1.Measure Phase Review 2.Introduction to Analyze Phase 3.Central Limit Theorem 4.Interval Estimation 5.Hypothesis Testing: Theory 6.Hypothesis Testing: Methods 7.Sample Size Selection 8.Contingency Table 9.Multi-Vari Analysis 10.ANOVA 11.Regression & Correlation 12.Project Review and Wrap-up