Short Form Tool 13

ITTTM

Tool #13 Short Form“Statistical Foundations For Data-based Improvement, Lean, Six Sigma Solutions”

Topics1. Focus and benefits of data2. Foundational definitions of quality3. Attributes, defects, defectives4. Inspection, data gathering systems5. Tool applications………

Short Form Tool 13

ITTTM

Focus And Benefits Of Data

Monitors process for team problem solving• Prevention rather than detection• Knowledge based to modify, adjust, correct• Disciplined approach, ongoing improvement• Uniformity decreases nonconformance• Core communication device • Fewer samples, inspection costs reduced• Provides enhanced measure of capability• Enables data based decisions to be made• Less scrap, rework and other waste

Short Form Tool 13

ITTTM

Documentation Tools, Lean

Data Tools, Six Sigma

Service, Tools Manufacturing, Non- Manufacturing

Synchronous Tools, New Product Development

Project Team

Cultural Change And Continuous Improvement

Information Analysis,Communication Systems

Applied Research, Project Structure

Enhanced Problem Solving, Decision Making

Internal, External, E-commerce Relationships

Quality Management Systems (QMS)International Standards Organization (ISO)

Professional Outcomes, Growth, Knowledge

Technological Infrastructure

Industrial Technologists’ Toolkit For Technical Management

Focus And Benefits Of Data

Short Form Tool 13

ITTTM

CharacteristicsAnd StandardsIdentification,

Evaluation

Standard Deviation, SPC DataCollected

Documentation,Process Control

By OperatorsUsing SOP

Brainstorming For

Corrective Action

OngoingImprovement

In Teams

Basic Relationships In Data, SPC, Teams, Documentation, Improvement

Focus And Benefits Of Data

Short Form Tool 13

ITTTM

Tracking, Collecting Data,

Short/Long Runs

Sampling Conformance To Standards

Attribute Data

Variable Data

In-process Control By

Operators ViaForms, SOP’s

Capability Studies And Gage R & R

SOP’s, Ongoing Process Control

Plan (OPCP)

BrainstormingFor Corrective

Action

Bar And Pie Charts, Paretos, Graphs

Cause/Effect, Failure Mode And Effects

Analysis (FMEA)

Disciplined Problem Solving

Ongoing Improvement Teams

Cost Reduction, Enhanced Communication, Competitiveness

Expanded Relationships In Data, SPC, Teams, Documentation, Improvement.

Characteristics And Standards Identification, Evaluation

Standard Deviation, SPC Data Collected

Focus And Benefits Of Data

Short Form Tool 13

ITTTM

0 4 8 12 16 20 24 28

Range Range = 20 - 4 R = 16

Range

Foundational Definitions Of Quality

1046 = 4.6X =

3, 3, 4, 4, 5, 5, 5, 5, 6, 6

Mean

Short Form Tool 13

ITTTM

Normal Curve, Standard Deviation 1 s 2 s 3 s -3 s -2 s -1 s

68.26%

95.46%

99.73%

Lower Spec Limit

Upper Spec Limit

Nominal

Foundational Definitions Of Quality

• +/- 1 standard deviation, 68% of population• +/- 2 standard deviation, 95% of population • +/- 3 standard deviation, 99.7% of population

Short Form Tool 13

ITTTM

Variation: range; variance; standard deviation • Variance is square of standard deviation• Broader look, range, behavior around mean • Standard deviation is total variation at mean

Normal Curve, Standard Deviation 1 s 2 s 3 s -3 s -2 s -1 s

68.26%

95.46%

99.73%

Lower Spec Limit

Upper Spec Limit

Nominal

Foundational Definitions Of Quality

Short Form Tool 13

ITTTM

Example calculation of standard deviation: Data 5, 6, 7, 6, 8 n = 5 X = 6.4

List the Xi List Xi - X List (Xi - X)2

5 - 1.4 1.966 - 0.4 0.167 0.6 0.366 - 0.4 0.168 1.6 2.56 Sum ( ) 5.20

Normal Curve, Standard Deviation

Foundational Definitions Of Quality

Short Form Tool 13

ITTTM

The formula for sample standard deviation is:

= ∑ (Xi - X)2

n -1

Normal Curve, Standard Deviation

= “the sum of”Xi = individual measuresX = averagen = sample sizes, standard deviation

2

n -1s, = ∑(Xi - X)

s, = 5.204

s, =1.30

s, = 1.14

s,

Foundational Definitions Of Quality

Short Form Tool 13

ITTTM

Foundational Definitions Of Quality

Central Tendancy

• Mean or average• Mode or most• Median or position

Inferential Statistics

• Inferences in data • Probabilities

Descriptive Statistics

• Distribution• Range, highs to lows• Tolerance, acceptance range

Defects

• Non-functional• Non-conforming• Varies from specification• Defect may not spoil product• Defect, unacceptable product• Judged as unfit for use

Defective

• Multiple defects• Unacceptable or acceptable• Depends on severity• Customer demands

Short Form Tool 13

ITTTM

Attributes, Defects, Defectives

Attributes Defined

• Not measurable• Good or bad• Judgement calls• May not be gaged• Obvious characteristics• Go, no-go gages

Attribute Examples• Appearance• Texture, touch• Color coordinates• General fit

Variable Defined

• Measurable, such as diameter• Discreet differences• Variation defined precisely• Instrumentation• Defined, detailed characteristics• Objectivity is goal

Variable Examples• Diameter• Length• Cloth density• Surface finish

Short Form Tool 13

ITTTM

Shifting Attribute To Variable Data

Clothing Characteristics

Attribute Characteristics

Variable Characteristics

Overall Appearance

Color Coordinates

Material Texture

General Fit

Length

Diameter

Cloth Density

Cloth Color

Attribute And Variable Clothing Characteristics.

Attributes, Defects, Defectives

Short Form Tool 13

ITTTM

Characteristics, Charting, Data, Foundations

Analyze,

Assess Process

Compare Characteristics

Documentation,

Improvement

Provide, Pursue

Benchmark

Data

Vendor

Certification, Communication

Baseline For Adjustments

Determine

Consistency, Capability

Evaluate For

Standard Procedures

Attributes As Broad Foundational Characteristics’ Relationships.

Attributes, Defects, Defectives

Short Form Tool 13

ITTTM

Quality characteristics are important features

• Defined by customer• Refined by engineering and design groups• Variable or attribute data • Explained in context of print, notes• Characteristics may be ranked by importance• Goal is to further define a characteristic• Use characteristic as a measure for quality• Continuously evaluating characteristics• Shift from attribute to variable data over time

Attributes Identified, Inspection, Start For Charting

Inspection, Data Gathering Systems

Short Form Tool 13

ITTTM

Freq-uency

Of Occur-rence

20 42

% Of Total Occur-rence

%

General Shape Of Chart Is Constant, But Frequency And % Values Shift To Present Relationships Inherent In Facts Being Shown.Pareto Is Often Done Early In Analyses, Piggy-Backed On Histograms. It Is Used To Show Areas Needing Attention Versus Those We Can Postpone. Thus It Is A Good Decision Tool.

18 38

16 34

14 30

12 26

10 21

8 17

6 13

4 9

2 5

0 1

Shade Columns To Show Differences Among FindingsRank Findings From Highest To Lowest And Left To Right

High RPM Squeal

Noise Level

Finish Blemishes

Too Heavy

Availability

% Of Occurrences Is For Each Attribute Relative To Total Of All Occurrences.Chart Can Be Expanded To Show Unlimited Numbers Of Attributes

Histograms, Bar, Pie, Pareto Charts, ChecklistsInspection, Data Gathering Systems

Short Form Tool 13

ITTTM

Histograms, Bar, Pie, Pareto Charts, ChecklistsWork function:

Date ofObservation

Talking Idle, Not AtWork Area

Walking Idle, Work Station

Other Non- Productive

GeneralObservations

Part: Reviewed By: General Inspection Description:

Supplier: Gage/Device:

Operation: Characteristic:

No. Date Operator Run Quantity

Sample Size

Number Rejected

Number Accepted

Corrective Actions

1

2

……Forms The Base For The Inspection System

Inspection, Data Gathering Systems

Short Form Tool 13

ITTTM

Attributes Identified, Inspection, Start For ChartingInspection, Data Gathering Systems

Operation: Example Part: Example Characteristic/Attributes: Shape, Color, Buldge, Rip

Operator: Example

Shape

Color

Buldge

Rip General Corrective Actions/Other:

Location: Example

# SampleSize (n)

NumberDef.(np)

Explanations/Reasons For Rejects:

1 60 10 5 1 3 1

2 60 7 4 1 2

3 60 6 2 2 2

4 60 5 3 1 1

5 60 9 5 3 1

6 60 8 2 2 2 2

7 60 8 3 4 1

8 60 11 5 4 2

9 60 12 5 3 3 1

10 60 7 4 3

Short Form Tool 13

ITTTM

Tool Applications…….

Tool 13 applications are:• VSPC, introduced, continuously built, not just at start• PASPC also introduced, built gradually, evolved• Documentation System Design, Communication, DSDC• ISOQSAOPP, designed to help set a plan for team• GOTA, vacabulary, glossary of terms• All follow through, do and post, independently

Toolkit applications are a key part of the courseware• Located in separate folder of the CD• Provides the template for team portfolio• Each application s part of team project, portfolio• Designed to be done by all, each team member• First read long form, then short review, applications• Total contribution in application form is compiled• Portfolio is gradually evolved around applications

Short Form Tool 13

ITTTM

Tool Applications…….P-Attribute Statistical Process Control (PASPC)• First logical step for SPC, based on attributes• Interactive with GSIC, integrated systems• Inspect, track attributes as key characteristics• Do key statistical analysis, charting around on this• Analysis tool for improvement, leads to variable data• Partial table below is start for collection, calculation

Supplier: Customer: Product or process:

Inspection/data gathering description:

Operation: Part: Part characteristic being analyzed:

Date Time

Sample n

# def (np)

P = np/n

Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Short Form Tool 13

ITTTM

Tool Applications…….Variable Statistical Process Control (VSPC)• Interactive with, base for, most other statistical systems• Inspect, track key characteristics, document process• Do key statistical analysis, charting around on this• Analysis tool for improvement, leads to variable data• Partial table starts continuous development in project

Part: Operator: Inspection, Data Gathering Description (Attach Pertinent Information):

Characteristic: Operation:

Date Time

MeasureValue

1

2

3

4

5

Sum

Average

Range

Calculate Grand Mean or X Double Bar = All Averages Summed/n

Calculate UCL = X Double Bar + (A2) (R Bar); Calculate LCL = X Double Bar – (A2) (R Bar) Where A2 = .58 Constant

Calculate R Bar = All Ranges Summed/n

Calculate UCL R = (D4) (R Bar); And LCL R = (D3) (R Bar) Where D3 = 0 And D4 = 2.11 Constants

Configure Graphs To Accommodate Values Calculated, And To Fit Within Work Areas, Illustrating Process

Sample 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Short Form Tool 13

ITTTM

Tool Applications…….Glossary Of Terms, Applications (GOTA)• Continuously added to over entire course, by all• Helps enhance vocabulary, get all on same page• Terms are in toolkit, various parts, not just this course• A sampling of the form (partial) is shown……..

Provide A Definition For Each Term Identified, Explain How Your Team Will Apply The Concepts, Principles To Your Project:

Ongoing Process Control Plan:

Corrective Action System:

QFD:

Pareto Analysis:

Statistical Process Control:

Variable Measurement, Charting:

Attribute Measurement, Charting:

Capability:

Mean, Range:

Gage Repeatability & Reproducibility:

Normal Curve:

Short Form Tool 13

ITTTM

Tool Applications…….ISO/QS Audit, Objective Prioritization Plan (ISOQSAOPP)• Preliminary plan, setup of assessments, work for team• Familiarize with ISO, auditing, all on same page, terms• Strategic planning, team level, change and improvement• Project 50% done when “problem” nailed down• “hot spots” focus, project objectives, gradually PPDPOA• Gantt from SDA form or template, for time, sequence• Partial form is shown……..

Organization Under Discussion: Current Operation: Location:

General Description Of Operations/Production Functions/Systems Being Assessed As An Internal Audit:

ISO/QS Element (TS 16949 2002—Others) Technical Function Description Audit Preliminary Information Actions, Recommendations For Change

(list each element separately for analysis/audit)

(describe technical function being audited) (How does function compare to standard) (explain anticipated necessary actions, changes)

Planning Statement Or Issue, Particularly As Associated With The Service Environment: Criticality Level: HML (H = 5; M = 3; L = 1)

Fac = Facility issues; Cost = Cost issues; Time = Time issues; Pers = Personnel issues

Objectives Prioritized, 5 Being Highest: Criticality HML

Fac Cost Time Pers

5, 4, 3, 2, 1

Problem Background: Resources? (Budget/Other Concerns)?

Task/Deliverable/Objective: Who Will Do? How Measured?

Short Form Tool 13

ITTTM

Tool Applications…….

Documentation System Design, Communication (DSDC)• Initial design, plan for how the team will work• Given that all work is about communications…….• Documentation is blackboard is critical• Must consider initially how this will happen, DSDC• DSDC provides opportunity to reflect on, discuss

Researcher Communication Method, Internal And External Customers:

Toolkit/Blackboard Design Element, How Does It Work?

How To Improve Professional Relationships, Communication?

1. 1. 1. 1.

Identify How The Systems’ Design You Are Advocating Can Assist IN Tieing Together PPDPOA, TPMSS, FACR, TRIRPA And Other Elements Of Team Problem Solving And Improvement:

Explain ISO/QS Characteristics And Other Necessary Entities To Be Possessed By Documentation And Communication Systems, Categorically, Particularly Focused On Service Functions:

Using The Template At The End Of The Applications Complete A Cause And Effect Diagram Indicating Issues And Opportunities For Systemic Documentation Relationships/Improvements, Particularly Focused On Service Functions:

Identify And Explain Why Your Organization Is Well Suited To The Documentation And Communication System Being Developed, Particularly Focused On Service Functions: