Learn how to use the seven tools of quality and the normal ... · The Seven Tools of Quality 1. Ishikawa (fishbone) diagram 2. Check sheets 3. Control charts 4. Histograms 5. Pareto

Process Improvement Webinar

Learn how to use the seven tools of quality and the normal curve

to control processes

By: Merwan Mehta, Ph. D.

Central Theme of Webinar

• Overview of the seven basic tools of quality

• Using the normal curve to control processes

• Utilizing statistics to control processes

Predictive Maintenance Technologies 2

The Seven Tools of Quality

1. Ishikawa (fishbone) diagram

2. Check sheets

3. Control charts

4. Histograms

5. Pareto charts

6. Scatter diagrams

7. Flowcharts

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Ishikawa (Fishbone) Diagram

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Machine Material Measurement

Method People Environment

Rejects

Variation Wear

Calibration

Standards

Enhance

Suppliers

Error

SQC

Motivation

Training

Humidity

Temperature

Check Lists

http://geoffmcdonald.com/atul-gawande-checklist-manifesto/

XmR Control Chart Using Excel

X Chart

mR Chart

Histograms Using Excel

Pareto Chart Using Excel

Scatter Plots Using Excel

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Activity 1

Activity 2

Activity 3

Activity 6

Activity 4

Activity 5 Activity 8

Activity 9

Activity 10

Activity 7

Employee A

Swim-lanes

Flow Chart with Swim Lanes

Document

the process

Employee B

Manager

Employee C

Process Mapping

Customer service rep

Enter in system

Visit customer For evaluation

Approve for Quoting?

Create Report

Notify CSR & FM

N Y Create Report

1

2

3

4 5 5

6 Notify CSR & FM

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Notify Customer

7 Notify Customer

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FILE 8 Credit Good?

N Y 9

Notify Engineer

10 Notify CSR

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Custom Design?

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Y

Create Design

Send to Engineer

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12

Check Design

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Create BOM 15

Price Components

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Final Quote

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Approve Quote

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Notify Customer

FILE

Order entry clerk

Receive request

Customer service manager

Finance manager

Engineer

Draft person

Purchasing agent

Engineering manager

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N

Documents

the process

Metrics are

absent

The Normal Curve

Minimum Mean Maximum

Source: Adapted from Certified Six Sigma Green Belt Primer. Quality Council of Indiana, April 2006.

• The histogram will closely trace the normal curve • Most data points are near the centerline or the mean. • Centerline divides the curve into two symmetrical halves • Some points approach the minimum and maximum values • Very few points are outside the bell-shaped curve

Possibilities for Two Dice Total appearing

on dice Possible Combinations of Dice

Total # of

possibilities

2 1

1

1

3 1 2

2

2 1

4 1 2 3

3

3 2 1

5 1 2 3 4

4

4 3 2 1

6 1 2 3 4 5

5

5 4 3 2 1

7 1 2 3 4 5 6

6 6 5 4 3 2 1

8 2 3 4 5 6

5

6 5 4 3 2

9 3 4 5 6

4

6 5 4 3

10 4 5 6

3

6 5 4

11 5 6

2

6 5

12 6

1

6

Possibilities for Three Dice

# Possibilities

0

5

10

15

20

25

30

35

# Possibilities 1 3 6 10 15 18 25 27 30 25 21 15 10 6 3 1

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

The Empirical Rule

0.13% 2.14%

13.60%

34.13%

-3S -2S -1S X +1S +2S +3S

95.46%

99.73%

68.26%

13.60%

34.13%

2.14%

0.13%

-∞ +∞

Empirical Rule

Our Process

• Mean = 124.9 days

• SD for Mean = 5 days

• UCL for Mean = 139.8 days

• LCL for Mean = 110.0 days

• Based on the Empirical Rule, only 0.26% of the time the “time for the process” will be outside the control limits

Our Process

• Question: What % of the projects will be completed between 110 to 120 days?

X1 = 110 X2 = 120

Normal Curve

Mean = 124.9 days

SD = 5 days

Group Exercise

• What % of the projects will be completed between 100 to 105 days?

• Work in groups of 2 or 3

Designing a Process

• What will we have to do if we want to make sure that 99.7% of the time a project is done in 100 to 120 days?

• LCL = 100 days

• UCL = 120 days

Limits Based on Probability

• If we are able to bring the mean for the process to 100 days and the standard deviation to 3 days, what are the limits between which 60% of the time projects will get done?

Group Question

• The project process with mean of 110 days and standard deviation of 4 days will have 75% of projects completed between _____ days to _____ days!

110 days

Probability = 75%

____

____

Group Question

• If the process drifted to make mean = 138 and the SD changed to 6.5 days, what percentage of the time the project time will be outside the specification limits?

• Work in groups of 2 or 3

Goal of Statistical Presentation in the Conference

• How to structure any process to take advantage of statistical knowledge

• How to create metrics for processes based the normal curve

• How to create control charts based on the normal curve

• How to predict future process behavior based on the normal curve

Predictive Maintenance Technologies 23

Lean and Six Sigma Conference 2013

• For engineers by engineers

• Your organization's success = your success

• Latest innovations and techniques

• Industry and research professionals

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• CEO & founder: consulting and software solutions

• High mix manufacturers improve profitability

• Manufacturing executive at Alcoa & Siemens

• Three degrees from the MIT

• Chairman of NSF’s Small Business Innovation Research Advisory Committee

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• VP of process management for Macy’s

• Six Sigma strategic direction and implementation

• Certified master black belt

• 31-year career in industrial engineering, quality assurance and operations with Lockheed Martin, NCR Corp. and Macy’s

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• Former director of the CIM Systems Research Center

• Research interests:

– Global new product development

– Model-based enterprises

– Global supply networks integration

• Book: Integrated Process Design & Development

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