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

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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

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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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