I.4 Implementation I.4 Implementation IssuesIssues

Fundamentals of Problem SolvingFundamentals of Problem Solving DOE Implementation IssuesDOE Implementation Issues

– DOE StagesDOE Stages– Helicopter ExperimentHelicopter Experiment– Project ReportsProject Reports

Problem Solving/DOEProblem Solving/DOELevels of UnderstandingLevels of Understanding

Fundamentals of Fundamentals of Problem SolvingProblem Solving

The Scientific MethodThe Scientific Method Science is built of facts the Science is built of facts the way a house is built of bricks; way a house is built of bricks; but an accumulation of facts is but an accumulation of facts is no more science than a pile of no more science than a pile of bricks is a house.bricks is a house.

-Henri Poincare-Henri Poincare

Fundamentals of Fundamentals of Problem SolvingProblem Solving

The Scientific MethodThe Scientific Method The Scientific MethodThe Scientific Method

– Cycle Between Theories (or Cycle Between Theories (or Hypotheses) and Data Hypotheses) and Data Collection/Analysis to Repute or Collection/Analysis to Repute or Refute the TheoriesRefute the Theories

– The Shewhart/Deming Plan-Do-Study-The Shewhart/Deming Plan-Do-Study-Act Cycle Is Based on ThisAct Cycle Is Based on This

Fundamentals of Fundamentals of Problem SolvingProblem Solving

PDSA Cycle--The Shewhart/Deming CyclePDSA Cycle--The Shewhart/Deming Cycle Most Problem Solving Most Problem Solving Strategies Are Elaborations Strategies Are Elaborations on the PDSA Cycleon the PDSA Cycle

ACT DO

STUDY

PLAN

Fundamentals of Problem Fundamentals of Problem SolvingSolving

The PDSA CycleThe PDSA Cycle

PLAN

Problem And Its Scope

Processes• Define

Assess Current Situation

Analyze Causes

DO Experiment With Theories

STUDY Analyze The ResultsVerify Conclusions

ACT

Adopt or Abandon The Change

Revise The Standard Operating Procedure

Plan Continuous Improvement

Fundamentals of Problem Fundamentals of Problem SolvingSolving

CommentsComments Getting Rid Of ACV (Assignable Getting Rid Of ACV (Assignable Or Special Cause Variation) Is Or Special Cause Variation) Is NOTNOT Process Improvement! Process Improvement!

Conclusions Drawn From Data Conclusions Drawn From Data Collected When The Process Is Collected When The Process Is Not Stable Are Suspect!Not Stable Are Suspect!

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

Stages and Substages Are Just Stages and Substages Are Just An Elaboration Of The PDSA An Elaboration Of The PDSA Cycle and The Seven Steps Cycle and The Seven Steps

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

A DOE Project Is ComposedA DOE Project Is ComposedOf A Number Of StagesOf A Number Of Stages– The Preliminary StageThe Preliminary Stage– The Basic Understanding StageThe Basic Understanding Stage– The Refinement StageThe Refinement Stage– The Verification Stage The Verification Stage

Each One Of These Stages And Each One Of These Stages And Their Substages Have Certain Their Substages Have Certain ObjectivesObjectives

DOE Implementation DOE Implementation IssuesIssues

DOE Stages - ObjectivesDOE Stages - Objectives The Overall Objective Of The The Overall Objective Of The ProjectProject– Oftentimes Broad And Not SpecificOftentimes Broad And Not Specific– E.g, The Overall Objective May Be E.g, The Overall Objective May Be To Simply Improve A ProcessTo Simply Improve A Process

Stage Objectives Are SpecificStage Objectives Are Specific

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

The Preliminary StageThe Preliminary Stage ConsiderationsConsiderations– Measurement MethodsMeasurement Methods– Factor SelectionFactor Selection– Process and Measurement VariationProcess and Measurement Variation

Some Relevant Objectives For Some Relevant Objectives For This StageThis Stage– Determining The Quality Of The Determining The Quality Of The Measurement ProcessMeasurement Process

– Understanding The Current SituationUnderstanding The Current Situation

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

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

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

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

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

Helicopter Experiment - The Basic DesignHelicopter Experiment - The Basic Design

11"

4.75"

4.75"

4.25"

1.5" 1.5"

Cut

Fold

Cut Cut

Fold

Cut

CutCut Cut

Fold Fold CutCut

Cut

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

Helicopter Experiment - Stage ObjectivesHelicopter Experiment - Stage Objectives Overall Objective: To increase flight Overall Objective: To increase flight time.time.

Stage One Objectives: Brainstorm to Stage One Objectives: Brainstorm to decide on factors that possibly decide on factors that possibly influence flight time. Decide which influence flight time. Decide which factors are control factors and which factors are control factors and which ones are noise factors.ones are noise factors.

Stage Two Objectives: Decide on Stage Two Objectives: Decide on factors that are to be included in an factors that are to be included in an eight run screening design and eight run screening design and determine their levels for the design.determine their levels for the design.

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

Helicopter Experiment - Stage ObjectivesHelicopter Experiment - Stage Objectives Stage Three Objectives: Run the DOE Stage Three Objectives: Run the DOE from Stage Two to screen out active from Stage Two to screen out active factors from inactive ones. For the factors from inactive ones. For the active factors, decide on possible active factors, decide on possible settings for the next DOE Decide settings for the next DOE Decide on what new factors might be on what new factors might be included in the next design.included in the next design.

Stage Four Objectives: Run the DOE Stage Four Objectives: Run the DOE for the factors and their settings for the factors and their settings decided in the previous stage.decided in the previous stage.

DOE Implementation DOE Implementation IssuesIssuesDOE StagesDOE Stages

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

Problem Solving/DOEProblem Solving/DOELevels of UnderstandingLevels of Understanding

The Operational Level - The Operational Level - Empirical Model BuildingEmpirical Model Building– What Factors Affect the ResponseWhat Factors Affect the Response– How Do They Affect the ResponseHow Do They Affect the Response

The Basic Research Level - The Basic Research Level - Fundamental TheoriesFundamental Theories– Why Do They Affect The ResponseWhy Do They Affect The Response

Problem Solving/DOEProblem Solving/DOELevels of UnderstandingLevels of Understanding

Two Approaches To Correct Defects Two Approaches To Correct Defects - Theoretical and Empirical- Theoretical and Empirical1.1. Theoretical Approach (Mechanistic Theoretical Approach (Mechanistic

Models and Technical Analysis) - Models and Technical Analysis) - Theoretical Principles are Used to Theoretical Principles are Used to Search for Cause-and-Effect Search for Cause-and-Effect RelationshipsRelationships

2.2. Statistical Based (Empirical Model Statistical Based (Empirical Model Building) Allows One to Discover Building) Allows One to Discover Corrective Measures.Corrective Measures.

Problem Solving/DOEProblem Solving/DOELevels of UnderstandingLevels of UnderstandingTale of the TV TunerTale of the TV Tuner

(Karatsu)(Karatsu)

Statistical analysis discovered Statistical analysis discovered that a TV tuner should be that a TV tuner should be placed as far as possible from placed as far as possible from the speaker to avoid the speaker to avoid malfunction. There was no good malfunction. There was no good theoretical explanation for theoretical explanation for this.this.