Implementing Lean Six Sigma Using Statgraphics

Transcription

1 Implementing Lean Six Sigma Using Statgraphics Neil W. Polhemus, CTO, StatPoint Technologies, Inc. Copyright 2011 by StatPoint Technologies, Inc. Web site:

2 2 Lean Six Sigma

3 Lean Six Sigma Lean manufacturing focuses on reducing cost through process optimization. Six Sigma focuses on meeting customer requirements and stakeholder expectations, and improving quality by measuring and eliminating defects. www-935.ibm.com/services/uk/bcs/pdf /driving_operational_innovation_using_lean_six_sigma.pdf 3

4 Statgraphics Software Statgraphics Centurion XVI.I Windows standalone application with over 170 basic and advanced statistical methods. Statgraphics Sigma Express 1.1 Excel add-in with 70+ procedures covering the needs of Six Sigma green belts and most black belts. Available for Excel 2003, 2007, 2010.* *Pre-release evaluation version available by sending contact information to 4

5 5 Statgraphics Centurion XVI.I

6 6 Statgraphics Sigma Express

7 Example #1 (Define) Cause-and-Effect Diagram Cause-and-effect diagrams (also called fishbone or Ishikawa diagrams) illustrate the causes of specific events. Event: defects Major causes: material, personnel, environment, machines, 7

8 Input Analysis Options dialog box creates diagram 8

9 9 Data structure for saving

10 10 Sigma Express also provides Excel template

11 Example #2 (Measure) Gage Studies Gage Studies refers to the process of evaluating measurement processes to verify that they are capable of measuring responses well enough to permit the use of SPC and DOE techniques. In Statgraphics, the main procedures all follow the AIAG guidelines: Gage Study Setup to create a data template. Analysis of Variable Data 1. Average and Range Method and ANOVA Method evaluate R&R based on full study. 2. Range Method evaluates R&R based on short study. 3. *Gage Linearity and Accuracy evaluates bias. Analysis of Attribute Data 1. *Risk Assessment Method based on consistency of appraisals 2. *Analytic Method and *Signal Theory Method other approaches 11 * Not in Sigma Express product.

12 Statistical Model total 2 product 2 measurement. process 2 2 measuremen t. process repeatabil ity reproducibility 12

13 13 Gage study setup

14 14 Typical gage study data file

15 15 Data input dialog box

16 Analysis Options Tolerance = USL LSL (distance between specification limits) If operators measure the same parts, the structure is crossed. 16

17 17 Tables and Graphs

18 Deviation from Average R&R Plot R&R Plot for Anne_1-Carlos_ Anne Bob Carlos Operators 18

19 19 R&R Table

20 Tolerance Analysis Precision-to-tolerance ratio: ˆ measurement. process tolerance % 20

21 Example #3 (Analyze) Capability Analysis Determines whether a process is capable of meeting established specification limits. DPMO Defects Per Million Opportunities. Defect = nonconformance to a specification. 21

22 Typical Data Measured resistivity of n = 100 electronic components. USL =

23 23 Capability Assessment SnapStat

24 24 Analysis Options

25 25 After Box-Cox Transformation

26 26 Capability Analysis Statlet

27 Example #4 (Improve) DOE Step 1: Define Responses 27

28 28 Step 2 Define Experimental Factors

29 29 Step 3 Select Design

30 30 Step 4 Paste to Excel Worksheet

31 31 Analyze Experiment

32 32 Tables and Graphs

33 33 Analysis Window

34 34 Paste Back to Excel

35 Example #5 (Control) Individuals with EWMA Suggested by Stu Hunter 35

36 36 Data Input Dialog Box

37 37 X Chart Pane Options

38 X X Chart with EWMA (l = 0.2) X Chart for strength :00 3:20 6:40 10:00 13:20 16:40 time Note: inner zone provides 3-sigma limits for the EWMA. 38

39 39 Exponential Smoothing Statlet

40 Example #6 - Monte Carlo Simulation Cycle time = Step 1 + Step 2 + MAX(Step 3, Step 4) Step 1 Normal (12.1, 1.9) Step 2 Normal (7.3, 0.5) Step 3 Exponential (0.2) Cycle time Step 4 Uniform (2.0, 6.0) 40

41 41 Data Input Dialog Box

42 42 Analysis Options

43 43 Results

44 frequency Histogram of cycle time Histogram Cycle time 44

45 More Information Go to Or send to 45