Six Sigma 5 - Control

D M A I C Control
Control
Six Sigma Road Map
industrial engineering ui - where the science of engineering and management blends
TEKNIK INDUSTRI
UNIVERSITAS INDONESIA
Moving into the Control Phase Control

Strategy Cookbook
Define the problem Select cross-functional team Define team charter
D M A I C
Tools & Concepts
Define Measure
Product
1 Select CTQ Characteristics 2 Define Performance Standards 3 Validate Measurement System 4 Establish Product Capability 5 Define Performance Objectives 6 Identify Variation Sources 7 Screen Potential Causes 8 Discover Variable Relationships 9 Establish Operating Tolerances 10 Validate Measurement System 11 Determine Process Capability 12 Implement Process Controls
QFD Process Mapping Measurement Systems Benchmarking/Baselining Yield & Sigma Basic Quality Tools
Analyze
or
Improve
Service
Design of Experiments Brainstorm & Workout
Control
Control Charts Procedures Training
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D M A I C Control
Control: Main Objectives/Deliverables

Develop and implement control system To make sure that our process stays in control after the solution has been implemented. To quickly detect the out of control state and determine the associated special causes so that actions can be taken to correct the problem before nonconformances are produced. Determine improved process capability Given the planned capability for controlling the Xs, what will be the new and improved capability for the process CTQ(s)?
LSL USL
LSL
USL
Process Before industrial engineering ui - where the science of engineering and management blends Improvement
Process After Improvement
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D M A I C Control
Maintaining Control
Keep Xs within tolerance by using appropriate controls (Risk Management, Mistake Proofing, etc.) Apply control charts to Xs to monitor and control variation. Understand implications on existing quality plans due to modification of current control systems. Establish transition plan for maintaining control of improved process (training plan, audit plan, etc.).
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What is a Process Control System?
D M A I C Control
A process control system

strategy for maintaining the improved process performance over time identifies the specific actions and tools required for sustaining the process improvements or gains
A control system may incorporate

Risk Management Mistake-proofing devices Statistical process control (SPC) Data collection plans Ongoing measurements Audit plans Response or Action plans Product drawings Process documentation Process ownership
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Why is a Process Control System Important?
D M A I C Control
Defines the actions, resources, and responsibilities needed to make sure the problem remains corrected and the benefits from the solution continue to be realized. Provides the methods and tools needed to maintain the process improvement, independent of the current team.
Ensures that the improvements made have been documented (often necessary to meet regulatory requirements).
Facilitates the solution's full-scale implementation by promoting a common understanding of the process and planned improvements. TEKNIK INDUSTRI industrial engineering ui - where the science of engineering and management blends
Key Steps in Developing a Process Control System

1. Complete an implementation plan.

D M A I C Control
Plan and implement the solution and develop a method to control each vital X or key sources of variation Define all possible areas that may require action in order to control the process X and then determine the appropriate course of action to take
2. Develop a data collection plan to confirm that your solution meets your improvement goals.
Establish ongoing measurements needed for the project Y and create a response plan to follow in case process performance falls below established standards
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D M A I C Control
Key Steps (contd)

3) Communicate your strategy.
Document the process and control plan to ensure process standardization and the continuation of the solution's benefits
4) Train Personnel. 5) Run the new process and collect the data to confirm your solution.
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Three Main Control Mechanisms
D M A I C Control
Risk Risk Management Management

Avoid Potential Problems
Mistake Mistake Proofing Proofing
SPC SPC
Control Potential Problems
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D M A I C Control
Risk Management
Determine the probability and impact of each risk presented by the planned process change.
Link the probability and impact of occurrence to the risk, then determine the abatement action.
Assign ownership and determine timing for each abatement action.
Recommended tool Failure Modes & Effects Analysis (FMEA)

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D M A I C Control
Mistake Proofing
Helps to sustain a solution by eliminating the possibility that an X can be set outside the desired level or configuration...or
Warns the process operator before the X goes outside limits so preventative action can be taken.
Mistake proofing can be used alone or with either risk management or statistical process control to sustain a solution.
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D M A I C Control
Statistical Process Control

Control charts can be used to monitor Xs and quickly detect a change in the process due to special cause variation.
Very helpful when your Xs cannot be mistake proofed or easily controlled within the required tolerance range.
Tool we will look at Shewhart control charts, as an introduction to SPC
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D M A I C Control
Introduction to Statistical Process Control (SPC)

(Recommended reference: Montgomery, Doug (2001). Introduction to Statistical Quality Control, 4th edition, John Wiley & Sons, New York, NY.)
From Montgomery: SPC a powerful collection of problem-solving tools useful in achieving process stability and improving capability through the reduction of variability. SPC can be applied to any process. Its seven major tools (often Focus of referred to as the magnificent seven) are: remaining
lectures
Histogram or stem-and-leaf display Check sheet Pareto chart industrial engineering ui - where the science ofdiagram engineering and management blends Cause-and-effect
Control chart Scatter diagram Defect concentration INDUSTRI diagram TEKNIK UNIVERSITAS INDONESIA
D M A I C Control
Concepts/definitions: Common cause variability Inherent or natural variability in a process, which is the cumulative effect of essentially unavoidable causes. Assignable cause or special cause variability - above and beyond the natural process variability. In a manufacturing process, this often comes from improperly adjusted machines, operator error or defective raw material. This may result in a shift in the process mean, an increase in the process variability, or both. Statistical process control charts are used to detect the presence of an assignable causes, by detecting a shift in the mean of the parameter being monitored, an increase in its variance, or both. TEKNIK INDUSTRI industrial engineering ui - where the science of engineering and management blends
D M A I C Control
Statistical basis of the Control Chart Sample quality characteristic
Upper control limit (UCL)

Usually center line + 3s, where s is the standard error of the quality characteristic being plotted.
Center line avg value of the

sample quality characteristic when the process is in control
Lower control limit (LCL)
Sample number or time
Usually center line - 3s, where s is the standard error of the quality characteristic being plotted.
When the process is in control, all points should fall within the UCL TEKNIK INDUSTRI UNIVERSITAS INDONESIA and LCL, in an essentially random pattern.
D M A I C Control
Relationship between control charts and hypothesis testing

Some similarities: Suppose the sample quality characteristic being plotted (vertical axis) is X . If the current value of X plots between the control limits, then we conclude that the process mean is in control; that is, it is equal to some value 0 . If X exceeds either limit, we conclude that the process mean is out of control; that is, it is equal to some value 1 0. Type I and II errors apply to performance of control charts - Type I error is concluding that an in-control process is out of control - Type II error is concluding that in out-of-control process is in control Some differences: When testing statistical hypothesis, usually check for validity of assumptions. Control charts are used to check for departure from an assumed state. Assignable cause can result in different types of shifts in process parameters (e.g. sustained shift or abrupt temporary shift or steady drift).
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D M A I C Control
Controlling the process parameter within specification/tolerance

Upper specification limit (USL)
Sample quality characteristic
Upper control limit (UCL)
Center line
Lower control limit (LCL) Lower specification limit (LSL)

Sample number or time
Detect a process shift and correct it, before it ever exceeds the TEKNIK INDUSTRI UNIVERSITAS INDONESIA specification limits (ie results in unacceptable quality)
D M A I C Control
Process improvement using a control chart Input Process Process MeasurementSystem System Measurement
Verify and follow up Detect assignable cause
Output
Implement corrective action
Identify root cause of the problem
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D M A I C Control
Guide to Univariate Process Monitoring and Control

Assumption: Process data is not autocorrelated Continuous or Discrete data? Continous Sample size n>1 Shift size to detect large small n=1 Shift size to detect large small Cusum EWMA Discrete (attribute) Data type fraction Shift size to detect large small p np Cusum EWMA Using p Defects (count) Shift size to detect large small c u Cusum EWMA Using c,u; time between events
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(<1.5)
X,R X,S
Cusum EWMA
X (individuals) MR
Shewhart control charts Dr. Walter Bell Labs, blends 1920s industrial engineering ui - where theShewhart, science of engineering and management
D M A I C Control
Sensitizing rules for Shewhart control charts

1. 2. One or more points outside of the control limits. Two of 3 consecutive points outside the 2-sigma warning limits but still inside the control limits. 3. Four of 5 consecutive points beyond the 1-sigma limits. 4. A run of 8 consecutive points on one side of the center line. 5. Six points in a row steadily increasing or decreasing. 6. Fifteen points in a row in zone C. 7. Fourteen points in a row alternating up and down. 8. Eight points in a row on both sides of the center line with none in zone C. 9. An unusual or nonrandom pattern in the data. 10. One or more points near a warning or control limit.
+ 3 s.e. + 2 s.e. + 1 s.e.
Western Electric Rules
Zone C
-1 s.e. -2 s.e.
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-3 s.e.
D M A I C Control
Guide to Univariate Process Monitoring and Control

Assumption: Process data is not autocorrelated Continuous or Discrete data? Continuous Sample size n>1 Shift size to detect large small n=1 Shift size to detect large small Cusum EWMA fraction Shift size to detect large small p np Cusum EWMA Using p Discrete (attribute) Data type Defects (count) Shift size to detect large small c u Cusum EWMA Using c,u; time between events
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(<1.5)
X,R X,S
Cusum EWMA
X (individuals) MR
Shewhart control charts Dr. Walter Bell Labs, blends 1920s industrial engineering ui - where theShewhart, science of engineering and management
D M A I C Control
Shewhart control charts for a continuous Y or X Need to monitor both the mean and variability of the variable (Y or X). Assume n > 1, for every sample collected over time Monitor X to control the process mean ( X chart) Monitor S (sample std dev) or R (sample range) to control the process variability. (S chart or R chart) Typically use an S chart if n >10-12 or if n varies from sample to sample.
R chart is more commonly used than an S chart.
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D M A I C Control
Constructing the X and R charts Statistical basis: Assume that X, the process parameter to be monitored, is normally distributed with mean and std deviation , both known. Assume that we are collecting m samples of size n from the process over time. The sample data can be summarized by xi and ri for i= 1, m. Therefore,
P Z / 2 x i < x i < + Z / 2 x i = 1
Basis for LCL of
for i=1, 2, m
X chart
TEKNIK Basis for UCL of X INDUSTRI chart
D M A I C Control
Typically, and are unknown, so they must be estimated from the sample data. Unbiased estimator for is x =
1 xi , i = 1,..., m m i 1 R Unbiased estimator for is , where R = Ri , i = 1,..., m m i d2

and d2 is listed for various sample sizes in Appendix Table VI of Montgomerys SQC book (reference given in Control 2.ppt).
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D M A I C Control
Constructing the X chart Centerline = X LCL =
X 3
R d2 n
UCL =
X +3
R d2 n
X A2 R
X + A2 R
Where A2 is found in Appendix Table VI. See Piston ring example from handout (Montgomery, pages 213-215).
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D M A I C Control
Constructing the R chart Centerline = LCL = D 3 R
R
UCL = D 4 R
D3 and D4 are found in Table VI. See pages 210 and 211 of handout from Montgomerys text for explanation of D3 and D4. See Piston ring example.
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D M A I C Control
Constructing the X and R charts in Minitab Piston ring example:
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D M A I C Control
Select Xbar-R chart
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D M A I C Control
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D M A I C Control
Minitab output:
Xbar/R Chart for x1-x5
74.015 3.0SL=74.01
Sample Mean
74.005 X=74.00 73.995 -3.0SL=73.99 73.985 Subgroup 0 5 10 15 20 25
0.05
3.0SL=0.04914
Sample Range
0.04 0.03 0.02 0.01 0.00 -3.0SL=0.00E+0 R=0.02324
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Shewhart control charts for discrete (attribute) data

p (fraction of np (number of 1 nonconforming ) nonconforming1) p np Centerline UCL n p + 3 n p (1 p ) p (1 p ) p+3 n LCL n p 3 n p (1 p ) p (1 p ) p 3 n Notes If n varies, use n must be a average n or constant individual ni
1Though
D M A I C Control
c (count of u (count of 1 nonconformances ) nonconformances1/unit) c u

c +3 c c 3 c n must be a constant u +3 u 3 u n
u n If n varies, use average n or individual ni
this is presented as if one is monitoring nonconformances, any attribute can be monitored in this way. For example, GEFA is going to set up a p-chart for each of the underwriting rate classes, to monitor for significant changes in the % of insurance applications placed in a given underwriting rate class. TEKNIK INDUSTRI
D M A I C Control
P-chart example (with Minitab) See example 6-1 in Montgomery, pages 288-290 of handout. N=50 for each of the 30 samples
Sample Sample Di num num 16 1 12 17 2 15 18 3 8 19 4 10 20 5 4 21 6 7 22 7 16 23 8 9 24 9 14 25 10 10 26 11 5 27 12 6 28 13 17 29 14 12 industrial engineering ui - where the science of engineering and management blends 30 15 22 Di 8 10 5 13 11 20 18 24 15 9 12 7 13 9 6
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D M A I C Control
Minitab input:
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D M A I C Control
Since our n was constant for all samples, it can be entered as a constant here.
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D M A I C Control
Minitab output:
P Chart for Di
0.5 1 0.4 3.0SL=0.4102 1
Proportion
0.3 P=0.2313 0.2 0.1 -3.0SL=0.05243 0.0 0 10 20 30
Sample Number
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Six Sigma 5 - Control

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D M A I C Control

industrial engineering ui - where the science of engineering and management blends

Moving into the Control Phase Control

Tools & Concepts

Design of Experiments Brainstorm & Workout

Control Charts Procedures Training

industrial engineering ui - where the science of engineering and management blends

Control: Main Objectives/Deliverables

Process After Improvement

industrial engineering ui - where the science of engineering and management blends

What is a Process Control System?

A process control system

A control system may incorporate

industrial engineering ui - where the science of engineering and management blends

Why is a Process Control System Important?

Key Steps in Developing a Process Control System

industrial engineering ui - where the science of engineering and management blends

Key Steps (contd)

industrial engineering ui - where the science of engineering and management blends

Three Main Control Mechanisms

Risk Risk Management Management

Mistake Mistake Proofing Proofing

Control Potential Problems

Assign ownership and determine timing for each abatement action.

Recommended tool Failure Modes & Effects Analysis (FMEA)

industrial engineering ui - where the science of engineering and management blends

Statistical Process Control

Tool we will look at Shewhart control charts, as an introduction to SPC

industrial engineering ui - where the science of engineering and management blends

Introduction to Statistical Process Control (SPC)

Statistical basis of the Control Chart Sample quality characteristic

Upper control limit (UCL)

Center line avg value of the

Lower control limit (LCL)

Sample number or time

industrial engineering ui - where the science of engineering and management blends

Relationship between control charts and hypothesis testing

Controlling the process parameter within specification/tolerance

Upper control limit (UCL)

Lower control limit (LCL) Lower specification limit (LSL)

industrial engineering ui - where the science of engineering and management blends

Implement corrective action

Identify root cause of the problem

industrial engineering ui - where the science of engineering and management blends

Guide to Univariate Process Monitoring and Control

Sensitizing rules for Shewhart control charts

Western Electric Rules

Guide to Univariate Process Monitoring and Control

R chart is more commonly used than an S chart.

TEKNIK Basis for UCL of X INDUSTRI chart

1 xi , i = 1,..., m m i 1 R Unbiased estimator for is , where R = Ri , i = 1,..., m m i d2

industrial engineering ui - where the science of engineering and management blends

Constructing the X chart Centerline = X LCL =

Constructing the R chart Centerline = LCL = D 3 R

Constructing the X and R charts in Minitab Piston ring example:

industrial engineering ui - where the science of engineering and management blends

Select Xbar-R chart

industrial engineering ui - where the science of engineering and management blends

industrial engineering ui - where the science of engineering and management blends

74.005 X=74.00 73.995 -3.0SL=73.99 73.985 Subgroup 0 5 10 15 20 25

0.04 0.03 0.02 0.01 0.00 -3.0SL=0.00E+0 R=0.02324

industrial engineering ui - where the science of engineering and management blends

Shewhart control charts for discrete (attribute) data

c (count of u (count of 1 nonconformances ) nonconformances1/unit) c u