The Scientific Method and Quality Improvement:The Scientific Method and Quality Improvement OCMA 2006 tom.sutton@mohawkcollege.ca


Continuous Improvement:Continuous Improvement


Slide 3:Ideas


Seven Statistical Tools:Seven Statistical Tools Check sheet Pareto chart Cause and effect diagram Histogram Scatter plot Stratification Graphs (control charts)


Problem:Problem 75 defective springs in a week’s production Check sheet with defect type Display on a Pareto chart Identify the important problem Focus on the “vital few” not the “trivial many”


Pareto Chart:Pareto Chart


Histogram of Crack Size:Histogram of Crack Size


Slide 11:Ideas DESIGN


Experiment for three factors:Experiment for three factors


Slide 13:Ideas DESIGN RUN


Slide 14:Ideas DESIGN RUN ANALYZE


Slide 16:Ideas DESIGN RUN ANALYZE


Slide 17:Ideas DESIGN RUN ANALYZE More Ideas KNOWLEDGE


What is Six Sigma?:What is Six Sigma?


Process Capability:Process Capability


99% Quality Level:99% Quality Level 20,000 lost mail articles per hour Unsafe drinking water 15 minutes /day 5000 incorrect surgical operations per week 2 short or long landings at major airports/day 200,000 wrong drug prescriptions per year No electricity for 7 hours per month


Six Sigma Capability:Six Sigma Capability


Six Sigma:Six Sigma Define Measure Analyze Improve Control


Six Sigma Black Belt:Six Sigma Black Belt Define Project scope Metrics Problem statement


Six Sigma Black Belt:Six Sigma Black Belt Measure Process analysis Probability and statistics Collecting and summarizing data Properties and applications of prob. Distributions Measurement systems Analyzing process capability


Six Sigma Black Belt:Six Sigma Black Belt Analyze Exploratory data analysis Sources of variation Regression, analyze residuals Hypothesis testing Interval estimates Tests for means, variances and proportions Paired comparisons ANOVA Contingency tables


Six Sigma Black Belt:Six Sigma Black Belt Improve Design of experiments Design principles One factor experiments Full factorial experiments Fractional factorial experiments Robustness concepts Mixture experiments Response surface methodology Steepest ascent Higher order experiments Evolutionary Operation (EVOP)


Six Sigma Black Belt:Six Sigma Black Belt Control Statistical Process Control Application of control charts Analysis of control charts Advanced SPC Short run SPC EWMA, CUSUM Lean tools for control Measurement system analysis Design for Six Sigma Quality Function Deployment Robust design Failure mode and effects analysis


Six Sigma Black Belt:Six Sigma Black Belt Improve Design of experiments Design principles One factor experiments Full factorial experiments Fractional factorial experiments Robustness concepts Mixture experiments Response surface methodology Steepest ascent Higher order experiments Evolutionary Operation (EVOP)


Design of Experiments:Design of Experiments


Popcorn Experiment:Popcorn Experiment


Analysis:Analysis


The Helicopter Experiment:The Helicopter Experiment Design an experiment to study the factors that may affect flight time. Measure distance from target as well


Helicopter Factors:Helicopter Factors


References:References Paper by George Box www.statease.com www.minitab.com www.asq.org www.isixsigma.com